Tigercat M724D MULCHER SERVICE MANUAL - PDF DOWNLOAD

SERVICE MANUAL Tigercat M724D MULCHER ISSUE 1.0, JANUARY 2004

TABLE OF CONTENTS SECTION INTRODUCTION ........................................................................................................ iii SAFETY ..................................................................................................................... 1 USING HIGH SPEED DISC SAWS SAFELY ................... APPENDIX TO SECTION 1 CONTROLS AND OPERATION .................................. SEE OPERATOR'S MANUAL LUBRICATION AND MAINTENANCE ....................................................................... 3 PILOT SYSTEM ......................................................................................................... 5 ELECTRICAL, GAUGES AND ALARMS ................................................................... 6 ENGINE ..................................................................................................................... 7 DRIVE ........................................................................................................................ 8 BRAKES AND DIFFERENTIAL LOCKS .................................................................... 9 OIL COOLER, RADIATOR AND CROSS-FLOW FAN ............................................ 10 STEERING AND CENTER JOINT ........................................................................... 11 LIFT BOOM .............................................................................................................. 12 TILT .......................................................................................................................... 13 ATTACHMENT DRIVE ............................................................................................. 17 CLAMPS WITH SAW ATTACHMENT ..................................................................... 18 MULCH DEFLECTOR DOOR .................................................................................. 19 M724DSM00

M724D Available Literature Operator's Manual ............................... Part Service Manual (this manual) .............. Part Parts Catalog ....................................... Part Hydraulic Adapters Book ..................... Part Hose Assemblies Book ....................... Part

No. No. No. No. No.

21324A 21325A 21323A 1472A 3707A

Tigercat

®

Tigercat Industries Inc. P.O. Box 544 Paris, Ontario Canada N3L 3T6 Tel: (519) 442-1000 Fax: (519) 442-1855

Tigercat M724D Mulcher

Introduction

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Tigercat M724D Tigercat M724D MulcherMulcher

Introduction

INTRODUCTION An Operator's manual, Service manual and a Parts catalog are made available by Tigercat to assist the dealer, customer and operator in becoming familiar with the features of the M724D Mulcher.

The operator's manual will assist the operator with the techniques of proper and safe operation of the M724D Mulcher. In addition, the operator's manual contains important information regarding the safe operation of both a mulching head and a saw head, as the M724D Mulcher is convertible for use as a Feller Buncher. The service manual contains safety and servicing procedures and a preventive maintenance schedule to ensure optimum machine performance.

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

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

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

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

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

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

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

Tigercat Industries Inc.

WORKING 1

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Tigercat M724D Mulcher

Introduction

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

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

Tigercat may officially grant approval for modifications only by: i.

Written approval of repairs or modifications signed by the Tigercat Engineering Manager; or

ii.

Approved modifications officially released by Tigercat.

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

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

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

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

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

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

Tigercat Industries Inc.

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Tigercat M724D Mulcher

Introduction

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

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

The relevant options for that product must be shown or listed on current Tigercat documentation or literature such as a printed specification sheet, price list, parts manual, or product literature issued by Tigercat.

ii)

Approved options or product changes authorized in writing by the Tigercat Engineering Manager.

Authorization by any other person is unacceptable.

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

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

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

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

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

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

Tigercat Industries Inc.

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Introduction

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Tigercat M724D Mulcher

SECTION 1 - SAFETY SEPTEMBER 2003

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

Read and understand all manuals for any attachments or accessories.

CONTENTS - SECTION 1 ARTICULATION LOCK BAR ........................................................................ 1.13 BATTERY DISCONNECT SWITCH .............................................................. 1.8 BOOM LIFT LOCK ....................................................................................... 1.13 ENGINE ACCESS PANELS ......................................................................... 1.14 EXHAUST FUMES ....................................................................................... 1.14 FELLER BUNCHER OPERATION SAFETY ................................................ 1.11 FIRE PREVENTION ..................................................................................... 1.15 FIRE PREVENTION GUIDELINES ........................................................... 1.15 WHAT ELSE TO DO BEFORE YOU EXPERIENCE A FIRE .................... 1.16 WHAT TO DO AFTER A FIRE ................................................................. 1.17 WHAT TO DO IN CASE OF A MACHINE FIRE ........................................ 1.16 FIRST AID ...................................................................................................... 1.4 FLUID LEAKS .............................................................................................. 1.12 HAZARD ZONE ............................................................................................. 1.3 HYDRAULIC PRESSURE HAZARD ............................................................ 1.12 LOOSE CLOTHING HAZARD ..................................................................... 1.13 MULCHING OPERATION SAFETY ............................................................... 1.9 PARKING THE MACHINE ............................................................................. 1.8 PROTECTIVE CLOTHING ............................................................................. 1.3 SAFETY INTERLOCK SWITCHES ON CAB DOORS ................................... 1.8 SAFETY PRECAUTIONS, GENERAL ........................................................... 1.3 SAFETY PRECAUTIONS, OPERATING ....................................................... 1.6 SAFETY PRECAUTIONS, SERVICING ....................................................... 1.12 SAFETY SYMBOLS ....................................................................................... 1.2 SIGNAL WORDS ........................................................................................... 1.2

Tigercat M724D Mulcher

Safety

SAFETY SYMBOLS

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

Follow the instructions in the safety message.

Understanding Signal Words

DANGER DANGER identifies the most serious hazards where failure to follow listed procedures would result in a high probability of death or serious injury.

WARNING WARNING denotes a hazard exists which can result in serious injury or death if proper precautions are not taken.

CAUTION CAUTION is used in areas where failure to follow listed procedures may cause personal injury, component damage or subsequent malfunction.

IMPORTANT IMPORTANT is used to focus attention on items that should be checked, controlled, adjusted or cleaned to ensure the efficiency and long term operation of the machine.

1.2

Tigercat M724D Mulcher

Safety

GENERAL SAFETY PRECAUTIONS 500 FEET

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.

500 FEET

500 FEET

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

500 FEET

M724D-03

HAZARD ZONE

DANGER ROTATING CUTTER (OR SAW)

Follow all instructions from safety inspector and supervisors.

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

The safety of persons outside the cab is the responsibility of the machine operator When approaching an operating machine on foot, stay at least 500 feet (150 meters) away until the operator recognizes your presence. Make sure that all mulching (or harvesting) equipment has been shut down before advancing to the machine.

Do not let an untrained person operate the machine.

KEEP BACK 500 FEET DANGER Thrown debris keep back 500 feet.

The following diagram illustrates the HAZARD ZONE. All personnel should be kept clear of this zone while the mulching head or felling head is operating.

Use recommended protective clothing and safety devices such as orange safety vest, gloves, safety boots, safety hat, goggles, and ear protection when necessary. These safety rules highlight both general and specific measures the operator should be familiar with and adhere to.

More specific measures are illustrated with pictograms which may also be attached to the machine in locations pertinent to their respective message. Keep safety labels in good condition.

Repair or replace damaged labels.

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

DANGER Danger caused by flying debris.

Improper operation of the mulching head (or saw head) and failure to follow safety precautions can result in personal injury.

1.3

Tigercat M724D Mulcher

Safety clean up or cover slippery surfaces with a nonslip material.

GENERAL SAFETY PRECAUTIONS continued

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

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

Machine should be washed completely at every major service.

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

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.

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

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

Check windows and door guards for damage.

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

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

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

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

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

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

Do not use the machine foot controls as a step.

Check all fluid levels.

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

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

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

Avoid mounting or dismounting the machine in areas with slippery surfaces. If this is not possible 1.4

Tigercat M724D Mulcher

Safety

GENERAL SAFETY PRECAUTIONS continued

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.

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

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.

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

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

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

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.

•

•

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

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

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

Install the articulation lock bar when ever the machine is to be transported.

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

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

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

Read, understand and follow all general safety precautions specified by the mulching head (or felling head) manufacturer.

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

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

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

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

Wash hands after handling.

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

1.5

Tigercat M724D Mulcher

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

OPERATING SAFETY PRECAUTIONS

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

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

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

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

Sound the machine horn before starting the machine.

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

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

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

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

Keep the brake properly adjusted at all times.

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

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

Mulching (or felling) operations should only be performed from the operator's seat.

Secure loose items in the cab.

1.6

Tigercat M724D Mulcher

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

OPERATING SAFETY PRECAUTIONS continued

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

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

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

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

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

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

•

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

•

Serious injury or death could result from crushing.

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

NEVER travel across a STEEP slope or side hill:

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

Do not turn on rotating cutter (or saw blade) until machine is at cutting site.

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

Do not allow people or other pieces of equipment near the mulching (or felling) operation.

It is the operator's responsibility to warn all persons in area of the HAZARD ZONE to stay clear of the HAZARD ZONE. Refer to HAZARD ZONE in THIS SECTION. The operator must stay alert for outsiders entering the work area who may not be aware of the HAZARD ZONE. Refer to HAZARD ZONE in THIS SECTION. Use only prearranged and approved signalling practices.

1.7

•

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

•

FELLER BUNCHER CONFIGURATION ONLY : As logs are added to the accumulator pocket the handling and the stability of the machine will change.

•

FELLER BUNCHER CONFIGURATION ONLY : To avoid tip over, keep the felling head as low as possible to maintain a low center of gravity.

•

FELLER BUNCHER CONFIGURATION ONLY : Always be prepared to dump the load in case of an emergency.

•

FELLER BUNCHER CONFIGURATION ONLY : Do not overload the machine as this can create an unstable condition and cause a roll-over.

Tigercat M724D Mulcher

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

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

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

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

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

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

When parking the machine: •

Park on level ground.

•

Do not park on a hillside or incline.

•

Lower the attachment onto level ground.

•

Engage the parking brake.

•

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

SWITCH

• • ACTUATOR

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

INTERLOCK SWITCH (L.H. DOOR SHOWN)

197-5

Complete either steps 2A or 2B.

SAFETY INTERLOCK SWITCHES ON DOORS:

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

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

2B.Turn rear differential switch ON and hold front differential lock switch ON for 30 seconds. While waiting, pump brake foot pedal at least 10 times.

CAUTION

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

Use caution when loosening hydraulic connections.

Safety interlock switches DO NOT lock out the steering function on machines equipped with a steering wheel.

For additional information, refer to RELEASE PILOT SYSTEM PRESSURE in SECTION 5 of the SERVICE MANUAL.

CAUTION DO NOT use the steering joystick or steering wheel to assist entering or leaving the cab.

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

To operate: Close both doors and press the PILOT RESET switch.

CAUTION •

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

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

Once the safety interlock system has been 1.8

Tigercat M724D Mulcher

Safety DANGER ZONES

OPERATING SAFETY PRECAUTIONS continued

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

activated, the safety of both the operator and all persons outside the cab becomes the responsibility of the operator.

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

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

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

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

MULCHING OPERATION SAFETY

Poor maintenance increases the danger.

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

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

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

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

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

REAR DANGER ZONE

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

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

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

Replace all worn cutter tools.

Always replace the fastener whenever replacing a cutter tool.

Inspect the rotor for weld cracks and other damage.

•

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

•

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

•

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

FRONT DANGER ZONE

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

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

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

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

Check that the cutter housing is clear and undamaged.

DANGER ROTATING CUTTER

• •

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

DANGER

•

Danger caused by flying debris.

Improper operation of the mulching head (or saw head) and failure to follow safety precautions can result in personal injury.

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

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

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

DO NOT operate without guards.

1.9

Tigercat M724D Mulcher OPERATING SAFETY PRECAUTIONS continued URBAN PRECAUTIONS Increased safety precautions are required when working: • • • •

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

Near buildings

Establish Safety parameters that fit the site: • • •

String coloured warning tape to cordon off the area.

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

Erect barriers.

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

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

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

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

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

CAUTION

ASSESSING THE POTENTIAL DANGERS OF THE JOB SITE Before working in a new area a visual survey of the area to be worked is helpful in identifying undesirable materials which may be present.

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

AVOID METAL AND WIRE. Metal can break cutter tools and create a projectile hazard.

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

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

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

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

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

To prevent component damage, always have deflector door open when preparing to fell standing trees Work within your operating skills, do not attempt to cut down a tree that is too large to handle.

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

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

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

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

Stop the rotating cutter before leaving the mulching area. NOTE: The cutter will continue to free wheel for several minutes after the saw/ cutter switch has been turned OFF. To stop cutter from rotating, CAREFULLY lower the rotor onto a stump. This should be done gently to prevent unnecessary loading of the rotor, housing and bearings.

Any time is a good time to inspect the rotor for clinging strands.

1.10

Tigercat M724D Mulcher OPERATING SAFETY PRECAUTIONS continued FELLER BUNCHER OPERATION SAFETY Pieces of wood, debris from the ground and even teeth separating from the saw blade become potentially dangerous projectiles when thrown from these machines.

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

Ensure that all saw tooth retaining bolts are at correct torque value.

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 the saw blade has missing teeth, teeth retaining bolts or a bent saw disc.

Shut down machine immediately if vibration occurs during cutting.

Check that the saw discharge area is clear and undamaged.

Safety When making the cut, properly position felling head in front of tree and have saw blade running at full rpm.

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.

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

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.

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

Stop the saw blade before leaving the cutting area. NOTE: The saw blade will continue to free wheel for several minutes after the saw/cutter switch has been turned OFF. To stop the blade from rotating, 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.

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

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.

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

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

DANGER Danger caused by flying debris.

Improper operation of the mulching head (or saw head) and failure to follow safety precautions can result in personal injury.

1.11

Tigercat M724D Mulcher

Safety

SERVICING SAFETY PRECAUTIONS

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

Conduct maintenance inspections at least as frequently as recommended in SECTION 3 of the OPERATOR'S MANUAL. When servicing or repairing equipment, shut the engine down, and disconnect the positive (+) battery cable from both batteries.

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

Never use bare hand to check for fluid leaks.

Fluid leaks under pressure may not be visible.

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

Wear safety goggles for eye protection.

Pressure can be maintained in a hydraulic system long after the power source and pump have been shut down. Lower the attachment to the ground, stop engine and relieve trapped pressure from pilot system and brake accumulators before performing work on components, or disconnecting any hoses. For the procedure on how to RELIEVE PRESSURE, refer to PARKING THE MACHINE in THIS SECTION.

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

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

This machine is equipped with a reversible cooling fan to facilitate cleaning of the radiator/oil cooler assembly and engine compartment doors. Exercise care when working in this area with the engine running. If the fan switch in the cab is in the AUTO position, the fan could turn ON. Prior to welding on any part of the machine, it should be cleaned and a fire extinguisher should be made available at the welding location. Care must be taken in attaching the welding machine grounding clamp so electrical current does not pass through bearings, especially the center joint bearing. Also, disconnect the positive (+) battery cable from both batteries.

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

1.12

Tigercat M724D Mulcher

Safety

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

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

195-24

FRAME ARTICULATION LOCK BAR

To prevent accidental articulation of the machine and injury when working in the center joint area, install the frame articulation lock bar between the frames and hold in place with the lynch pins provided.

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

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

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

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

WARNING Always allow the rotating cutter (or saw blade) to come to a COMPLETE STOP before approaching to make adjustments.

WARNING

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

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

SAFETY7

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.

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

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

1.13

Tigercat M724D Mulcher

Safety

SERVICING SAFETY PRECAUTIONS continued CAUTION The LOWER engine compartment access panels on a standard configuration are NOT HINGED or permanently attached to the machine, the UPPER doors when closed hold the LOWER panels in place. Once an UPPER DOOR is opened remove the LOWER panel from the machine. DO NOT apply any weight or pressure to the LOWER panel. DO NOT use these LOWER panels as hand grips, when servicing the machine.

UPPER DOORS

HAND KNOB

•

Compartment door and panel handles should be hand tight only at all times for easy access to the engine compartment and the pressurized water system in the event of a fire or other emergency. Refer also to FIRE PREVENTION in THIS SECTION.

HAND KNOB

• •

•

• LOWER ACCESS PANELS 724D-D15

20231A R1

•

STANDARD ENGINE ACCESS PANELS

LOWER ACCESS PANELS

RETAINING BRACKETS

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

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

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

•

• 724D-D14

LOWER ACCESS PANELS To avoid excess oil spillage during service relieve hydraulic tank pressure by opening valve in top of tank.

Dispose of fluids properly.

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

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

1.14

Tigercat M724D Mulcher

FIRE PREVENTION

Safety can fall into other areas of the machine and thereby spread a fire.

5. 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.

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

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

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.

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

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

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

3. Remove debris and blow out dust regularly from the air intake doors, engine radiator, hydraulic oil cooler and A/C condenser core to prevent overheating of the engine and hydraulics. Refer to CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR in SECTION 2 of the OPERATOR’S MANUAL. 4. Blow off all debris and dust accumulated near hot engine exhaust components (turbocharger and exhaust manifold as well as exhaust pipes and muffler) at the completion of each work shift or more frequently depending on operating conditions. Visual inspection after blow off to ensure thorough cleanliness is vital. Engine exhaust systems provide numerous small pockets where saw dust, small wood chips and other flammable forest debris can gather. Even small accumulations close to hot exhaust components can ignite and smolder. If dislodged by vibration this smoldering debris

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

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

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

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

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

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

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

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

1.15

Continued on page 16

Tigercat M724D Mulcher FIRE PREVENTION continued

Safety WHAT TO DO IN CASE OF A MACHINE FIRE •

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

•

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

•

Shut the engine off.

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

•

Activate the fire suppression system*

•

Radio or call for help (as appropriate).

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

•

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

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

•

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

•

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

•

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

•

Use the PASS method with most extinguishers.

Continued from page 15

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

EQUIPMENT FIRES ADVERSELY EFFECT YOUR ABILITY TO OPERATE, MAY INCREASE YOUR INSURANCE PREMIUMS DRAMATICALLY OR PREVENT YOU FROM OBTAINING INSURANCE COVERAGE AT ALL. WHAT ELSE TO DO BEFORE YOU EXPERIENCE A FIRE

•

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

•

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

•

•

Ensure that your fire suppression system* is charged and functional.

•

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

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

•

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

•

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

•

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

•

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

•

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

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

•

Prevent the fire from happening by ensuring that the machine is cleaned regularly and all systems are well maintained. *NOTE: Dry chemical fire suppression systems are offered by Tigercat as an optional installation on some of the Tigercat product lines. Please disregard any references made to fire suppression systems if not installed on your machine.

1.16

Tigercat M724D Mulcher

Safety WHAT TO DO AFTER A FIRE

FIRE PREVENTION continued

20229A

•

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

•

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

•

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

•

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

TYPICAL FIRE EXTINGUISHER ACCESS HOLE

•

If you are unable to open the access door(s), but can safely reach the fire extinguisher access hole, place the nozzle of the fire extinguisher into the appropriate fire extinguisher access hole and discharge the extinguisher.

•

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

•

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

•

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

1.17

Tigercat M724D Mulcher

Safety

1.18

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

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

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

Tigercat

5211A • R2-1101

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using high speed disc saws safely FORWARD:

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

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

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

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

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

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

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

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

THE DANGERS

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

• Soil particles are thrown from the ground.

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

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

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

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

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

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

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

THROW ANGLE

IF A SAW HEAD IS PUSHED AGAINST THE SIDE OF A FELLED TREE, SNOUTS PREVENT SAW TEETH FROM CONTACTING WOOD.

•

•

FIGURE 3: TYPICAL COMMONLY USED SAW HOUSING, CONTINUOUS SKIRT WITH OPENING WHERE TREES ARE CUT. SNOUTS ON BOTH SIDES OF THE MOUTH.

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

THROW ANGLE

IF A SAW HEAD WITHOUT SNOUTS IS PUSHED AGAINST THE SIDE OF A FELLED TREE, SAW TEETH WILL CONTACT WOOD.

FIGURE 4: ANOTHER COMMONLY USED HOUSING PLAN WITH NO SNOUTS, BLADE TEETH PROTRUDE AHEAD OF THE HOUSING.

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

THROW ANGLE

NUDGED LOG WILL NOT CONTACT SAW TEETH.

• EXTRA LENGTH OF SNOUT WILL INTERCEPT PORTION OF THROWN MATERIAL.

FIGURE 5: HOUSING USES LONGER SNOUT ON IN-GOING SIDE OF MOUTH WHERE ROTATING BLADE ENTERS HOUSING.

5

using high speed disc saws safely Housing types cont.

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

A CHIP ESCAPE PORT CAN ALLOW THROW BEHIND THE MACHINE

REAR

FRONT

FIGURE 6a

FIGURE 6b

FIGURE 6c

FIGURE 6: ADDITIONAL OPENING IN THE HOUSING SKIRT.

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

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

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

6

using high speed disc saws safely COMMENTS AND INSTRUCTIONS

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Recognizing the Dangers While it may appear that these illustrated danger areas can be visually recognized on the job by observing how far chips fly during a cut, that is only true for chips and other light weight materials.

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

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

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

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

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

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using high speed disc saws safely Comments and Instructions cont.

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

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

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

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

FIGURE 7a

PLAN VIEW OF MACHINE SHOWING CLOCKWISE AND COUNTERCLOCKWISE BLADE ROTATION

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

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

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using high speed disc saws safely Comments and Instructions cont.

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

A SLAB, WHICH COULD LATER BE THROWN, MIGHT HAPPEN WHEN NOT ENOUGH ROOM IN HEAD TO COMPLETELY CUT THE LAST TREE

SLAB

•

SLAB

• FE

ED

IN

FIGURE 8a: HOW A SLAB CAN BE THROWN FROM THE SIDE OF A LOG

TH DIR ROW EC TIO N

SAW HOUSING HAS SKIS, BUT WITHOUT SNOUTS AND BLADE TEETH PROTRUDE AHEAD OF THE HOUSING.

FIGURE 8

THROW ENGAGEMENT DISTANCE FELLING HEAD MOVING INTO SLAB/LOG

®

SLAB

LOG A LONG THROW ENGAGEMENT DISTANCE CAN CAUSE A DANGEROUS SPEAR THROW

• •

FIGURE 8b SIDE VIEW

FEED IN

IF THE SIDE OF A LOG CAN CONTACT THE SAW, THE THROW ENGAGEMENT DISTANCE CAN BE LONG

10

FIGURE 8c TOP VIEW

using high speed disc saws safely Comments and Instructions cont.

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

A SMALL LOG IN A PILE OF OTHER LOGS MIGHT ALSO BE PROPELLED OUT WITH ENOUGH LENGTH OF CONTINUED CONTACT WITH THE BLADE TO REACH NEAR SAW TIP SPEED.

• FE

ED

IN

FELLING HEAD MOVING INTO LOG PILE

FIGURE 9a: HOW A LOG CAN BE THROWN LIKE A SPEAR SAW HOUSING WITHOUT SNOUTS AND BLADE TEETH PROTRUDE AHEAD OF THE HOUSING.

SMALL LOG

THROW ENGAGEMENT DISTANCE LOG PILE

FEED IN

•

•

A SAW HOUSING WITHOUT SNOUTS ALLOWS A LONG THROW ENGAGEMENT DISTANCE

FIGURE 9b SIDE VIEW

FIGURE 9c TOP VIEW

IF THE SIDE OF A LOG CAN CONTACT THE SAW, THE THROW ENGAGEMENT DISTANCE CAN BE LONG

FEED IN

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using high speed disc saws safely Comments and Instructions cont.

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

UNCUT TREE OR STUMP BACKUP THROW ENGAGEMENT DISTANCE

• WHEN ONLY THE END OF A LOG CAN MAKE CONTACT WITH THE SAW, THERE IS NOT MUCH THROW ENGAGEMENT DISTANCE

FIGURE 10: FELLING HEAD HOUSING WITH SNOUTS DOES NOT ALLOW A LONG THROW CONTACT

FELLING HEAD MOVING INTO LOG

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

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

FELLING HEAD MOVING INTO STUMP (FEED SPEED)

FIGURE 11: A BLOCK OF WOOD CAN BE TOSSED WHEN TRIMMING STUMPS

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using high speed disc saws safely Comments and Instructions cont.

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

THROW GAP

FIGURE 12: SAW BLADE THROW GAP

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using high speed disc saws safely Comments and Instructions cont.

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

THE INGOING ENTRANCE OF THE HOUSING FOR THE SAW RIM OF TEETH SHOULD BE SMALL

THE OUTGOING OPENING IS LARGER TO ALLOW THE HOUSING TO CLEAN ITSELF AND WILL ALLOW MOST THINGS INSIDE TO BE THROWN OUT

FIGURE 13: SAW BLADE ENTRANCE AND EXIT SPACE

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using high speed disc saws safely Comments and Instructions cont.

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

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

The following are some “SAW HEAD DON’TS” that apply particularly to throw prevention.

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

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

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

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

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

Do not over speed the blade rpm.

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

Do not neglect tooth fastening inspection, maintenance and replacement.

Do not neglect to repair worn or damaged saw housings.

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

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

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

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

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

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

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

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

Do not select and operate heads that throw rearward.

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

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

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Tigercat M724D Mulcher SECTION 3 - LUBRICATION & MAINTENANCE JANUARY 2004

CONTENTS - SECTION 3 AIR CLEANER MAINTENANCE ........................................................................................ 3.14 AIR CONDITIONING SYSTEM, CHECKING ..................................................................... 3.18 BELT, ENGINE SERPENTINE, REPLACING ................................................................... 3.25 BOOM LIFT LOCK ................................................................................................... 3.32, 3.38 CENTER JOINT LUBRICATION .................................................................................................................

MAINTENANCE ..............................................................................................................

CONVERTING FELLER BUNCHER CONFIGURATION TO MULCHER ................................................

PRESSURE SETTINGS ATTACHMENT PUMP MULCHER .....................................

PRESSURE SETTINGS MULCH DEFLECTOR DOOR ............................................

RESET ATTACHMENT PUMP MAXIMUM DISPLACEMENT ...................................

MULCHER TO FELLER BUNCHER CONFIGURATION ...............................................

PRESSURE SETTINGS ATTACHMENT PUMP SAW ..............................................

PRESSURE SETTINGS SAW CLAMP AND ACCUMULATOR ................................

RESET ATTACHMENT PUMP MAXIMUM DISPLACEMENT ...................................

3.20 3.20 3.34 3.35 3.38 3.34 3.28 3.29 3.32 3.28

DRIVE SHAFT SPLINE LUBRICATION, MIDDLE AND REAR ........................................ 3.26 EMERGENCY EXITS, CHECK MONTHLY ......................................................................... 3.3 ENGINE SERPENTINE BELT, REPLACING .................................................................... 3.25 FILTERS ENGINE AIR CLEANER ................................................................................................. 3.14 FUEL FILTER/WATER SEPARATOR ........................................................................... 3.10 FUEL TANK STRAINER ................................................................................................. 3.11 HYDRAULIC OIL RETURN FILTERS ............................................................................. 3.12 HYDROSTATIC CHARGE PUMP PRESSURE FILTERS ............................................ 3.12 SERVICING GUIDELINES FOR OIL FILTERS .............................................................. 3.13 FIRE PREVENTION ............................................................................................................. 3.3 HYDRAULIC OILS ................................................................................................................ 3.7 NEW MACHINE MAINTENANCE FIRST 50-100 HOUR INSPECTION AND SERVICE REPORT ....................................... 3.2 INITIAL PRE-DELIVERY INSPECTION ............................................................................ 3.2 TIGHTENING POINTS ...................................................................................................... 3.2 OIL LOST FROM LEAKAGE ............................................................................................... 3.2 PRESSURIZED WATER SYSTEM MAINTENANCE ....................................................... 3.16 RELIEF VALVE ADJUSTING PROCEDURE .................................................................... 3.40 REPLACING THE ENGINE SERPENTINE BELT ............................................................. 3.25 SCHEDULED MAINTENANCE GENERAL ......................................................................................................................... 3.3 8 HOURS .......................................................................................................................... 3.4 125 HOURS ...................................................................................................................... 3.5 250 HOURS ...................................................................................................................... 3.5 500 HOURS ...................................................................................................................... 3.6 1000 HOURS .................................................................................................................... 3.6 2000 HOURS .................................................................................................................... 3.6 SEASONAL ...................................................................................................................... 3.7 SERVICE AND LUBRICATION CHART .............................................................................. 3.9 SPEED CONTROL LEVER ADJUSTMENT ...................................................................... 3.21 STARTUP PROCEDURE AFTER MAINTENANCE .......................................................... 3.22 TORQUE CHART ...............................................................................................................

TORQUE CHART, GENERAL ...........................................................................................

TRANSMISSION ................................................................................................................

CHECK OIL LEVEL ........................................................................................................

3.41 3.42 3.20 3.20

WHEELS, INSTALLING ....................................................................................................... 3.2

Tigercat M724D Mulcher

Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE FOR M724D MULCHER NEW MACHINE MAINTENANCE *INITIAL PRE-DELIVERY INSPECTION:PERFORM THE INITIAL PRE-DELIVERY INSPECTION USING Tigercat FORM NUMBERS 5281 AND 5283; "PDI AND 50-100 HOUR INSPECTION REPORT"

*FIRST 50-100 HOUR INSPECTION AND SERVICE REPORT:WITH THE OWNER'S MECHANIC PRESENT, PERFORM AN INSPECTION AND SERVICE ACCORDING TO THE Tigercat FORM NUMBERS 5281 AND 5283; "PDI AND 50-100 HOUR INSPECTION REPORT" THIS MUST BE COMPLETED WITHIN THE FIRST 50-100 HOUR TIME FRAME. *IMPORTANT: TO QUALIFY FOR CONTINUED WARRANTY, THIS REPORT MUST BE COMPLETED AND RETURNED TO Tigercat Industries Inc. WARRANTY DEPARTMENT.

Tightening points for First 50-100 hour inspection report:~

IMPORTANT!

All hydraulic connections

Wheels:

Hose clamps

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

Center joint pin securing bolts Transmission securing bolts Engine mounting bolts

For additional instructions also refer to section 8 of the service manual.

Pump drive gearbox securing bolts Axle mounting bolts

Hour meter ~ maintenance:

Wheel retaining bolts

Check the hour meter on a regular basis to determine your scheduled maintenance times.

Cab securing bolts Pin retainers

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

Any other loose nut, bolt or fitting

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

NOTE: Use of filters other than genuine Tigercat replacement filters is not recommended.

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

*OIL LOST FROM LEAKAGE LEAKAGE RATE ONE DROP IN 10 SECONDS ONE DROP IN 5 SECONDS ONE DROP PER SECOND THREE DROP PER SECOND DROPS BREAK INTO STREAM

3.2

LOST 0IL (GALLONS) PER PER PER DAY MONTH YEAR 0.112 3.36 40.0 0.225 6.75 81.0 1.125 33.75 405.0 3.75 112.5 1,350.0 24.00 720.0 8,640.0

Tigercat M724D Mulcher

Lubrication and Maintenance

GENERAL CAUTION All handles, steps and platforms must be kept free of grease, oil fuel, mud snow and ice and forest debris to prevent risk of personal injury.

Clean around filler caps before checking or adding fluids.

CHECK EMERGENCY EXITS MONTHLY~

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

Plug or cap immediately.

Two alternate exit routes are provided: right hand cab door and the skylight/emergency exit. These are only to be used if the left hand cab door cannot be opened.

It is therefore essential that these emergency exits be checked at least once per month to ensure they are fully operational.

Clean up spills as soon as possible.

Always use clean hydraulic oil and filters.

Drain dirty oil while still warm.

Do not exceed recommended fluid levels.

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

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

Clean up oil spills on walking surfaces and top of engine enclosure immediately.

Before welding on machine be sure master switch is disconnected.

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

Clean away all branches, bark and chips.

Clean up all traces of oil to avoid fires.

Always have a fire extinguisher at hand.

For safety, always lower boom assembly to the ground when leaving cab, leaving machine unattended or during service.

For safety, when working under boom, always lower to ground, support properly or install lift boom cylinder locking device . (Refer to section 2 of this manual)

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

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

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

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

3. Read the fire suppression system manual and have the system serviced regularly by qualified personnel.

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

Also refer to the SAFETY section of this manual for additional information on how to prevent fires from starting on the machine.

CAUTION

To avoid excess oil spillage during service relieve hydraulic tank pressure by opening valve in top of tank. Refer to HYDRAULIC RESERVOIR in SECTION 2 of the OPERATOR'S MANUAL.

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

3.3

Tigercat M724D Mulcher

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 8 HOURS (EVERY SHIFT):~

• Lubricate steering cylinder ends, 4-fittings, purge

• Check engine oil level

• Lubricate tilt and lift cylinder ends, 8-fittings, purge

• Drain fuel/water separator • Check air intake precleaner, clean as required

• Lubricate lift boom and tilt linkage, 9 or 10 fittings, depending on the attachment), purge

• Check air cleaner unloader valve • Check engine air filter restriction indicator

• Drain water from the compressed air tank by pulling drain valve cable. Refer to COMPRESSED AIR TANK in SECTION 2 of the OPERATOR'S MANUAL.

• Check hydraulic oil level • Check pump drive gearbox oil level with dipstick

Clean:~ • Potentially damaging limbs or sticks from machine

• Check transmission oil level at dipstick • Lubricate axles ~ outer bearings ‡ 1 fitting, 4-places, lubricate until grease flows out past the outer seals. Do not use power greasers as it will damage the seals.

• Between air conditioner condenser and oil cooler/radiator

‡ Under normal conditions every 125 hours.

Under adverse conditions, mud, water, snow etc. every 8 hours.

Check:~ • For leakage around hydraulic components and flexible hoses

Note: Manual lubrication of outer axle bearings applies only to earlier axles with cartridge lip seals and grease fittings. Later axles have face seals and do not require manual lubrication. Refer to diagram to determine which axles apply to your machine.

CARTRIDGE LIP SEAL

GREASE FITTING

••

••

EARLIER AXLES

M724D-15

• For loose nuts, bolts and fittings • Condition and tension of accessory drive belt.

• Water pressure gauge in cab (60 psi) for pressurized water system.

If the water system has been operated, refer to PRESSURIZED WATER SYSTEM MAINTENANCE in THIS SECTION for refilling and charging instructions.

FACE SEAL

• Conduct an overall visual inspection.

•

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

LATER AXLES

• Lubricate mid drive shaft slip joint* 1-fitting, purge *Note: Lubricate mid drive shaft slip joint with machine articulated

• Lubricate front drive shaft support bearing, 1-fitting, purge • Lubricate center joint bearings, 2-fittings, purge

3.4

Tigercat M724D Mulcher

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 125 HOURS:~

Visually check for damage to:• Lift boom and tilt linkage

• Perform 8 hour maintenance

• Front and rear frame

And in addition:~ • Lubricate rear axle pivot, 2-fittings, purge

• Center joint area • Attachment Make repairs immediately

• Lubricate rear drive shaft slip joint 1-fitting, purge

Visually inspect for:• Frayed electrical wiring and hydraulic hose

• Lubricate axles ~ outer bearings ‡ 1-fitting, 4-places, lubricate until grease flows out past the outer seals. Do not use power greasers as it will damage the seals.

• Wear in any other components Clean/replace:• Inspect for debris buildup between radiator, oil cooler and A/C condenser

‡ Under normal conditions every 125 hours.

Under adverse conditions, mud, water, snow etc. every 8 hours.

Note: Manual lubrication of outer axle bearings applies only to earlier axles with cartridge lip seals and grease fittings. Later axles have face seals and do not require manual lubrication.

Refer to earlier diagram to determine which axles apply to your machine.

Check:• Engine coolant level

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

EVERY 250 HOURS:~ • Perform 8 hour maintenance • Perform 125 hour maintenance And in addition replace:~ • Engine oil and change oil filter

• Air intake primary filter element, check restriction indicator at FULL rpm

• Engine fuel filter

• Fluid level in batteries unless maintenance free

• Air intake primary element

• Engine rpm.

• Oil in pump drive gearbox

• Hydraulic oil restriction indicator for boom/saw circuit with engine at FULL rpm

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

• Hydraulic pump and motor securing bolts • Check fuel tank filler screen • Torque tightening points as per new machine maintenance

Continued on page 6

• Proper operation of pressurized water system.

(Refer to PRESSURIZED WATER SYSTEM in SECTION 2 of the OPERATOR'S MANUAL and PRESSURIZED WATER SYSTEM MAINTENANCE in THIS SECTION) • Carry out A/C system inspection; Refer to CHECKING THE AIR CONDITIONING SYSTEM in THIS SECTION

3.5

Tigercat M724D Mulcher

Lubrication and Maintenance

SCHEDULED MAINTENANCE Continued from page 5

EVERY 500 HOURS:~

EVERY 1000 HOURS:~

• Perform 8 hour maintenance

• Perform 8 hour maintenance

• Perform 125 hour maintenance

• Perform 125 hour maintenance

• Perform 250 hour maintenance

• Perform 250 hour maintenance

And in addition replace:~ • Air intake safety element

• Perform 500 hour maintenance And in addition replace :~ • Engine air cleaner unloader valve

• Hyd. Oil return filter, case drain † 1blue, water absorbing element

• Fuel intake strainer

• Hyd. Oil return filters, boom/attachment † 3 white, high performance elements

• Strainer in accumulator charge valve

• Hyd. Oil return filter, low pressure †

Check:~ • Motion between center joint lugs

• Hyd. Oil press. Filter, drive charge press. †

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

• Hyd. Oil press. Filter, fan drive charge press. † Lubricate:~ • Door screen hinges Check:~ • All hydraulic pressures

EVERY 2000 HOURS:~

• Transmission mounting, Check, re-torque

• Perform 8 hour maintenance

• Parking brake lever in cab, apply WD-40 to both sides of slide and clevis pin

• Perform 250 hour maintenance

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

• Perform 1000 hour maintenance

• Perform 125 hour maintenance • Perform 500 hour maintenance And in addition replace:~ • Oil in axles, front and rear.

• Oil in hydraulic reservoir • Water in pressurized water system • Refer to diesel engine service manual and attachment manual for additional required maintenance at this scheduled time period.

† Use of filters other than genuine Tigercat replacement filters is not recommended.

3.6

Tigercat M724D Mulcher

Lubrication and Maintenance

SCHEDULED MAINTENANCE SEASONAL:~ Drain and refill hydraulic oil tank and both front and rear axles with recommended hydraulic oil. See "approved hydraulic oils". Also see section 8 of the service manual for axle draining procedure.

Drain and refill pressurized water system.

(Refer to PRESSURIZED WATER SYSTEM in SECTION 2 of the OPERATOR'S MANUAL and PRESSURIZED WATER SYSTEM MAINTENANCE in THIS SECTION)

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

Wet disk brakes in the axles require oil with specific properties to ensure reduced chatter and ensure proper lubrication of mechanical components.

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

Chevron

Tractor hydraulic fluid (summer)

Citgo

Tractor hydraulic fluid (33-310) (summer)

Imperial

Esso hydraul 56 (summer) Hydraul 50 (low visc) (winter)

Shell

Donax TD (summer) Donax TDL (winter)

Sun

Sunfleet th fluid (summer)

John Deere

Type J20C (hy-gardtm) (summer) Type J20D (hy-gardtm) (winter)

3.7

Tigercat M724D Mulcher

Lubrication and Maintenance

OUTER AXLE BEARINGS 22

4 FTG/8

26

1

16

4

7

8

23

6 5 14

SEE APPROPRIATE ATTACHMENT MANUFACTURER'S MANUAL

13 12 13 15 20 STEER CYLINDERS

8 FTG/8

4 FTG/8

BOOM CYLINDER PINS

10 FTG/8

8 FTG/500

2 FTG/125

DOOR SCREEN HINGES

AXLE OSCILLATION

25

BOOM/LINK PINS

1

10 11

9

27

5 6 17

ATTACHMENT HEAD 4 24 19 REAR DRIVE SHAFT

2 FTG/8

19

CENTER JOINT 3

2 FTG/8

21

23

18

1 FTG/125

MID DRIVE SHAFT & FRONT DRIVE PILLOW BLOCK BEARING

LEGEND *** 2 FTG/125

STEER MACHINE FULLY BEFORE GREASING MID DRIVE SHAFT SLIP YOKE. LUBRICATION POINT WITH A DESIGNATED NUMBER OF FITTINGS (2 FTG) AND HOURS BETWEEN SERVICING (125 ). JOINT TO BE PURGED.

†

Use of filters other than genuine Tigercat replacement filters is not recommended.

17988B R0

3.8

CHK REP DRN D/R LUB

HOURS CHECK REPLACE DRAIN DRAIN AND REFILL LUBRICATE

Tigercat M724D Mulcher

Lubrication and Maintenance

Tigercat® Model M724D SERVICE AND LUBRICATION POINTS REFER TO Tigercat OPERATOR'S MANUAL FOR FURTHER INFORMATION

3 4

CENTER JOINT PIVOT ENGINE OIL AND FILTER CUMMINS 'C'

5 6

FUEL FILTER FUEL WATER SEPARATOR FUEL CAP SCREEN INTAKE FUEL STRAINER

7 8 9 10 11 12

AIR INTAKE PRECLEANER AIR INTAKE PRIMARY AIR INTAKE SAFETY FILTER ELEMENT HYDRAULIC OIL FILTER CASE DRAIN

LUB

35

9.3

CHK

CHK

QTY

2000

500

250

CHK

USG

COOLING SYSTEM

CAPACITY LITERS

1

125

8

ITEM

1000

SERVICE POINT NO.

SERVICE EVERY

2

REP

19

5

REP

1 1 1 1

DRN CHK CHK

REP †

1

USE BLUE WATER ABSORBING ELEMENT

REP †

3

REP

HYDRAULIC OIL FILTER BOOM/ATTACHMENT

14

HYDRAULIC OIL FILTER LOW PRESSURE

REP †

1

15

HYDRAULIC DRIVE CHARGE PRESSURE FILTER

REP †

1

16

HYDRAULIC FAN DRIVE CHARGE PRESSURE FILTER

REP †

1

18

PUMP DRIVE GEARBOX

CHK

D/R

2.6

0.7

TRANSMISSION - TIGERCAT 1 SPEED - FUNK 2 SPEED

CHK CHK

D/R D/R

5.7 8.2

1.5 2.2

19

AXLES:

20

HYDRAULIC RESERVOIR

21

PARKING BRAKE

22

ATTACHMENT

LUB

23

PRESSURIZED WATER SYSTEM

CHK TEST

24

ACCUMULATOR CHARGE VALVE STRAINER

25 26

A/C & HEATER FILTERS CHK LUB* LUB* OUTER AXLE BEARINGS **NOTE: MANUAL OUTER AXLE BEARING LUBRICATION APPLIES ONLY TO EARLIER AXLES WITH CARTRIDGE LIP SEAL AND GREASE FITTINGS. LATER AXLES HAVE A FACE SEALS AND DO NOT REQUIRE MANUAL LUBRICATION.

FRONT (EARLIER) ** REAR (EARLIER) ** FRONT (LATER)** REAR (LATER)**

27

COMPRESSED AIR TANK

M724DLUBCHART-MANUAL.XLS 17988BR0 & 19679BR0

CLEAN OR REPLACE AS NECESSARY DRAIN TANK, CLEAN OR REPLACE AS NECESSARY CHECK RESTRICTION INDICATOR ON INTAKE PIPE AT FULL RPM. CLEAN UNLOADER VALVE EVERY 8 HOURS. REPLACE VALVE EVERY 1000 HOURS.

CHK REP

13

17

60 % ANTIFREEZE / 40 % DISTILLED WATER (GM6035M SPEC.) CHECK MOTION BETWEEN CHASSIS LUGS SEE ENGINE MANUFACTURER'S MAINTENANCE MANUAL

1 1

CHK

CHK

DESCRIPTION

D/R D/R D/R D/R CHK

CHECK LEVEL WITH DIPSTICK. FILL WITH MIL-L-2105C OR API-GL-5 BELOW -10Fº(-23ºC) USE 75W-90 UP TO 100ºF(38ºC) USE 80W-90 ABOVE 100ºF(38ºC) USE 85W-140 DRAIN AND REFILL COMPLETE SYSTEM ANNUALLY OR AS REQUIRED SEASONALLY. MUST MEET JOHN DEERE TYPE J20C (HY-GARD) SUMMER OR TYPE J20D (HY-GARD) WINTER

50 13.2 28 7.4 53 14 31 8.2

D/R 227

60

CHK LUB

REFER TO SECTION 2 OF OPERATOR'S MANUAL. APPLY WD-40 TO BOTH SIDES OF SLIDE AND CLEVIS PIN ON HANDLE. SEE ATTACHMENT MANUFACTURER'S MANUAL D/R REP

CHECK SYSTEM PRESSURE, 60 PSI REFER TO SECTION 2 OPERATOR'S MANUAL. 1 CLEAN OR REPLACE AS NECESSARY ALWAYS WITH A HAND GREASE GUN. LUBRICATE UNTIL GREASE FLOWS OUT PAST THE OUTER SEAL. * UNDER NORMAL CONDITIONS EVERY 125 HOURS, UNDER ADVERSE CONDITIONS (MUD, WATER, SNOW) EVERY 8 HOURS

DRN

DRAIN TANK DAILY IF APPLICABLE

3.9

Tigercat M724D Mulcher

Lubrication and Maintenance

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

FUEL FILTER/WATER SEPARATOR The fuel filter/water separator is a combination unit, with a replaceable fuel filter and a removable water sediment bowl on the bottom of the unit.

The water sediment bowl is only replaced if it becomes damaged or non-functional. For service and replacement intervals see SERVICE AND LUBRICATION CHART in THIS SECTION.

Changing the filter: 1. Park machine on level ground, install articulation lock bar, lower attachment to ground, stop engine, pull parking brake ON and block wheels.

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

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

4. Wearing face protection (in case of a fuel squirt) turn OFF the fuel shut-off valve on the side of the fuel tank and unscrew the old filter.

5. Remove and discard the small 1” I.D. gasket from the threaded extension on the filter head.

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

7. Clean the water sediment bowl.

8. Check the seating area for the gaskets on the filter head and the water sediment bowl and wipe clean.

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

FUEL LINE WATER SEPARATOR 718-D14

10. Lubricate the new 1” I.D. gasket with clean engine oil and install onto the threaded extension on the filter head.

11. Lubricate the gasket on top of the new filter with clean engine oil and pre-fill the filter with clean fuel.

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

13. Turn the fuel shut-off valve ON, start the engine and check for leaks.

• WATER SEPARATOR BOWL 216-2A

•• DRAIN TAP

3.10

Tigercat M724D Mulcher

Lubrication and Maintenance

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

Changing or cleaning the strainer: NOTE: This should only be required if excessive quantities of foreign material has built up inside the tank.

1. Park machine on level ground, install articulation lock bar, lower attachment to ground, stop engine, pull hand brake ON and block wheels.

2. Drain the fuel tank. (plug in bottom) 3. Remove the round fuel tank cleanout cover plate and “O” ring from the access hole.

4. Before removing the strainer, clean any debris from the bottom of the tank and wipe it clean.

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

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

7. Reinstall the strainer using the hex on end.

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

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

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

3.11

Tigercat M724D Mulcher

Lubrication and Maintenance

HYDRAULIC OIL RETURN FILTERS

6. The Tigercat spin-on filter element is supplied with two gaskets. The M724D uses the round ('O' ring style) section gasket for all four return filters. Discard the square section gasket.

There are five full flow filters mounted on filter heads with built-in bypasses. Three are in the attachment/boom return line. One is in the low pressure return line and one is in the case drain return line. The case drain filter is colored blue indicating that it contains a water absorbing element. For service and replacement intervals see SERVICE AND LUBRICATION CHART in THIS SECTION.

•

FILTER HEAD

•

CASE DRAIN FILTER WITH WATER ABSORBING ELEMENT (COLOR BLUE)

GASKET

• FILTER ELEMENT

•• FILTR_SEALS2

ATTACHMENT/ BOOM RETURN FILTERS

M724D-17

••

••

•• ••

LOW PRESSURE FILTER

HYDRAULIC OIL RETURN FILTERS

Changing the filters:

ROUND SECTION GASKET INSTALLATION 7. Remove used gasket and clean gasket seat in head.

8. Apply clean oil to new round gasket surfaces.

9. Install new round section gasket into inside lip of filter.

10. Screw on new filter until filter makes contact with filter head.

1. Park machine on level ground, install articulation lock bar, lower attachment to ground, stop engine, pull parking brake ON and block wheels.

11. Tighten filter until top edge makes metal to metal contact with head. (Approximately 1 1/2 additional turns after gasket contact)

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

12. Start the engine and check for leaks.

HYDROSTATIC CHARGE PUMP PRESSURE FILTERS

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

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

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

There are two full flow filters mounted on filter heads with built-in bypasses. One is in the output side of the hydrostatic drive charge pump and the other is in the output side of the hydrostatic fan drive pump. For service and replacement intervals see SERVICE AND LUBRICATION CHART in THIS SECTION. Changing the filters: 1. Park machine on level ground, install articulation lock bar, lower attachment to ground, stop engine, pull parking brake ON and block wheels.

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

3.12

Tigercat M724D Mulcher

Lubrication and Maintenance

HYDRAULIC FILTER SERVICING GUIDELINES FOR M724D MULCHERS IMPORTANT

NEVER PRE-FILL ANY HYDRAULIC FILTERS ON M724D MULCHERS

••

Tigercat generally does not recommend the prefilling of spin-on filters due to the risk of damage to the hydraulic system caused by unfiltered oil.

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

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

FAN DRIVE CHARGE PRESSURE FILTER LOCATED BEHIND REMOVABLE PANEL IN FAN DRIVE AREA

724D-D03

CHARGE PRESSURE FILTER HYDRAULIC FAN DRIVE

DRIVE CHARGE PRESSURE FILTER LOCATED ON HYDRAULIC TANK WALL

•• 724D-D01

CHARGE PRESSURE FILTER HYDROSTATIC DRIVE

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

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

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

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

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

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

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

9. Start the engine and check for leaks.

3.13

Tigercat M724D Mulcher

Lubrication and Maintenance ENGINE AIR CLEANER

AIR CLEANER MAINTENANCE ENGINE AIR CLEANER

ENGINE AIR PRECLEANER

••

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

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

••

FILTER RESTRICTION INDICATOR

•

UNLOADER VALVE

AIR CLEANER AND PRECLEANER ENGINE AIR PRECLEANER 724D-D13

The engine air precleaner cleans engine air before it reaches the air cleaner filter elements. It removes contaminants such as dust, powder, insects, rain and snow. This precleaner is self powered and self cleaning requiring virtually no maintenance. However, it should be checked periodically to make sure that foreign materials have not plugged the intake area or the exhaust port area.

AS THE AIR SPINS, CENTRIFUGAL FORCE SEPARATES FOREIGN MATERIALS FROM THE CLEAN AIR

•

M724D-12

FILTER RESTRICTION INDICATOR

A filter restriction indicator is mounted to the output side of the air cleaner. This should show green when the engine is running at FULL RPM. Service is required only if the indicator shows red.

CONTAMINANTS ARE BLOWN OUT OF SPECIAL DISCHARGE PORTS BY HIGH VELOCITY, AIR POWERED ROTOR

•

••

UNLOADER VALVE

• 724D-D49

•

AIR CLEANER UNLOADER VALVE

AIR CLEANER UNLOADER VALVE

•

THE TURBO II PRECLEANER HAS SPECIALLY DESIGNED BLADES THAT CAUSE THE INCOMING AIR TO SPIN TURBO 2

ONLY THE PURIFIED AIR GOES TO THE AIR FILTER

TURBO II PRECLEANER OPERATION

EXHAUST PORT AREA

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

This valve should be replaced every 1000 hours.

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

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

218-21

PRECLEANER REAR VIEW 3.14

Tigercat M724D Mulcher

Lubrication and Maintenance

In addition to the LUBRICATION AND MAINTENANCE SCHEDULE outlined in THIS SECTION, the following instructions should also be noted:

IMPORTANT STEPS TO FOLLOW WHEN CHANGING FILTER ELEMENTS 1. Release the cover latch gently to reduce the amount of dust dislodged.

The most common and damaging servicing problems are:

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

OVER SERVICING

3. Check your old filter sealing surfaces, This will help detect foreign material on the sealing surface that is causing leakage.

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

PRIMARY OUTLET ELEMENT TUBE

SAFETY ELEMENT

724D-D13X

4. Always clean the inside of the outlet tube.

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

ENGINE AIR PRECLEANER

•• •

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

6. Inspect the new filter for damage.

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

••

AIR FILTER ELEMENTS

NOTE: This does not apply to hydraulic oil or diesel engine oil filters.

8. Check connections and ducts for an air tight fit. Ensure that all clamps, bolts and connections are tight. Check rubber elbows for splits or wear points. Leaks in these locations send dust directly to the engine.

SERVICING Engine exposure to dust during servicing is a large reason for engine damage due to dust.

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

3.15

Tigercat M724D Mulcher

Lubrication and Maintenance

PRESSURIZED WATER SYSTEM MAINTENANCE

FILL & CHARGE PRESSURIZED WATER SYSTEM

OPERATION:

1. Open water shut off valve and completely discharge all water and compressed air from the tank via the hose end nozzle.

Turn the hand operated ball valve (shut off valve) under the seat to the ON position to draw water from the 10.5 USgallon (39.7 liter) pressurized holding tank at the rear of the machine. When not in use turn the water supply OFF at this valve and relieve the pressure in the rubber hose, under the operator's seat.

HOSE

CAUTION Never remove fill plug before depressurizing tank or injury may result. This fill plug incorporates a vent hole to release air pressure from the tank before the threads disengage. DO NOT replace this fill plug with any substitute.

WATER SHUT OFF VALVE (SHOWN CLOSED)

9

••

196-16A

••

2. Slowly unscrew fill plug two full turns. Any remaining air in the tank will be heard expelling from the special fill plug. Do not remove fill plug until all air has been expelled.

•

PRESSURIZED WATER SYSTEM CONTROL VALVE (UNDER SEAT)

The pressure gauge on the side of the seat should read 60 psi.

AIR CHARGE VALVE

• •

TANK FILL PLUG

•• PRESSURE GAUGE

196-9A

PRESSURIZED WATER SYSTEM

718-D19

Refer also to FIRE PREVENTION in SECTION 1 of THIS MANUAL. SYSTEM TEST:

3. Close water shut off valve.

4. Fill tank with water. Tank capacity is approximately 10.5 USgallons (39.7 liters) When temperatures below 32°F are anticipated, use a 60/40 solution of Nontoxic R. V. Antifreeze or other suitable antifreeze.

Antifreeze solution must meet GM 6038M specifications.

This system should be tested once every month by turning the shut-off valve ON and expelling water from the hose end nozzle. A very forceful discharge of water should be obtained. If the water does not come out with force (with pressure gauge reading 60 psi) the system needs to be PURGED. Refer to PURGING PRESSURIZED WATER SYSTEM in THIS SECTION. After testing, the tank must be refilled and pressurized to 60 psi. Refer to the following FILL AND CHARGE procedure. This FILL AND CHARGE procedure should be carried out yearly.

PRESSURIZED WATER SYSTEM

NOTE: Most Nontoxic RV Anti freeze solutions contain corrosion and algae inhibitors, it is therefore suggested that this solution be added to the water on a continual basis regardless of temperature conditions.

5. Install fill plug in tank.

3.16

NOTE: This is a special plug designed to withstand pressurization of the water tank. Do not substitute.

Tigercat M724D Mulcher

Lubrication and Maintenance

6. Pressurize the system to 60 psi as indicated on pressure gauge by connecting an air hose to air charge valve beside the pressure gauge.

PURGING PRESSURIZED WATER SYSTEM

7. Open the water shut off valve 8. Discharge about 1/2 US gallon (2 liters) of fluid into an empty antifreeze jug or other suitable container.

There will be significant foaming as the fluid is discharged into the jug. Continue until a very forceful flow is obtained and any contamination that may have been in the tank is flushed from the system.

Purging should be carried out whenever the flow of water does not forcefully discharge from the end of the hose with the pressure gauge reading 60 psi.

1. Open water shut off valve and completely discharge all water and compressed air from the tank via the hose end nozzle.

CAUTION Never remove fill plug before depressurizing tank or injury may result. This fill plug incorporates a vent hole to release air pressure from the tank before the threads disengage. DO NOT replace this fill plug with any substitute.

9. Check fluid in the jug for contamination. If fluid is dirty dispose of it properly.

10. Close the water shut-off valve.

11. Release pressure and fluid from the hose.

12. Pressurize the system to 60 psi as indicated on pressure gauge by connecting an air hose to air charge valve beside the pressure gauge.

13. Return the hose to its storage location.

2. Slowly unscrew fill plug two full turns. Any remaining air in the tank will be heard expelling from the special fill plug. Do not remove fill plug until all air has been expelled.

3. Close the water shut off valve and add 2 USgallons (8 litres) of clean water to the tank.

4. Install fill plug in tank.

NOTE: This is a special plug designed to withstand pressurization of the water tank. Do not substitute.

5. Pressurize the system to 60 psi as indicated on pressure gauge by connecting an air hose to air charge valve beside the pressure gauge.

6. Open the shut off valve and completely discharge all the water in the tank via the hose end nozzle.

7. Discharge all the water into an empty antifreeze jug or other suitable container.

There will be significant foaming as the fluid is discharged into the jug. Continue until a very forceful flow is obtained and any contamination that may have been in the tank is flushed from the system.

8. If a forceful discharge was not achieved, repeat the purging procedure. If a second purging does not work, remove lines and check for an obstruction.

9. After the purging operation, fill and charge the system as described in FILL & CHARGE PRESSURIZED WATER SYSTEM in THIS SECTION.

3.17

Tigercat M724D Mulcher

Lubrication and Maintenance

CHECKING THE AIR CONDITIONING SYSTEM

IMPORTANT

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

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

AIR CONDITIONING TOTAL SYSTEM VOLUME R134a Refrigerant

PAG Oil

2 LBS. 12 OZ.

7 OZ.

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

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

7850AR1

The compressor and charge valves are accessed from the right side engine compartment. The receiver drier is accessed from the left side engine compartment. The evaporator core is accessed on the right hand side of the machine just inside the cab door.

Perform following inspection along with 125 HOURS inspection outlined in SCHEDULED MAINTENANCE in THIS SECTION.

e. Check all A/C hoses for kinks.* f.

Run air conditioning system for 3 - 5 minutes.

g. Check air temperature exiting vents in cab. h. Listen to compressor and blower motor for abnormal noises.* i.

a. Check re-circulating and fresh air filters in operator's cab. Refer to SECTION 2 of the OPERATOR'S MANUAL.

Check to see that compressor clutch will engage.*

CAUTION Use compressed air for cleaning only when the machine is cold to avoid the risk of fire caused by debris contacting hot surfaces.

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

Always use personal protective equipment to guard against flying debris

CAUTION

724D-D12

CHECK A/C CONDENSER CORE

b. Check the condenser core for dirt and debris.

Clean as required. Refer to CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR in SECTION 2 of the OPERATOR'S MANUAL. c.

Check for dirt and debris; on the evaporator coil, located inside the A/C-heater unit, and the inside of the A/C-heater unit. Clean as required.

d. Check and adjust compressor drive belt tension.

3.18

Avoid the risk of fire caused by debris accumulating on surfaces that may become hot during machine operation. Always use care when cleaning to ensure that debris removed from one area of the machine does not accumulate on other areas of the machine.

Tigercat M724D Mulcher j.

Lubrication and Maintenance

Inspect sight glass on receiver dryer with A/C ON. A constant stream of bubbles indicates system requires charging.* SIGHT GLASS INDICATES CONDITION OF CHARGE

•

• BINARY SWITCH, SYSTEM PROTECTION

•• MOISTURE INDICATOR BLUE - OK PINK - REPLACE DRYER, RECHARGE SYSTEM

• A/C RECEIVER/DRYER

870-D43

A/C RECEIVER/DRYER

Check colour in moisture indicator, BLUE is OK. PINK indicates desiccant material in dryer is saturated with moisture. In this situation replace receiver/dryer, evacuate system recharge system with both refrigerant PAG oil.* * Indicates that these repairs must only be carried out by a certified A/C technician.

For additional SERVICE information refer to the Tigercat A/C SERVICE MANUAL part number 18795A, available from Tigercat parts department.

3.19

Tigercat M724D Mulcher

Lubrication and Maintenance

CENTER JOINT

TRANSMISSION:

MAINTENANCE OF CENTER JOINT Maintenance in this area is usually limited to:

By carefully following these procedures, the service life of the transmission will be extended and costly down time will be avoided.

a) Regular lubrication of the two center joint grease fittings to purge the pivot bearings of debris and water. Refer to SERVICE AND LUBRICATION POINTS in THIS SECTION for lubrication intervals. Use only high quality, lithium based EP2 grease containing molybdenum disulphide.

For additional information, refer to TRANSMISSION in SECTION 8 of the SERVICE MANUAL. TRANSMISSION OIL LEVEL CHECK/FILL

b) Visually checking the center joint pivot for looseness every 1000 hours. With an observer on the ground, keeping well clear of the center joint area, perform the following test to check for looseness of center joint.

••

1. Have operator lift the attachment off the ground and then rapidly raise and lower the head several times to "bounce" machine.

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

M724D-18

CHECK TRANSMISSION OIL LEVEL

CHECK OIL LEVEL Check oil level at end of every 8 hour shift.

Procedure: • Park on level ground, lower attachment, set parking brake on and turn off engine.

REAR CHASSIS

CHECK FOR MOVEMENT IN THIS JOINT AREA

FRONT CHASSIS

•

Clean dirt and debris from around oil dipstick and check oil level.

•

If required: add the recommended grade of oil through oil fill plug located on top of transmission housing.

Do not overfill.

724D-D11

1000 HOUR CHECK

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

Refer to SECTION 11 of the SERVICE MANUAL for more information..

3.20

Tigercat M724D Mulcher

Lubrication and Maintenance

SPEED CONTROL LEVER ADJUSTMENT 7

The friction setting on the speed control lever is variable and can be adjusted to allow proper operation.

•

The friction setting on the speed control lever may reduce over time, during normal operation, and not maintain the set position of the lever, especially at maximum throw.

PROCEDURE Before starting work, read and follow all servicing safety precautions in SECTION 1 of THIS MANUAL. 1. Park machine on level ground, apply parking brake, lower attachment to ground, shut off engine.

2. Position the speed control lever in the neutral position (pointing straight up).

3. Raise the protective rubber ‘boot’ from the speed control valve body, located on the side instrument panel.

M724D-02

SPEED CONTROL LEVER

4. Locate the adjustable friction set screw.

SPEED CONTROL LEVER

5. Tighten the adjustable friction set screw as required (2.5mm hex key)

•

6. Replace the protective rubber ‘boot’ over the speed control valve body.

PROTECTIVE RUBBER BOOT

RIGHT HAND SIDE OF MACHINE

• ADJUSTABLE FRICTION SET SCREW

••

CONTROL PANEL

••

630B-31

3.21

SPEED CONTROL LEVER FRICTION SET SCREW LOCATION

Tigercat M724D Mulcher

Lubrication and Maintenance

START-UP PROCEDURE AFTER MAJOR MACHINE MAINTENANCE

•

Remove the air bleed plug from the steel suction tube on the side of the oil reservoir.

This procedure should be followed:

•

Remove the hydraulic tank pressure release valve from the hydraulic tank and pressurize the hydraulic tank through this opening using air or nitrogen. To ensure that the hydraulic tank is not contaminated use a clean rag as a filtering device.

•

As the tank becomes pressurized the hydraulic oil will move up the suction tube and over into the supply lines. Air will begin to exit at the air bleed plug.

•

When a constant stream of oil without any air exits the suction tube replace the air bleed plug. Do not remove pressure from the tank until the air bleed plug is fully tightened.

•

Remove the pressure from the tank and reinstall the pressure release valve.

•

After major service or a rebuild.

•

Whenever the machine has been drained of hydraulic oil.

•

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

PRE-STARTUP AND FILLING 1. Check oil levels in the engine, the pump drive gearbox and the transmission.

2. Check coolant level in the radiator.

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

4. Install the articulation lock bar and apply the parking brake.

NOTE: If the axles were drained of oil, refer to FILLING THE AXLES in SECTION 8 of the SERVICE MANUAL.

5. Turn both differential lock switches to OFF. 6. Do not start engine. Purge air from hydraulic system as follows: •

Fill the hydraulic tank if it has been drained.

•

Ensure all filters are in place.

•

Fill the drive and saw pumps with hydraulic oil through the case drain ports.

• HYDRAULIC TANK PRESSURE RELEASE VALVE AIR BLEED PLUG

•

M724D-20

REMOVE THE AIR BLEED PLUG 3.22

Tigercat M724D Mulcher

Lubrication and Maintenance

MACHINE START-UP

NOTE: It is necessary to press and hold the bulb test/engine start switch while turning the key switch to the START position to crank the engine. Refer to STARTING ENGINE in SECTION 2 of the OPERATOR'S MANUAL.

Before beginning this procedure, perform the PRE START-UP AND FILLING steps.

NOTE (MULCHER ATTACHMENT): When the mulcher head is attached, re-torque all cutter tool fasteners (See manufacturer's manual). 4. Reconnect wires on injector pump solenoid.

Do not start engine.

Block rotating cutter to prevent rotation.

NOTE (FELLER BUNCHER ATTACHMENT): When the saw head is attached, re-torque all teeth (See saw manual). Attach the SAW BLADE GUARD and insert the SAW BLADE LOCKING PIN.

INSTALL A 0-1000 PSI. GAUGE AT ‘G’ PORT. DRIVE PUMP

••

UNPLUG ENGINE START SOLENOID

•• •

•• DRIVE PUMP 'G' TEST PORT CONNECTION 5. Install a 0-1000 psi. gauge on drive pump to check charge pressure at ‘G’ port. Watch gauge closely during startup.

724D-D06

724D-D05

DISCONNECT ENGINE START SOLENOID (CUMMINS SHOWN)

1. Ensure the articulation lock bar is installed.

2. Disconnect the engine start solenoid (prevents engine starting).

CAUTION

7. Remove pressure gauge from 'G' port.

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

3. Crank engine for 3 seconds, wait for 5 seconds. Repeat 5 times to pump oil into pumps.

••

6. Start engine. If charge pressure does not rise within 20 to 30 seconds, TURN ENGINE OFF. If charge pressure is between 420 and 450 psi., run engine at IDLE for 20 minutes.

Check engine oil pressure in cab. Do not operate any functions.

8. Install a 0 - 1000 psi. gauge on pilot manifold. ("P2" on right side, quick connect fitting) 9. Turn pilot pressure reducing valve (far left end, top of pilot manifold) all the way IN until it is lightly seated.

PILOT PRESSURE RELIEF VALVE 675 PSI.

INSTALL A 0 - 1000 PSI. GAUGE ON "P2" PORT

•• •• PILOT PRESSURE REDUCING VALVE 550 PSI. 724D-D07

PILOT MANIFOLD

3.23

Tigercat M724D Mulcher

Lubrication and Maintenance

10. Adjust pilot pressure relief valve (second from left, top of pilot manifold) using gauge and set to 675 psi. and lock.

IMPORTANT Without a head attached, the tilt function can cause damage to the arms. Watch the two LINK ARMS very carefully, as they may drop down beside the boom arms and wedge, causing the crank arms to bend. When necessary, lower the boom DOWN, watching closely and tilt FORWARD, again watching the link arms closely.

11. Using same gauge, reset pilot pressure reducing valve to 550 psi. and lock.

12. Remove pressure gauge from the pilot manifold.

•

STEER CIRCUIT MAIN RELIEF 2500 PSI.

CRANK, LINK AND BOOM ARMS

••

CRANK ARM

INSTALL A 0-5000 PSI. GAUGE

LINK ARM

• ••

STEER CIRCUIT MAIN RELIEF VALVE 13. Install a 0-5000 psi. gauge on steer circuit main relief (quick connect fitting).

724D-D04

BOOM ARM

14. Set steer relief to 2500 psi. on gauge.

••

15. With engine at IDLE, parking brake ON, hold foot brake down, bleed brakes in rear axle.

192-21A

16. Remove pressure gauge from steer relief valve.

21. Top up the radiator with clean coolant. With cylinders fully retracted, top up the hydraulic oil reservoir with clean hydraulic oil.

17. Turn both differential locks ON and run engine at IDLE for 30 minutes to purge air and fill axles with oil (axles fill with leakage from diff. locks). If wheels have been removed, operate forward and reverse pedals very slowly to fill axles with oil.

18. Set throttle to IDLE and run each BOOM function for 2 minutes to purge air from circuit.

19. Set throttle to FULL and run each BOOM function again for 2 minutes to flush circuit.

20. At FULL throttle, operate all other functions for 2 minutes to flush circuits.

NOTE: If the machine was on wheels, the steer and drive functions were not properly purged or flushed. Remove the articulation lock bar and at LOW IDLE, slowly operate the steer function right and left a few times.

With the parking brake released and at LOW IDLE, slowly operate the drive function forward and reverse a few times.

NOTE: If possible, allow the machine to stand for 4 to 6 hours before setting any of the operating pressures. This will allow any air bubbles in the oil to escape and is a good time to check for leaks.

3.24

Tigercat M724D Mulcher

Lubrication and Maintenance

REPLACING THE ENGINE SERPENTINE BELT In order to replace the engine serpentine belt it is necessary to disassemble the fan drive pump coupling.

4. Carefully slide the black rubber section of the coupler towards the fan pump. This will provide enough clearance to replace the serpentine belt.

SLIDE BACK THE RUBBER SECTION OF THE COUPLER TO CREATE A SPACE

SHOWN WITH FAN AND HOSES REMOVED FOR CLARITY SERPENTINE BELT

••

COUPLER

•

•• •

724D-D56

SLIDE BACK THE BLACK RUBBER SECTION OF THE COUPLER

FAN DRIVE PUMP 724D-D54

PASS BELT THROUGH SPACE CREATED BETWEEN THE COUPLER

REMOVING SERPENTINE BELT

1. Park the machine on level ground. Parking brake ON, attachment resting on the ground and engine off.

••

2. Disconnect the fuel solenoid to prevent engine from starting when "jogging" the engine.

UN-PLUG CONNECTOR

• 724D-D57

•

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

FUEL SOLENOID 724D-D55 DISCONNECT FUEL SOLENOID 3. Remove the (8) socket head bolts that hold the pump drive coupler together. NOTE: the engine will have to be 'jogged' to access all of the bolts.

BLACK RUBBER COUPLER

•

6. Reassemble the pump drive coupler, using the original bolts. Use loctite 242 (temporary) or equivalent. Torque all bolts to 8-10 lbf-ft using an opposing torque pattern.

7. Reconnect the fuel solenoid.

REMOVE THE (8) SOCKET HEAD BOLTS

•

724D-D58

REMOVE\REPLACE SERPENTINE BELT

REMOVE BOLTS 3.25

Tigercat M724D Mulcher

Lubrication and Maintenance

MIDDLE AND REAR DRIVE SHAFT SPLINE LUBRICATION

MIDDLE SLIP SPLINE LUBRICATION

When operating in extremely wet or dusty conditions or when the regular service schedule has been neglected, insufficient lubrication to the spline area of the middle drive shaft will result in premature wear. In addition old grease often forms into a semi-solid, rubber-like plug preventing the purging of contaminants (water, dirt, sand, etc.) through the slip spline seal.

3. Apply grease to grease nipple until new, clean grease appears at slip spline seal, FIG. 'A'.

GREASE GUN

NEW GREASE APPEARS AT SLIP SPLINE SEAL

•

The most common cause of joint and slip spline failure is lack of proper lubrication.

SLIP SPLINE LUBRICATION

FIG. 'A' MIDDLE DRIVE SHAFT SLIP SPLINE LUBRICATION If grease is going IN but not coming OUT at the spline location, check to see if grease is exiting from the relief fitting at yoke end of slip

1. Park machine on level ground, and steer fully to the right. Lower attachment to the ground.

Set parking brake ON.

724D-D52

2. Stop the engine and relieve trapped pressure from pilot system and brake accumulators by performing the following steps:

GREASE GUN

•

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

Complete either steps 2A or 2B. 2A.Fully apply brake foot pedal 50 times or more.

2B.Turn rear differential switch ON and hold front differential lock switch ON for 30 seconds. While waiting, pump brake foot pedal at least 10 times.

GREASE APPEARS AT RELIEF FITTING 724D-D51

3. Pressure may remain in the system after completing all of the above steps. Use caution when loosening hydraulic connections.

For additional information, refer to RELEASE PILOT SYSTEM PRESSURE in SECTION 5 of the SERVICE MANUAL. .

FIG. 'B' MIDDLE DRIVE SHAFT YOKE END spline, FIG. 'B'. If so, cover the end of the relief fitting with a finger and continue to apply pressure to the grease nipple FIG. 'C'. If NEW GREASE APPEARS AT SLIP SPLINE SEAL

COVER RELIEF FITTING WITH FINGER

•

GREASE GUN

724D-D53

FIG. 'C' MIDDLE DRIVE SHAFT SLIP SPLINE LUBRICATION

grease pressure continues to exit from the relief fitting, remove the drive shaft and inspect for "hardened" grease build up, rust or other contaminants within the drive shaft. Repair or Replace drive shaft.

3.26

Tigercat M724D Mulcher

Lubrication and Maintenance

REAR SLIP SPLINE LUBRICATION 4. Apply grease to grease nipple until new, clean grease appears at the relief hole at yoke end of slip spline, FIG. 'D'.

GREASE GUN

•

GREASE APPEARS AT RELIEF HOLE 720C-01

FIG. 'D' REAR DRIVE SHAFT YOKE END 5. Cover relief hole with a finger and continue to apply pressure to grease nipple until new, clean grease appears at slip spline seal, FIG. 'E'.

GREASE GUN

•

NEW GREASE APPEARS AT SLIP SPLINE SEAL 720C-02

FIG. 'E' REAR DRIVE SHAFT SLIP SPLINE LUBRICATION

6. If grease does not appear at slip spline seal and continues to exit from the covered relief hole, remove the drive shaft and inspect for "hardened" grease build up, rust or other contaminants within the drive shaft. Repair or Replace drive shaft.

3.27

Tigercat M724D Mulcher

Lubrication and Maintenance

CONVERTING MULCHER TO FELLER BUNCHER CONFIGURATION

PUMP CONTROL

1. Park machine on level ground, lower attachment to the ground, stop engine and install articulation lock.

•

2. Disconnect mulcher head hoses at the boom bulkhead. There are six hoses used for a standard mulcher head. Cap all fittings and hoses to prevent contamination of the hydraulic system.

3. Remove the mulcher head from the boom by removing two pins from the boom arms and two pins from the tilt link connections.

4. Install felling head using 4 pins and shims.

NOTE: Some types of felling heads may require replacement of tilt links and crank arms.

5. Connect felling head hoses to the boom bulkhead. Seven hoses are used for the felling head. The two felling head clamp arm connections should have been capped securely when the mulching head was installed.

6. Securely cap the fitting previously used for the mulching head (extra return line).

RESET ATTACHMENT PUMP MAXIMUM DISPLACEMENT Attachment pump maximum displacement must be lowered to prevent overspeeding of the saw blade.

Overspeeding of the saw blade is dangerous and may result in serious injury or death. Overspeeding may also result in component damage or subsequent malfunction.

• M724D-21

MAXIMUM DISPLACEMENT ADJUSTING SCREW

ATTACHMENT PUMP

8. Check saw rotation speed and adjust to the correct blade speed as required. Refer to SAW SPEED ADJUSTMENT in the Tigercat SAW OPERATING AND SERVICE MANUAL (or other MANUFACTURER'S MANUAL) for saw speed measurement and adjustment procedure.

RESET PRESSURES. 9. Reset attachment pump pressure settings.

Refer to ATTACHMENT PUMP PRESSURE SETTINGS SAW ATTACHMENT in THIS SECTION. 10. Adjust saw clamp arm pressure settings.

Refer to CLAMP ARM PRESSURE SETTINGS in THIS SECTION.

7. Reset attachment pump maximum displacement. Turn the attachment pump maximum displacement adjusting screw IN 10.5 full turns. (Note: X dim should now be .03" (0.75 mm))

"X"

DIM X

DANGER DO NOT operate saw before adjusting the attachment pump maximum displacement.

Attachment pump maximum displacement is significantly lower for the saw attachment (33 gpm) than for the mulcher attachment (78 gpm).

Attachment pump maximum displacement must be lowered to prevent overspeeding of the saw blade. Overspeeding of the saw blade may result in serious injury or death.

Overspeeding may also result in component damage or subsequent malfunction.

3.28

MAXIMUM DISPLACEMENT "X" DIMENSION

Tigercat M724D Mulcher PRESSURE SETTINGS ATTACHMENT PUMP SAW ATTACHMENT NOTE: Refer to RELIEF VALVE ADJUSTING PROCEDURE in THIS SECTION. Before starting this procedure, read the following safety precautions:~ •

Never assume that other workers are aware of disc saw dangers.

•

Do not point the discharge side of the saw toward people, vehicles, buildings, or the machine.

•

Guards, wear plates and covers must be properly attached during operation of saw blade.

•

Do not, under any circumstances, overspeed the saw blade RPM.

•

Be aware that the saw blade is virtually silent as it coasts to a stop.

•

A slowly rotating blade can crush bones.

Beware of pinch points when rotating blade by hand.

•

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

•

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

•

Clamp and Accumulator arms open and close very rapidly. Keep clear of their operating range.

• • •

•

•

Wear safety shoes and safety glasses when working on saws.

Keep clamp and accumulator arms closed whenever possible during setup.

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

Lubrication and Maintenance NOTE: When converting a machine from Mulcher configuration to Feller Buncher configuration ensure that attachment pump maximum displacement is reset for mulcher configuration before setting pressures. Refer to CONVERTING MULCHER CONFIGURATION TO FELLER BUNCHER CONFIGURATION - RESET ATTACHMENT PUMP MAXIMUM DISPLACEMENT in THIS SECTION 1. Park machine on level ground, lower saw head, set parking brake ON. Install articulation lock bar, block wheels and stop engine.

WARNING To prevent injury caused by accidental steering of the machine when setting pressures, make sure the articulation lock bar is held securely in place by the lynch pins provided.

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

3. Rotate blade slowly by hand and check for "runout " and "wobble ".

4. Check the torque on both the saw blade mounting bolts and the saw tooth mounting bolts.

5. Properly install the saw blade guard using all hardware provided. Guard must be secure.

6. Block saw blade from rotating as outlined in saw head manufacturer’s manual.

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

8. Keep saw head 6" off the ground (15 cm) for the remaining steps of this procedure.

Check torque on saw blade mounting bolts and tooth mounting bolts before starting saw.

WARNING Workers on the ground should stand behind the wheels of the machine to provide an added barrier to thrown objects.

Install saw blade locking pin, except when setting motor "begin of stroke" and blade RPM.

WARNING WARNING Do not stand above or below the felling head and lift boom or between the boom and front chassis during this procedure.

Always allow the blade to coast to a COMPLETE STOP before approaching saw head to make adjustments.

3.29

Tigercat M724D Mulcher

Lubrication and Maintenance

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

PUMP CONTROL

10. Start the engine and raise hydraulic oil temperature to 120°F - 140°F.

•

11. Set throttle control to 1200 rpm.

• M724D-21

MAXIMUM DISPLACEMENT ADJUSTING SCREW

ATTACHMENT PUMP

PRESSURE COMPENSATOR VALVE M724D-03

CUTTER/SAW PRESSURE GAUGE

STANDBY VALVE

12. Measure stand-by pressure with saw/cutter switch in the OFF position. Gauge should read 600 psi, if not, adjust standby valve on the saw pump pressure compensator valve.

•• ••

13. Stop engine.

14. Install two 0-5000 psi pressure gauges in test ports 'GM' and 'GP' on cutter control valve.

CUTTER CONTROL VALVE MAIN RELIEF ADJUSTING SCREW

•

TEST PORT 'GM'

TEST PORT 'GP'

M724D-05

• • CUTTER CONTROL VALVE

M724D-22

PUMP CONTROL

18. Loosen locknut and screw pressure compensator valve adjusting screw on the attachment pump in to a setting of 3900 psi on 'GP' test port. This is a temporary adjustment until the cutter control main relief valve has been set.

19. Adjust the cutter control valve main relief valve pressure to approximately 3900 psi on 'GM' gauge, a hissing sound will be heard as oil begins to pass over the relief and there will be a change in the sound of the engine.

Immediately place the saw/cutter switch in the OFF position to minimize heating of the hydraulic oil.

20. Turn the pressure compensator valve adjusting screw OUT one turn to ensure oil is not heated by flowing over the relief valve.

21. Place the saw/cutter switch in the ON position.

NOTE: Close both doors and press pilot reset switch to operate the saw/cutter.

15. Screw main relief valve adjusting screw on cutter control valve all the way IN. 16. Start the engine and set throttle control to 1200 rpm.

22. Set pressure compensator valve on attachment pump to 3650 psi on 'GP' gauge.

17. Place the saw/cutter switch in the ON position.

23. Place the saw/cutter switch in the OFF position. Stop engine and remove block from blade. Remove pressure gauges and wipe up any excess oil.

NOTE: Close both doors and press pilot reset switch to operate the saw/cutter.

3.30

Tigercat M724D Mulcher

Lubrication and Maintenance

NOTE: Some attachments are equipped with variable displacement motor(s) which may require adjustment. Other attachments are equipped with fixed displacement motor(s) which require no adjustment.

For explanation of attachment motor, refer to ATTACHMENT MANUFACTURER'S MANUAL. SET MOTOR POR (BEGIN OF DISPLACEMENT REGULATION) If applicable - applies only to variable displacement attachment motor(s).

SET MOTOR MINIMUM DISPLACEMENT If applicable - applies only to variable displacement attachment motor(s).

Refer to the attachment manufacturer's own OPERATOR AND MAINTENANCE MANUAL for this information.

3.31

Tigercat M724D Mulcher

Lubrication and Maintenance

PRESSURE SETTINGS SAW CLAMP AND ACCUMULATOR

2. Set parking brake ON. Install articulation lock bar, block wheels and stop engine

NOTE: Refer to RELIEF VALVE ADJUSTING PROCEDURE in THIS SECTION.

WARNING

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

• Wear safety glasses and safety shoes when working on shears.

• Keep clamp and accumulator arms closed whenever possible during setup.

To prevent injury caused by accidental steering of the machine when setting pressures, make sure the articulation lock bar is held securely in place by the lynch pins provided.

WARNING

• Clamp and accumulator arms open and close very rapidly, always keep clear of operating area.

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

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

NOTE: This procedure assumes that a Tigercat Bunching Saw Head is used. Follow same procedure for Koehring Waterous 20" Saw Head. Refer to illustration of LIFT BOOM CONTROL VALVE on page 2 for orientation and pressure value references .

1. Park machine on level ground. Completely raise lift boom and install lift boom cylinder lock over one of the two cylinder rods with the open side at the bottom and wide end up against the keeper plate bolt heads. Install retaining bolt and locknut through center hole. Slowly lower boom until lock is securely held in place.

WARNING

TO SET CLAMP AND ACCUMULATOR OPEN AND CLOSE RELIEF VALVES:3. Connect a 0 - 5000 psi pressure gauge (with at least 4' of hose) to the inlet test port on of the boom control valve.

4. Turn the boom inlet main relief adjusting screw all the way IN. 5. Turn the port relief valve adjusting screws on both the accumulator and clamp spool sections of the control valve OUT until spring pressure is relieved then turn adjusting screws one full turn IN. 6. Start the engine, and put the throttle control to the IDLE position.

7. Ensure that the hydraulic oil temperature is between 120°F - 140°F.

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

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

During the following procedures, DO NOT hold ANY function control for LONGER THAN 5 SECONDS.

IMPORTANT Avoid blowing oil over relief longer than 5 seconds, as excessive heating of hydraulic fluid and damage to boom pump can occur.

IMPORTANT Approach the gauge reading slowly and deliberately by turning the adjusting screw in a little at a time. The pressure setting must not exceed the above value.

3.32

Tigercat M724D Mulcher

Lubrication and Maintenance accumulator close port relief. Repeat above procedure until a gauge reading of 3200 psi is obtained.

8. While holding the left foot pedal down in the CLAMP OPEN position (cylinder fully retracted), check gauge pressure reading.

If less than 1100 psi, stop engine and readjust clamp open port relief. Repeat above procedure until a gauge reading of 1100 psi is obtained.

12. Stop engine, unscrew inlet main relief adjusting screw 3 full turns.

IMPORTANT

9. While holding the right foot pedal down in the CLAMP CLOSE position (cylinder fully extended), check gauge pressure reading.

If less than 3200 psi, stop engine and readjust clamp close port relief. Repeat above procedure until a gauge reading of 3200 psi is obtained.

10. While holding the right joystick thumb switch to the left in the ACCUMULATING ARM OPEN position (accumulator cylinder fully retracted), check gauge pressure reading.

If less than 3200 psi, stop engine and readjust accumulator open port relief. Repeat above procedure until a gauge reading of 3200 psi is obtained.

11. While holding the right joystick thumb switch to the right in the ACCUMULATING ARM CLOSE position (accumulator cylinder fully extended), check gauge pressure reading.

Never run engine at full throttle with main relief turned all the way in.

13. Start engine and move the throttle control to the FULL position.

14. While holding the joystick thumb switch in the ACCUMULATING ARM OPEN position, check gauge pressure reading.

If less than 2600 psi, stop engine and readjust inlet main relief. Repeat above procedure until a gauge reading of 2600 psi is obtained.

15. Remove pressure gauge and wipe up any excess oil from test port area.

SET PILOT LINE PRESSURES: NOTE: Refer to SECTION 5 of the SERVICE MANUAL.

If less than 3200 psi, stop engine and readjust

CLAMP 'CLOSE' PORT RELIEF (3200 PSI)

CLAMP 'OPEN' PORT RELIEF (1100 PSI) [CLAMP

TILT

ACCUMULATOR 'CLOSE' PORT RELIEF (3200 PSI)

•

CLAMP ARM

•

ACCUMULATOR ARM/ MULCH DEFLECTOR DOOR

• ACCUMULATOR 'OPEN' PORT RELIEF (3200 PSI)

•

LIFT BOOM INLET GAUGE TEST PORT

•

•

•

MAIN RELIEF (2600 PSI)

INLET SECTION

BOOM CONTROL VALVE

M724D-02

TIGERCAT DW5000, DW5600 AND SW5700 BUNCHING SAWS KOEHRING WATEROUS 20" DISC SAWS

3.33

Tigercat M724D Mulcher

Lubrication and Maintenance

CONVERTING FELLER BUNCHER CONFIGURATION TO MULCHER

PUMP CONTROL

1. Park machine on level ground, lower attachment to the ground, stop engine and install articulation lock.

•

2. Disconnect saw head hoses at the boom bulkhead. There are seven hoses used for a standard saw head. Cap all fittings and hoses to prevent contamination of the hydraulic system.

•

3. Remove the saw head from the boom by removing two pins from the boom arms and two pins from the tilt link connections.

M724D-21

MAXIMUM DISPLACEMENT ADJUSTING SCREW

ATTACHMENT PUMP

RESET PRESSURES

4. Install mulcher head using 4 pins and shims.

9. Reset attachment pump pressure settings.

Refer to PRESSURE SETTINGS ATTACHMENT PUMP MULCHER ATTACHMENT in THIS SECTION.

NOTE: Replacement of tilt links and crank arms may be required depending on which saw head was installed.

5. Connect mulcher hoses to the boom bulkhead.

Six hoses are used for the mulching head.

The mulcher extra return line connection should have been capped securely when the saw head was installed.

10. Adjust mulch deflector door pressure settings.

Refer to PRESSURE SETTINGS MULCH DEFLECTOR DOOR in THIS SECTION.

6. Securely cap the two fittings previously used for the felling head clamp arm hoses.

"X"

RESET ATTACHMENT PUMP MAXIMUM DISPLACEMENT Attachment pump maximum displacement must be raised for proper operation of the mulching head.

Note that attachment pump maximum displacement is significantly higher for the mulcher attachment (78 gpm) than for the saw attachment (33 gpm). For more information regarding settings for saw attachments refer to CONVERTING MULCHER TO FELLER BUNCHER CONFIGURATION. 7. Reset attachment pump maximum displacement. Turn the attachment pump maximum displacement adjusting screw OUT 10.5 full turns. (Note: X dim should now be 0.5" (12-13 mm)) 8. Adjust mulcher head as required. Refer to mulcher head manufacturer's manual for more information and instructions.

3.34

DIM X

MAXIMUM DISPLACEMENT "X" DIMENSION

Tigercat M724D Mulcher

Lubrication and Maintenance

PRESSURE SETTINGS ATTACHMENT PUMP MULCHER ATTACHMENT:

NOTE: When converting a machine from Feller Buncher configuration to Mulcher configuration ensure that attachment pump maximum displacement is reset for mulcher configuration before setting pressures. Refer to CONVERTING FELLER BUNCHER CONFIGURATION TO MULCHER - RESET ATTACHMENT PUMP MAXIMUM DISPLACEMENT in THIS SECTION.

NOTE: Refer to RELIEF VALVE ADJUSTING PROCEDURE in THIS SECTION. Before starting this procedure, read the following safety precautions:~ •

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

•

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

•

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

•

Do not, under any circumstances, overspeed the rotating cutter RPM.

•

1. Park machine on level ground, close mulcher door and lower mulching head to the ground adjust depth shoes or rest depth shoes on firm blocks so that the rotating cutter is approximately 6" off the ground. Set parking brake ON. Install articulation lock bar, block wheels and stop engine.

WARNING

A slowly rotating cutter can crush bones.

Beware of pinch points when rotating cutter by hand.

To prevent injury caused by accidental steering of the machine when setting pressures, make sure the articulation lock bar is held securely in place by the lynch pins provided.

•

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

•

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

•

Mulcher door opens and closes quickly.

Keep clear of its operating range.

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

•

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

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

•

Keep mulcher door closed whenever possible during setup.

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

•

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

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

•

Check torque on cutter tool mounting bolts before starting cutter.

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

For more safety information refer to SECTION 1 of THIS MANUAL.

7. Keep mulcher head 6" off the ground (15 cm).

WARNING

WARNING

Always allow the rotating cutter to coast to a COMPLETE STOP before approaching mulching head to make adjustments.

Workers on the ground should stand behind the wheels of the machine to provide an added barrier to thrown objects.

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

3.35

Tigercat M724D Mulcher

Lubrication and Maintenance PUMP CONTROL

• • M724D-03

CUTTER/SAW PRESSURE GAUGE

M724D-21

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

MAXIMUM DISPLACEMENT ADJUSTING SCREW

ATTACHMENT PUMP

PRESSURE COMPENSATOR VALVE

9. Start the engine and raise hydraulic oil temperature to 120°F - 140°F.

STANDBY VALVE

10. Set throttle control to 1200 rpm.

11. Measure standby pressure with saw/cutter switch in the OFF position. Gauge should read 600 psi, if not, adjust standby valve on the saw pump pressure compensator valve.

•• ••

12. Stop engine.

PUMP CONTROL NOTE: Close both doors and press pilot reset switch to operate the saw/cutter.

13. Install two 0-5000 psi pressure gauges in test ports 'GM' and 'GP' on cutter control valve.

CUTTER CONTROL VALVE MAIN RELIEF ADJUSTING SCREW

TEST PORT 'GP'

M724D-05

18. Loosen locknut and adjust pressure compensator valve adjusting screw on the attachment pump to a setting of 5800psi on 'GP' test port. This is a temporary adjustment until the mulcher head spike relief has been set

••

TEST PORT 'GM'

M724D-22

•• •• CUTTER CONTROL VALVE

14. Screw main relief valve adjusting screw on cutter control valve all the way IN. 15. Screw the mulcher head spike relief valve all the way IN. 16. Start the engine and set throttle control to 1200 rpm.

19. Adjust the mulcher head spike relief valve pressure lower to approximately 5800 psi on 'GM' gauge, a hissing sound will be heard as oil begins to pass over the relief and there will be a change in the sound of the engine.

Immediately place the saw/cutter switch in the OFF position to minimize heating of the hydraulic oil.

20. Turn the pressure compensator valve adjusting screw OUT one turn to ensure oil is not heated by flowing over the relief valve.

21. Loosen locknut and adjust pressure compensator valve adjusting screw on the attachment pump to a setting of 5500psi on 'GP' test port. This is a temporary adjustment until the cutter control main relief valve has been set.

17. Place the saw/cutter switch in the ON position.

3.36

Tigercat M724D Mulcher

Lubrication and Maintenance

22. Place the saw/cutter switch in the ON position.

23. Adjust the cutter control valve main relief valve pressure to approximately 5500 psi on 'GM' gauge, a hissing sound will be heard as oil begins to pass over the relief and there will be a change in the sound of the engine.

Immediately place the saw/cutter switch in the OFF position to minimize heating of the hydraulic oil.

24. Turn the pressure compensator valve adjusting screw OUT one turn to ensure oil is not heated by flowing over the relief valve.

25. Place the saw/cutter switch in the ON position.

NOTE: Close both doors and press pilot reset switch to operate the saw/cutter.

26. Set pressure compensator valve on attachment pump to 5000 psi on 'GP' gauge.

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

27. Place the saw/cutter switch in the OFF position. Stop engine and remove block from rotating cutter. Remove pressure gauges and wipe up any excess oil.

NOTE: Some attachments are equipped with variable displacement motor(s) which may require adjustment. Other attachments are equipped with fixed displacement motor(s) which require no adjustment.

For explanation of attachment motor, refer to ATTACHMENT MANUFACTURER'S MANUAL. SET MOTOR POR (BEGIN OF DISPLACEMENT REGULATION) If applicable - applies only to variable displacement attachment motor(s).

SET MOTOR MINIMUM DISPLACEMENT If applicable - applies only to variable displacement attachment motor(s).

Refer to the attachment manufacturer's own OPERATOR AND MAINTENANCE MANUAL for this information.

3.37

Tigercat M724D Mulcher

Lubrication and Maintenance

PRESSURE SETTINGS MULCH DEFLECTOR DOOR WARNING

NOTE: Refer to RELIEF VALVE ADJUSTING PROCEDURE in THIS SECTION.

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

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

TO SET MULCH DEFLECTOR DOOR OPEN AND CLOSE RELIEF VALVES:-

• Wear safety glasses and safety shoes when working on shears.

3. Connect a 0 - 5000 psi pressure gauge (with at least 4' of hose) to the inlet test port on of the boom control valve.

• Keep mulch deflector door closed whenever possible during setup.

4. Turn the boom inlet main relief adjusting screw all the way IN.

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

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

NOTE: This procedure assumes that a Fecon BH250 mulching head is used. Refer to illustration of BOOM CONTROL VALVE on page 2 for orientation and pressure value references .

1. Park machine on level ground. Completely raise lift boom and install lift boom cylinder lock over one of the two cylinder rods with the open side at the bottom and wide end up against the keeper plate bolt heads. Install retaining bolt and locknut through center hole. Slowly lower boom until lock is securely held in place.

WARNING

5. Turn the port relief valve adjusting screws on the mulch deflector door spool section of the control valve OUT until spring pressure is relieved then turn adjusting screws one full turn IN. 6. Start the engine, and put the throttle control to the IDLE position.

7. Ensure that the hydraulic oil temperature is between 120°F - 140°F.

IMPORTANT During the following procedures, DO NOT hold ANY function control for LONGER THAN 5 SECONDS.

IMPORTANT Avoid blowing oil over relief longer than 5 seconds, as excessive heating of hydraulic fluid and damage to boom pump can occur.

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

• Always install 'T' handle retainer bolt • Use only to support boom and cutting head • Do not use to set hydraulics pressures 2. Set parking brake ON. Install articulation lock bar, block wheels and stop engine.

IMPORTANT Approach the gauge reading slowly and deliberately by turning the adjusting screw in a little at a time. The pressure setting must not exceed the above value.

WARNING To prevent injury caused by accidental steering of the machine when setting pressures, make sure the articulation lock bar is held securely in place by the lynch pins provided.

3.38

Tigercat M724D Mulcher

Lubrication and Maintenance

8. While holding the right joystick thumb switch to the left in the MULCH DOOR OPEN position (mulch deflector door cylinder fully retracted), check gauge pressure reading.

12. While holding the joystick thumb switch in the MULCH DOOR OPEN position, check gauge pressure reading.

If less than 1000psi, stop engine and readjust mulch deflector door open port relief. Repeat above procedure until a gauge reading of 1000 psi is obtained.

9. While holding the right joystick thumb switch to the right in the MULCH DOOR CLOSE position (mulch deflector door cylinder fully extended), check gauge pressure reading.

If less than 2600 psi, stop engine and readjust inlet main relief. Repeat above procedure until a gauge reading of 2600 psi is obtained.

13. Remove pressure gauge and wipe up any excess oil from test port area.

SET PILOT LINE PRESSURES: NOTE: Refer to SECTION 5 of the SERVICE MANUAL.

If less than 1000 psi, stop engine and readjust mulch deflector door close port relief. Repeat above procedure until a gauge reading of 1000 psi is obtained.

IMPORTANT Never run engine at full throttle with main relief turned all the way in.

10. Stop engine, unscrew inlet main relief adjusting screw 3 full turns.

11. Start engine and move the throttle control to the FULL position.

CLAMP ARM SECTION NOT USED FOR MULCHER APPLICATION

TILT • MULCH DEFLECTOR DOOR 'CLOSE' PORT RELIEF (1000 PSI)

•

CLAMP ARM

ACCUMULATOR ARM/ MULCH DEFLECTOR DOOR

MULCH DEFLECTOR DOOR 'OPEN' PORT RELIEF (1000 PSI)

•

LIFT BOOM INLET GAUGE TEST PORT

•

•

•

MAIN RELIEF (2600 PSI)

INLET SECTION

M724D-02

BOOM CONTROL VALVE - MULCHER ATTACHMENT 3.39

Tigercat M724D Mulcher

Lubrication and Maintenance ANTI-CAVITATION RELIEF VALVE ADJUSTING PROCEDURE For relief valve with adjusting screw

ANTI-CAVITATION RELIEF VALVE ADJUSTING PROCEDURE For relief valve with adjusting nut ADJUSTING NUT

•

JAMNUT

ADJUSTING SCREW

•

JAMNUT

• •

RELIEF VALVE 51055-2

RELIEF VALVE

WITH ADJUSTING NUT

51055-20

WITH ADJUSTING SCREW

1.

Loosen jamnut.

1.

Loosen jamnut.

2.

Turn adjusting nut to obtain desired pressure reading on gauge.

2.

Turn adjusting screw to obtain desired pressure reading on gauge.

3.

Lock jamnut against adjusting nut, making sure the adjusting nut does not turn.

3.

Lock jamnut against relief valve body, making sure the adjusting screw does not turn.

5.

Re-check relief setting.

5.

Re-check relief setting.

For complete step-by-step pressure setting procedures of circuits using these relief valves, refer to appropriate sections in THIS MANUAL.

For complete step-by-step pressure setting procedures of circuits using these relief valves, refer to appropriate sections in THIS MANUAL.

3.40

Tigercat M724D Mulcher

Lubrication and Maintenance

TORQUE CHART LOCATION

THREAD DIAMETER

Cylinders Pin bolts Piston nut, steer cyl.

Piston nut, boom/tilt cyl.

Gland, steer cyl.

Keeper plate bolts

TORQUE (LUBRICATED) lbf-ft Nm

3/4" UNC 1 1/4" UNF 1 1/2" UNF 3/4" UNC

282-310 930 1640 450 282-310

393-420 1282 2260 620 389-420

1/2" UNC 3/4" UNC

80-88 282-310

109-119 393-420

Engine mounting Bolts, mount to chassis Bolts, brackets to engine Bolts, bracket to pump drive

7/8" UNC M12-1.75 (10.9) 5/8" UNC

364 75 159-175

500 100 216-237

Pump drive gearbox Drive plate to flywheel Bell housing to CUMMINS engine

M10 x 1.5 (10.9) M10 x 1.5 (10.9)

32 32

43 43

1 1/4" x 18 UNEF 3/4" UNC

475-525 357

644-711 484

1/2" UNF 1/2" UNF 3/8" UNF

120-132 120-132 37-49

163-179 163-179 50-66

Axle mounting bolts Front Rear

7/8" UNC 3/4" UNC

364 226

500 310

Wheel bolts

7/8" UNF

500-550

679-745

Transmission housing to frame

7/8" UNC

364

500

Center joint bearing Bearing retaining bolts Pin retaining bolts

Drive shafts Yoke retaining nut, front shaft Pillow block retaining bolts Universal joint bolts Rear & Mid. drive shaft Front drive shaft to Mid. drive shaft Front drive shaft to axle

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

724D-TORQUECHART.XLS

3.41

Tigercat M724D Mulcher

Lubrication and Maintenance

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

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

IMPERIAL

GRADE 5 BOLTS

GRADE 8 BOLTS COARSE THREADS 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 THREADS 1/4" - 28 5/16" - 24 3/8" - 24 7/16" - 20 1/2" - 20 9/16" - 18 5/8" - 18 3/4" - 16 7/8" - 14 1" - 12 1 1/8" - 12 1 1/4" - 12

DRY lbf-ft Nm 11 - 12 15 - 16 20 - 28 27 - 38 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

LUBRICATED lbf-ft Nm 8 - 10 11 - 13 26 - 30 35 - 40 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

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

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

METRIC

SIZE

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

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

M6 M8 M10

4.8 12 23

3.5 8.5 17

6 15 29

4.5 11 21

9 22 43

6.5 16 32

11 28 55

8.5 20 40

13 32 63

9.5 24 47

17 40 80

12 30 60

15 37 75

11.5 28 55

19 47 95

14.5 35 70

M12 M14 M16

40 63 100

29 47 73

50 80 125

37 60 92

75 120 190

55 88 140

95 150 240

70 110 175

110 175 275

80 130 200

140 225 350

105 165 225

130 205 320

95 150 240

165 260 400

120 190 300

M18 M20 M22

135 190 260

100 140 190

175 240 330

125 180 250

260 375 510

195 275 375

330 475 650

250 350 475

375 530 725

275 400 540

475 675 925

350 500 675

440 625 850

325 460 625

560 800 1075

410 580 800

M24 M27 M30

330 490 675

250 360 490

425 625 850

310 450 625

650 950 1300

475 700 950

825 1200 1650

600 875 1200

925 1350 1850

675 100 1350

1150 1700 2300

850 1250 1700

1075 1600 2150

800 1150 1600

1350 2000 2700

1000 1500 2000

M33 M36

900 1150

675 850

1150 1450

850 1075

1750 2250

1300 1650

2200 2850

1650 2100

2500 3200

1850 2350

3150 4050

2350 3000

2900 3750

2150 2750

3700 4750

2750 3500

ISSUE 3 800

3.42

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

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

Tigercat M724D Mulcher

Lubrication and Maintenance

PRESSURE SETTINGS - Mulcher Configuration

PRESSURE SETTINGS With hydraulic oil at operating temperature (120°F - 140°F) Location

Pressure (PSI)

Engine RPM 2350-2400 High Idle 1100-1200 Low Idle

Engine RPM Pilot Manifold Pressure Relief Valve Pressure Reducing Valve

675 550

1200 1200

450-470 5000-5050 5000-5050 5650-5700 5650-5700

2200 2200 2200 2200 2200

Drive Motor Drive Motor P.O.R. Drive Motor Begin of Displacement Control Loop flushing Pressure Relief

2000-2500 125-135 360 Non-Adjustable

2200 2200

Fan Pump High Pressure Relief Forward and Reverse Charge Pressure Pressure Relief

3700-3900 Non-Adjustable 200-210

2200 2200

2500 3200 3200

2200 1200 1200

5500 5000 600 X=0.5" (12-13 mm)

1200 1200 1200

2600 2900 2900 1000 1000 2900 2200

1200 1200 1200 1200 1200 1200 1200

Drive Pump Charge Pressure Relief Valve P.O.R. Forward P.O.R. Reverse High Pressure Relief Forward with 135 psi @ 'X' High Pressure Relief Reverse with 125 psi @ 'X'

Steer Valve (Joystick Steering Only Steer Valve Main Relief Steer Right Port Relief Steer Left Port Relief Attachment Pump - Mulcher Cutter Control Valve Main Relief Attachment Pump P.O.R. Attachment Pump Standby Pressure Pump Maximum Displacement Boom Valve Inlet Main Relief Tilt In Port Relief Tilt Out Port Relief Mulch Deflector Door Open Port Relief Mulch Deflector Door Close Port Relief Boom Lift Port Relief Boom Lower Port Relief ISSUE 1 0903

IMPORTANT NOTES: ~ Boom support must be used part# 4128A ~ When performing tilt out function, without a felling head installed, do not allow crank arms to hit boom

3.43

Tigercat M724D Mulcher

Lubrication and Maintenance

PRESSURE SETTINGS - Feller Buncher Configuration With hydraulic oil at operating temperature (120°F - 140°F) Location

Pressure (PSI)

Engine RPM 2350-2400 High Idle 1100-1200 Low Idle

Engine RPM Pilot Manifold Pressure Relief Valve Pressure Reducing Valve

675 550

1200 1200

450-470 5000-5050 5000-5050 5650-5700 5650-5700

2200 2200 2200 2200 2200

Drive Motor Drive Motor P.O.R. Drive Motor Begin of Displacement Control Loop flushing Pressure Relief

2000-2500 125-135 360 Non-Adjustable

2200 2200

Fan Pump High Pressure Relief Forward and Reverse Charge Pressure Pressure Relief

3700-3900 Non-Adjustable 200-210

2200 2200

2500 3200 3200

2200 1200 1200

Attachment Pump - Saw Cutter Control Valve Main Relief Attachment Pump P.O.R. Attachment Pump Standby Pressure Pump Maximum Displacement

3900 3650 600 0.03" (0.75 mm)

1200 1200 1200

Boom Valve Inlet Main Relief Tilt In Port Relief Tilt Out Port Relief Accumulator Clamp Open Port Relief Accumulator Clamp Close Port Relief Clamp Open Port Relief Clamp Close Port Relief Boom Lift Port Relief Boom Lower Port Relief

2600 2900 2900 3200 3200 1100 3200 2900 2200

1200 1200 1200 1200 1200 1200 1200 1200 1200

Drive Pump Charge Pressure Relief Valve P.O.R. Forward P.O.R. Reverse High Pressure Relief Forward with 135 psi @ 'X' High Pressure Relief Reverse with 125 psi @ 'X'

Steer Valve (Joystick Steering Only Steer Valve Main Relief Steer Right Port Relief Steer Left Port Relief

ISSUE 1 0903

IMPORTANT NOTES: ~ Boom support must be used part# 4128A ~ When performing tilt out function, without a felling head installed, do not allow crank arms to hit boom

3.44

Tigercat M724D Mulcher SECTION 5 - PILOT SYSTEM JANUARY 2004

CONTENTS - SECTION 5 ACCUMULATOR CHARGE VALVE .................................................................. 2 OPERATING DESCRIPTION ........................................................................ 2 REPLACE FILTER ......................................................................................... 8 SCHEMATIC ................................................................................................. 2 ACCUMULATORS ............................................................................................ 3 BRAKE ACCUMULATOR .............................................................................. 3 CHARGING ................................................................................................... 9 CHECK PRE-CHARGE PRESSURE ............................................................. 9 PILOT ACCUMULATOR ............................................................................... 3 TESTING DEVICE ......................................................................................... 9 COMPONENTS ................................................................................................ 2 HYDRAULIC OIL HEATING PROCEDURE .................................................... 11 PILOT CIRCUIT DESCRIPTION ....................................................................... 6 PILOT CIRCUIT DIAGRAM .............................................................................. 7 PILOT MANIFOLD ............................................................................................ 4 ASSEMBLY DIAGRAM .................................................................................. 5 OPERATING DESCRIPTION ........................................................................ 4 PILOT SHUT OFF ......................................................................................... 4 PILOT PRESSURE SETTINGS ...................................................................... 10 RELEASE PILOT SYSTEM PRESSURE .......................................................... 8

Tigercat M724D Mulcher PILOT SYSTEM COMPONENTS

Pilot System For filter replacement procedures, refer to REPLACE CHARGE VALVE FILTER in THIS SECTION. No further adjustments or pressure settings are required.

Oil flow for the pilot system is supplied by the fixed displacement boom/steer pump. The accumulator charge valve diverts some of this oil to the pilot accumulator, brake accumulator and pilot manifold. The pilot manifold supplies oil at a reduced pressure, to two joysticks, a foot control valve and six solenoid operated control valves (within the manifold). A seventh solenoid valve is used as the pilot shut off to stop the flow of pilot oil to all pilot actuated functions.

••

PRESSURE PORT

STEERING PORT

••

For information on the BOOM/STEER PUMP and JOYSTICK CONTROL VALVES, refer to SECTION 11 in THIS MANUAL. For a detailed description of FOOT CONTROL VALVES, refer to SECTION 8 in THIS MANUAL. THIS SECTION details the location, and operation of the accumulator charge valve, accumulators and pilot manifold (including solenoid valves).

••

DRAIN PORT

ACCUMULATOR CHARGE VALVE

OPERATING DESCRIPTION

The accumulator charge valve controls the flow of oil to the steer valve, the pilot manifold and both the pilot and brake accumulators.

When the accumulator is charged above its lower limit (1200 psi), the charging valve spool is held against the spool stop by normal system back pressure. System pressure is directed to one end of the charging valve spool through a drilled passage. The lower limit check ball is held on its seat by accumulator pressure.

The accumulator charge valve has an internal sintered bronze filter, through which all oil passing to the pilot manifold and accumulators must flow.

This filter should be replaced every 1000 hours.

ACCUMULATOR PRESSURE

RETURN LINE PRESSURE

UPPER LIMIT CHECK BALL

UPPER LIMIT CHECK BALL

PILOT VALVE SPOOL TO ACCUMULATOR

FILTER LOCATION

ACCUMULATOR PORT M724D-23

ACCUMULATOR CHARGE VALVE

SYSTEM PRESSURE

••

•

PILOT VALVE SPOOL RETURN

TO ACCUMULATOR

LOWER LIMIT CHECK BALL

LOWER LIMIT CHECK BALL

PILOT VALVE SPRING

CHECK VALVE

RETURN

PILOT VALVE SPRING

CHECK VALVE ORIFICE

ORIFICE

CHARGING VALVE SPRING

SPOOL STOP

TO STEER VALVE

PRESS. PORT

CHARGING VALVE SPOOL

SPOOL STOP

CHARGING VALVE SPRING

TO STEER VALVE

ACCUMULATOR CHARGED

ACCUCHG

PRESS. PORT

CHARGING VALVE SPOOL

ACCUMULATOR BEING CHARGED

TYPICAL CHARGING VALVE SCHEMATICS 5.2

Tigercat M724D Mulcher When the pressure in the accumulator drops to its lower limit (1200 psi) charging is required.

Reduced accumulator pressure allows the pilot valve spring to unseat the lower limit check ball.

At the same time, the upper limit check ball is seated. The pilot valve spool permits only one limit check ball to be seated at any time.

Unseating the lower limit check ball allows pressure from the accumulator to enter the chamber behind the charging valve spool. A combination of accumulator hydraulic force and charging valve spring force balances the hydraulic force due to the pump pressure (system pressure) acting on the opposite end of the charging valve spool. Therefore pump pressure is higher than the accumulator pressure, which causes the accumulator to charge. The rate at which the accumulator is charged depends on the orifice in the check valve seat.

Pilot System pressure source for pilot manifold controlled functions. Second, it provides a stored pressure of 1800 psi for use as an emergency reserve for functions controlled through the pilot manifold.

Minimal movement of these functions is available after the engine stalls or is shut down.

BRAKE ACCUMULATOR The brake accumulator receives pressure from the accumulator charge valve. The brake accumulator ensures that the brake remains responsive at all times by maintaining an optimum pilot pressure of 1800 psi to the brake foot control valve. The brake accumulator holds sufficient pressure for up to 5 brake applications after the engine stalls or is shut down. Beyond this the pressure drops substantially. For further information about BRAKES refer to SECTION 9 of THIS MANUAL.

When the accumulator is charged to its high limit (1800 psi), accumulator pressure will unseat the upper limit check ball, and seat the lower limit check ball. Unseating the upper limit check ball releases the pressure in the chamber behind the charging valve spool, which flows to return and permits the charging valve spool to unload the pump.

VALVE GUARD

VALVE CAP GAS VALVE

BODY

When the operating pressure in the system (pump pressure) is greater than the pressure in the accumulator, the check valve at the accumulator charging orifice is forced off its seat; thus charging the accumulator to system pressure without the aid of the charging valve.

BLADDER

HYDRAULIC CONNECTION

ACCUMULATORS Both the pilot and brake accumulators are bladder type and are installed with a nitrogen precharge pressure. The gas pressures should be checked if the pilot system exhibits repeated and frequent charging cycles. Refer to CHECKING PRE-CHARGE PRESSURE in THIS SECTION.

ACCU-1

POPPET (Seats against oil port after oil evacuation)

ACCUMULATOR (BLADDER TYPE)

WARNING Hydraulic circuits with accumulators store hydraulic oil under pressure and may remain pressurized after the engine is turned off.

Prior to performing any maintenance or system modifications, exercise CAUTION to bleed off any stored system pressure by depressing the brake pedal at least 50 times and operating all controls several times. Refer to RELEASE PILOT SYSTEM PRESSURE in THIS SECTION for this procedure.

WARNING The accumulator must not be altered in any way. Do not weld or machine the pressure vessel. Use only NITROGEN for charging accumulators, never use oxygen or air due to risk of explosion.

PILOT ACCUMULATOR The pilot accumulator receives pressure from the accumulator charge valve. The pilot accumulator has two functions. First, it dampens system pressure fluctuations and provides a constant 5.3

Tigercat M724D Mulcher PILOT MANIFOLD

Pilot System

The pilot manifold is mounted under the edge of the outside rear wall of the cab and supplies pilot oil at a reduced pressure to the following circuits: • • • • • •

Steer joystick (P2) Boom joystick (P2) Clamp(s) foot pedal (P2) Rear Axle differential lock (C1) Solenoid valve Boom Float (optional) (C2) Solenoid valve Mulch deflector door close/ Accumulator arm(s) close (C3) Solenoid valve • Mulch deflector door open/ Accumulator arm(s) open (C4) Solenoid valve • Front Axle differential lock (C5) Solenoid valve • Spare (C8) Solenoid valve OPERATING DESCRIPTION The pilot manifold consists of a one piece manifold block into which, a pressure reducing valve, a pressure relief valve and a pilot shut off solenoid valve are installed. Six solenoid operated control valves are installed at outlet ports C1, C2, C3, C4, C5, and C8. Plugs are installed in ports C6 and C7 on standard machines. A “quick connect” type test port fitting is installed in port P2 for attaching a pressure gauge during hydraulic set-up procedures.

Oil is supplied to the pilot manifold (port P1) from the steer pump via the accumulator charge valve and the pilot accumulator. The pilot accumulator provides a constant pressure source for the pilot controls. For a more detailed description of accumulators and their operation, refer to ACCUMULATORS in THIS SECTION. Oil entering the pilot manifold passes through the pilot pressure reducing valve. The pilot pressure

PILOT PRESSURE RELIEF VALVE 675 PSI.

•

reducing valve reduces and maintains the pilot pressure on the outlet side of the pilot manifold to a pre-set value.

Pilot oil then passes through the pilot relief valve.

The relief valve is set higher than the pressure reducing valve and diverts pilot oil back to tank if the reducing valve fails to limit the pilot pressure.

To adjust the pressure reducing and the relief valves first loosen the jamnut, then to lower the pressure value screw OUT (counter-clockwise) the adjusting screw or, to raise the pressure value screw IN (clockwise) the adjusting screw. Tighten jamnut to lock this setting. For complete pressure setting instructions, refer to PILOT PRESSURE SETTINGS in THIS SECTION. The solenoid operated pilot shut off control valve blocks pilot oil to the solenoid valves (C1 - C8) when either of the cab doors are open. This will prevent the machine from being operated accidentally or in the case of an operator leaving the machine in an emergency. When the cab doors have been closed, and the pilot reset switch has been turned on, the pilot shut off solenoid is energized and pilot oil is allowed to flow to the outlet ports (P2) and solenoid operated pilot valves (C1 - C8). All functions controlled through the pilot manifold will respond to the operator’s movement. Refer to PILOT SYSTEM SHUT OFF in SECTION 2 of the OPERATOR’S MANUAL. The solenoid operated pilot valves control the position of the spool valves or pistons to which they are hydraulically connected. When a solenoid operated pilot valve is energized, usually by a switch in the cab, pilot oil is directed to shift the spool or piston in the function control valve.

When the solenoid is de-energized, a spring forces the spool back to the neutral position, blocking the pressure side and opening the pilot line back to tank. There are no adjustments on the solenoid valves.

PILOT SHUT OFF SOLENOID VALVE

INSTALL A 0 - 1000 PSI. GAUGE ON "P2" PORT

•

•

• PILOT PRESSURE REDUCING VALVE 550 PSI. M724D-24

PILOT MANIFOLD 5.4

Tigercat M724D Mulcher

Pilot System

• SOLENOID OPERATED CONTROL VALVE(S)

• • RELIEF VALVE

PILOT OIL TO BOOM JOYSTICK (END OF BLOCK)

PLUGGED PORTS PRESSURE REDUCING VALVE

•

PILOT SHUT OFF VALVE

• •

•

•

•

•

GAUGE TEST PORT

• • • •

•

•

•

MULCH DEFLECTOR DOOR/ ACCUMULATOR ARM (OPEN)

•

ORIFICE MULCH DEFLECTOR DOOR / ACCUMULATOR ARM (CLOSE)

•

BOOM FLOAT (OPTIONAL) REAR DIFFERENTIAL LOCK

IN FROM ACCUMULATOR CHARGE VALVE

AW119

SPARE FRONT DIFFERENTIAL LOCK ORIFICE

PILOT OIL TO STEER JOYSTICK AND CLAMP PEDAL (FRONT OF BLOCK)

PILOT MANIFOLD ASSEMBLY 5.5

Tigercat M724D Mulcher

Pilot System

PILOT CIRCUIT DESCRIPTION The boom/steer pump supplies oil to the pilot manifold (port ‘P1’) via the accumulator charge valve.

The accumulator charge valve controls the flow of oil to the pilot manifold, the steer valve, and to both the pilot and brake accumulators.

The pilot accumulator provides a constant pressure source for the pilot manifold controlled functions. The brake accumulator provides optimum pilot pressure to the brake foot control at all times. The pilot accumulator and brake accumulator are connected in series for charging.

A check valve is located between the two accumulators. This check valve prevents the pilot system from using brake accumulator pressure, but allows the brake accumulator to use pilot accumulator pressure.

Oil entering the pilot manifold passes through the pilot pressure reducing valve, pilot pressure relief valve and pilot shut off solenoid. The pilot shut off solenoid valve (in the pilot manifold) is energized when the cab doors are CLOSED and the pilot reset switch is ON. When the pilot shut off solenoid valve is energized, pilot oil can flow to the outlet ports (P2) and the solenoid operated pilot valves (C1 - C8) in the pilot manifold.

Pilot oil from the outlet ports (P2) supplies the steering joystick control valve, boom joystick control valve and clamp foot control valve.

These three valves are manually operated pilot valves.

When a solenoid operated pilot valve (C1-C8) is energized, by a switch in the cab, pilot oil is directed to shift the spool in the corresponding control valve and operate the required function.

In the case of front and rear differential lock, the pilot oil leaving the pilot manifold operates clutch packs in the axles to lock the differentials.

5.6

Tigercat M724D Mulcher

M724D-06

Pilot System

PILOT CIRCUIT 5.7

Tigercat M724D Mulcher RELEASE PILOT SYSTEM PRESSURE

Pilot System REPLACE CHARGE VALVE FILTER

WARNING Hydraulic circuits with accumulators store hydraulic oil under pressure and may remain pressurized after the engine is turned off.

Prior to beginning any service work on the pilot system or the braking system, pressure must first be released to prevent injury from oil spraying.

NOTE: This sintered bronze filter should be replaced every 1000 hours. The filter is included in kit number 90045. Do not clean and reinstall an old filter.

The accumulator charge valve is accessed from the left side engine door.

1. The machine should be parked on level ground with attachment lowered and oil cool.

Apply parking brake and shut off engine.

The following steps must be followed to release pressure: 1. Close both doors. Turn ignition switch to ON position. Do not start the engine. Press pilot reset switch.

Complete either steps 2A or 2B.

2. Prior to beginning any service work on the pilot system or the braking system, pressure must first be released to prevent injury from oil spraying. Refer to RELEASE PILOT SYSTEM PRESSURE in THIS SECTION. 3. The charge valve is between the frame and the engine. Clean all debris from this area.

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

2B. Turn rear differential switch ON and hold front differential lock switch ON for 30 seconds.

While waiting, pump brake foot pedal at least 10 times.

NOTE: With both of the differential locks ON when the engine is OFF pilot oil stored in the accumulator is vented to tank. This drains the pilot system accumulator only.

Pumping the brake foot pedal vents both the pilot system accumulator and the brake accumulator to tank. This is necessary to relieve the pilot pressure trapped in the brake accumulator by the brake check valve.

3. Pressure may remain in the system after completing all of the above steps. Use caution when loosening hydraulic connections.

4. Carefully remove the hex socket plug on the top of the valve (oil may run out). Loosen the outer locknut first and then the screw assembly. Remove carefully as parts may fall out.

5. Once the screw is out, there are 7 parts that need to be removed. These parts may need to be removed with a magnet or hook tool. The last washer, below the filter, does not have to be removed.

6. Discard the old filter. Do not clean this filter, replace it with a new filter. Reassemble the parts paying close attention to orientation and order of the parts. It is recommended that all items included in kit be replaced at this time.

7. Torque the screw assembly to 18 - 20 lbf-ft and then the outer locknut to 18 - 20 lbf-ft

STEERING PORT

PRESSURE PORT

DRAIN PORT

SPRING "O" RING

ACCUMULATOR PORT

PLUG WASHER

LOCKNUT

FILTER WASHER "O" RING SEAT POPPET AU001-3

ACCUMULATOR CHARGE VALVE 5.8

Tigercat M724D Mulcher CHARGING THE ACCUMULATORS NOTE: A detailed instruction sheet is provided with the charging and testing device. The following is only a suggested guide.

•

Close the drain valve on the charging and testing device and connect the hose to the nitrogen bottle.

•

Remove the valve guard and cap.

•

Screw the charging and testing device onto the gas valve.

HOSE*

PRESSURE GAUGE*

ADAPTER* ADAPTER* NITROGEN BOTTLE

ACCUMULATOR

Pilot System CHECKING THE PRE-CHARGE PRESSURE After the accumulator has been put in service, the pre-charge pressure should be checked with an accumulator charging and testing device.

Prior to beginning any service work on the pilot system or the braking system, pressure must first be released to prevent injury from oil spraying.

Refer to RELEASE PILOT SYSTEM PRESSURE in THIS SECTION. Install the charging and testing device on the gas valve. While depressing the button on the charging device, observe gas pressure reading on gauge. Refer to CHARGING THE ACCUMULATORS in THIS section for correct pressures.

If the gas pre-charge pressure is low, investigate the cause and correct it. Possible causes of lost pre-charge pressure include a leaking or damaged gas valve, or a damaged bladder.

ASSEMBLY PART NO. 90254 INCLUDES PARTS SHOWN * ACCU-

CHARGING AND TESTING DEVICE

•

Open the gas shut-off valve on the nitrogen bottle and allow gas to flow slowly into the accumulator.

•

Close the shut-off valve frequently and check the value of the pre-charge by depressing the button on the charging device and observing the gauge.

•

If pre-charge pressure is high, lower it by opening the drain valve and carefully depressing the button on the charging device.

Pilot Accumulator pre-charge - 700 psi Brake Accumulator pre-charge - 750 psi NOTE: The pre-charge pressure will vary depending on the temperature. Once the desired pre-charge is reached, wait two minutes for the gas temperature to equalize.

Re-check pre-charge and adjust if necessary.

•

Disconnect hose from nitrogen bottle.

•

Remove charging and testing device from accumulator and install valve cap and guard, torque to 175-350 lbf/ins.

•

Check to ensure there are no leaks, if the gas valve is leaking, it should be replaced. Use only valves approved for accumulator service.

NEVER USE AN AUTOMOTIVE TYPE VALVE.

5.9

Tigercat M724D Mulcher PILOT PRESSURE SETTINGS The following procedure deals with setting up the PILOT circuit, i.e., the pilot manifold relief valve and the pressure reducing valve.

WARNING To prevent injury caused by accidental steering of the machine when setting pressures, make sure the articulation lock bar is held securely in place by the lynch pins provided.

1. Park machine on level ground, lower attachment to the ground and set parking brake ON. Install articulation lock bar, block wheels and stop engine.

WARNING Hydraulic circuits with accumulators store hydraulic oil under pressure and may remain pressurized after the engine is turned off.

Pilot System 3. Connect a 0-1500 psi pressure gauge to the test port at ‘P2’ of the pilot manifold. The pilot manifold is located under the back edge of the cab, in front of the “A” frame which supports the front edge of the roof enclosure.

4. Ensure that the hydraulic oil temperature is between 120°F and 140°F. 5. Turn the pressure reducing valve adjusting screw (far left, top of manifold) all the way IN (clockwise).

6. Turn the relief valve adjusting screw (second from left) OUT (counter-clockwise) until the spring tension is completely relieved, then turn adjusting screw IN (clockwise) one full turn .

7. Start the engine and set the throttle control to IDLE. 8. Adjust the relief valve pressure to 675 psi.

9. Adjust the pressure reducing valve pressure to 550 psi.

10. Leave parking brake ON, shut off the engine.

Remove all pressure gauges and wipe up any excess oil from test port area.

2. Prior to beginning any service work on the pilot system or the braking system, pressure must first be released to prevent injury from oil spraying.

RELIEF VALVE

•

The following steps must be followed to release pressure:

••

a) close both doors, turn ignition switch to ON position, do not start the engine, press pilot reset switch. b) activate all controls (switches, joysticks, left foot pedal etc.) and pump brake foot pedal at least 50 times or more. c) pressure may remain in the system after these numerous applications, use caution when loosening hydraulic connections.

AW119

5.10

PILOT MANIFOLD

PRESSURE REDUCING VALVE

Tigercat M724D Mulcher HYDRAULIC OIL HEATING PROCEDURE

Pilot System 5. Adjust throttle to FULL.

There is a specific procedure for heating the hydraulic oil in the machine in preparation for hydraulic set-up procedures.

1. Park the machine on level ground, parking brake ON, attachment down and engine off.

Install articulation lock bar, block wheels and stop engine.

2. Connect a 0-5000 psi gauges to the inlet test port on the boom valve.

INLET TEST PORT

••

6. Operate mulch deflector door closed for 30 seconds, then stop for 5 seconds.

WARNING DO NOT leave the machine while heating the oil, as overheating of engine or oil can cause serious damage.

7. Repeat step 6 while monitoring hydraulic oil temperature until the temperature is between 120°F and 140°F. This process will take 20 to 30 minutes depending on ambient air temperature.

8. Ensure that hydraulic oil is between 120°F and 140°F (operating temperature), then proceed to required hydraulic set-up procedure.

INLET MAIN RELIEF

•• M724D-25

BOOM VALVE

3. Start the engine and adjust throttle to IDLE. Place a sheet of cardboard in front of the oil cooler side of the heat exchanger. The radiator must remain uncovered to prevent engine overheating.

4. Adjust the boom valve inlet main relief to 2000 psi using the mulch deflector door close function. (Note: For machines which have been converted to Feller Buncher configuration use the clamp close function.)

WARNING The temperature rises quickly when setting relief valves. Remove the cardboard blocking the oil cooler if necessary to maintain the proper temperature. Do not pass oil over relief valves for longer than 5 seconds at a time during set-up procedures. Damage to valves can occur from excessive heat.

9. Return boom valve inlet main relief to normal pressure settings using mulch deflector door closed function, refer to PRESSURE SETTINGS in SECTION 19. (Note: For machines which have been converted to Feller Buncher configuration refer to PRESSURE SETTINGS in SECTION 18 to reset clamp close function pressure setting.)

5.11

Tigercat M724D Mulcher

Pilot System

5.12

Tigercat M724D Mulcher SECTION 6 - ELECTRICAL, GAUGES & ALARMS JANUARY 2004

CONTENTS - SECTION 6 ELECTRICAL SCHEMATIC MACHINE WITH CUMMINS 'C' ENGINE ................................... 6.2, 6.3, 6.4 GAUGES AND ALARMS ................................................................................ 6.8 INSTRUMENT PANEL WIRING DIAGRAM ................................................... 6.5 RELAYS AND FUSES ............................................................................ 6.6, 6.7 SENSOR, SENDER LOCATIONS ................................................................. 6.9 START AND FUEL SOLENOIDS ................................................................... 6.6 TESTING GAUGES ....................................................................................... 6.8 WIRE COLOUR CODE CHART ..................................................................... 6.6

Tigercat M724D Mulcher

Electrical, Gauges and Alarms

REFER TO COLOUR CODE CHART IN THIS SECTION

M724D-08

MACHINE WITH CUMMINS 'C' ENGINE SCHEMATIC DIAGRAM 18293B (REV 0, SHEET 1) 6.2

Tigercat M724D Mulcher

Electrical, Gauges and Alarms

REFER TO COLOUR CODE CHART IN THIS SECTION

M724D-09

MACHINE WITH CUMMINS 'C' ENGINE SCHEMATIC DIAGRAM 18293B (REV 0, SHEET 2) 6.3

Tigercat M724D Mulcher

Electrical, Gauges and Alarms

REFER TO COLOUR CODE CHART IN THIS SECTION

M724D-10

MACHINE WITH CUMMINS 'C' ENGINE SCHEMATIC DIAGRAM 18293B (REV 0, SHEET 3) 6.4

Tigercat M724D Mulcher

M724D-07

Electrical, Gauges and Alarms

INSTRUMENT PANEL WIRING DIAGRAM 2911D (REV 2) 6.5

Tigercat M724D Mulcher

Electrical, Gauges and Alarms

Tigercat wire colour code chart applicable to all products manufactured by Tigercat Industries Inc. COLOUR Red Black White Blue Purple Tan Yellow Grey Brown Green Orange

FUNCTION EXAMPLE Power ........................................ (fused and unfused) Ground Engine control ........................... (fuel shut-off, start aid) Propulsion Control .................... (transmission/reverser solenoids) Monitor, electrical and mechanical systems ................. (air cleaner, alternator, wheel speed, engine speed) Electrical and electromechanical control ......... (park brake, alternator excitation) (power door motor, backup alarm) Monitors .................................... (flow, pressure, temperature, level) Standard monitor system .......... (logic module to monitor) Lights Electro-hydraulic control ........... (pilot solenoids) Accessories .............................. (horn, A/C, heater)

REMOTE START SOLENOID

FUEL SOLENOID

••

••

125 AMP FUSE

•• 724D-D38 724D-D47

REMOTE START SOLENOID

FUEL SOLENOID

••

••

RELAY 7 EMERGENCY SHUT-DOWN

RELAY 8 FDC OVERIDE

RELAY 10 A/C OFF

RELAY 9 FDC OVERIDE

RELAY 11 A/C FDC SWITCH

RELAY 12 ACCESSORY

• FAN DRIVE CONTROLLER

125 AMP FUSE

724D-24

19239A R0

START AND FUEL SOLENOIDS 6.6

Tigercat M724D Mulcher

Electrical, Gauges and Alarms

FUSE, DIODE AND RELAY PANEL

724D-D46

RELAY 6 LOW HYD. OIL LEVEL

RELAY 3 START

DIODE 1 HORN TEST

DIODE 4 BULB TEST

RELAY 2 DRIVE LOCK

DIODE 2 HORN TEST

DIODE 3 BULB TEST

RELAY 1 PILOT LOCK

21019A R0

RELAY 5 SAW

RELAY 4 DRIVE ENABLE 5A 1 GAUGES 15A 2 SAFETY 10A 3 CONTROLS 10A 4 FUEL 10A 5 RADIO 15A 6 BACK HORN 15A 7 FAN/ACC.

20A 8 AUX. 10A 9 AUX. FAN 30A 10 A/C - HEATER 20A 11 LIGHTER 25A 12 F. LIGHTS 25A 13 R. LIGHTS 15A 14 HORN/DOME

GROUND JUMPER

D PANEL POWER (RED) 1

2

G80 (BLK) A/C OFF G28 (BLK) GROUND

BAT

1

PANEL GROUND (BLK) G 7

G 28

(BLK) A/C GROUND

FAN PUMP REV "-" (BLK) G 81 70 (ORG) FRESH AIR BLOWER

G 59

(BLK) GAUGE & SWITCH GROUND

G 79

(BLK) FDC GROUND

G7 3

10A (ORG) A/C ON/OFF

55 (ORG) A/C & HEATER RUN LOW HYDRAULIC OIL (YEL) 53

5

6

28 (RED) A/C & HEATER FAN POWER 31 (RED) FRESH AIR BLOWER POWER

HORN (ORG) 38 REAR LIGHTS (BRN) 57 (2) WORK MODE (GRN) 42 ENGINE HOURS (YEL) 49 BACK-UP ALARM (RED) 47

(BACK) FRESH AIR BLOWER

RADIO IGNITION POWER (RED) 08 FUEL CONTROL VALVE (RED) 13B PARKING BRAKE (TAN) 11 PARKING BRAKE POWER (RED) 06 START SOLENOID RELAY (TAN) 16

RELAY (MIDDLE) A/C AND HEATER RUN

WARNING HYD. OIL TEMP (YEL) 27 WARNING HIGH COOLANT TEMP. (YEL) 29

(FRONT) HIGH SPEED FAN

(ORG) COMPRESSOR SWITCH

15

(RED) JOYSTICK POWER

41

(PUR) TACHOMETER

36

(TAN) DRIVE PREVENT

59

(TAN) DOOR SWITCH

45

(YEL) HYDRAULIC OIL TEMP.

44

(YEL) ENGINE COOLANT TEMP.

43

(YEL) ENGINE OIL PRESSURE

40

(GRN) REAR DIFF. LOCKS

39

(GRN) FAN PURGE

35

(TAN) SAW / CUTTER

21

(TAN) (1) DRIVE LIMITER

22

(YEL) WARNING ENGINE OIL PRESSURE

34

(YEL) WARNING LOW COOLANT LEVEL

17

(GRN) FAN PUMP REV "+" /PURGE (718)

20A/20 (GRN) FRONT DIFF. LOCKS

COMPRESSOR CLUTCH (ORG) 46A FAN PUMP FWD "+" (GRN) 88/88A

RELAY

10

33/33c (TAN) PILOT SHUT OFF/DOOR SWITCH

FRONT LIGHTS (BRN) 58

RADIO BAT./DOME PWR (ORG) 5A

RELAY

(BLK) PANEL GROUND

A1 B1

4

(RED) IGNITION POWER

BAT 1 (RED) FUSE BLOCK POWER

FAN PUMP FWD "-" (GRN) 91 (OIL) FDC SENSOR "-" (BLK) G96

93

(YEL) FDC SENSOR "+" (COOLANT)

G95

(BLK) FDC SENSOR "-" (COOLANT)

94

(YEL) FDC SENSOR "+" (HYD. OIL)

BOOM FLOAT (RED) 00 87 37

(WHT) FUEL HEATER (OPTION) (WHT) ETHER (OPTION)

6.7

21020A R0

Tigercat M724D Mulcher

Electrical, Gauges and Alarms

GAUGES AND ALARMS

•

The 724D is monitored for proper operation by sensors located in the hydraulic system and on the engine. These sensors are connected to either gauges or warning lights.

• GAUGE TERMINALS

To troubleshoot temperature and pressure type gauges, use an ohmeter to test between the terminals at the back of the gauge. Refer to illustration for reading values. If the resistance readings taken with the ohmeter are within the range shown, the gauge is functioning properly.

Faulty readings will therefore be the result of a poor sending unit.

•

For operation of the gauges and warning lights listed in the sensor chart below, refer to SECTION 2 of the OPERATOR'S MANUAL. The operator may sound the warning horn at any time. A back-up alarm will also sound when the machine is travelling in reverse.

For replacement parts information, refer to GAUGES AND SENDERS in GROUP 600 of the PARTS CATALOG. 726B07

ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13

SENSOR FUNCTION Attachment circuit pressure gauge Engine hours Hydraulic oil temperature Hydraulic oil temperature, FDC. Hydraulic oil temperature Hydraulic oil level, low Engine oil pressure Engine oil pressure Engine coolant level Engine coolant temperature Engine coolant temperature Engine coolant temperature, FDC. Tachometer

14 15

Volts Engine air cleaner

16 17

Back-up alarm Safety alert horn

R RANGE

0-10000 psi 0-9999.9 100°F-240°F 130°F-160°F high/low 0-100 psi 100°F-280°F 190°F-204°F 0-3000 RPM

LIGHT HORN ON ON ON ON ON ON ON ON ON ON -

8v-18v Green-Red

-

-

-

-

ON ON

6.8

•

Engine Oil Pressure

•

Hydraulic Oil Temperature

•

Engine Coolant Temperature OHMETER TEST READINGS

INFORMATION Refer to SECTION 17 - ATTACHMENT DRIVE Total running hours Stop machine above 180°F Fan starts cooling fan turning at 130°F Red light/horn turns on at 205°F Red light indicates 10 gallons below FULL Stop engine below 10 PSI. Red light/horn turns on at 10 PSI Red light/horn turns on when coolant low in rad.

Cummins - 190°F-210°F operating range Red light/horn turns on at 215°F Fan starts cooling fan turning at 190°F Refer to THROTTLE CONTROL in SECTION 2 of the OPERATOR'S MANUAL Normal operation range 12-13.5 volts Green at high RPM - Filter OK Red at high RPM - Replace Filter Reverse Drive Pedal Switch on instrument panel

Tigercat M724D Mulcher

Electrical, Gauges and Alarms

SWITCH PILOT SHUT OFF LEFT CAB DOOR

16 SWITCH -

BACK-UP ALARM

•

SWITCH PILOT SHUT OFF RIGHT CAB DOOR

•

• 5

•

6

8

LIGHTS AND 9 11 WARNING CONTROL PANEL HORN

• SWITCH, 17 HORN SAFETY HORN

FUEL SOLENOID

START SOLENOID PARKING BRAKE PROXIMITY SENSOR

• •

•

SENDER 9 ENGINE COOLANT LEVEL FOR WARNING LIGHT/HORN HORN, SAFETY 17

•

• SENDER - 12 ENGINE COOLANT TEMPERATURE FDC CONTROL

125 AMP FUSE

•

SENDER ENGINE 10 COOLANT TEMPERATURE FOR GAUGE

• •

VIEW 'A' SWITCH - ENGINE COOLANT TEMPERATURE 11 FOR WARNING LIGHT/HORN SWITCH BATTERY DISCONNECT

•

•

•

BACK-UP ALARM

•

16

SWITCH - ENGINE OIL 8 PRESSURE FOR WARNING LIGHT/HORN 2 BATTERIES SWITCH ENGINE 4 SENDER HOURS HYDRAULIC OIL TEMPERATURE FDC CONTROL

•

5 SWITCH - HYDRAULIC OIL 6 SWITCH - HYDRAULIC OIL LEVEL FOR WARNING LIGHT/HORN M724D-11

•

VIEW 'A'

• • • • • •

•

SENDER - HYDRAULIC OIL 3 TEMPERATURE FOR GAUGE

TEMPERATURE FOR WARNING LIGHT/HORN

SENSOR & SWITCH LOCATIONS 6.9

13 SENSOR TACHOMETER

7 SENDER ENGINE OIL PRESSURE FOR GAUGE

Tigercat M724D Mulcher

Electrical, Gauges and Alarms

6.10

Tigercat M724D Mulcher SECTION 7 - ENGINE JANUARY 2004

CONTENTS - SECTION 7 CIRCUIT DESCRIPTION CUMMINS ENGINE .................................................................................... 7.2 COOLING SYSTEM COOLANT FLOW DIAGRAM ..................................................................... 7.6 COOLANT FLOW DURING OPERATION .................................................. 7.6 FILLING THE SYSTEM WITH COOLANT .................................................. 7.6 PARKING BRAKE .......................................................................................... 7.2 PRECLEANER OPERATION ............................................................................................... 7.7 SERVICE .................................................................................................... 7.7 RELAYS, DIODES AND FUSES PANEL ....................................................... 7.3 START AND FUEL SOLENOIDS ................................................................... 7.2 START CIRCUIT DIAGRAMS - CUMMINS 'C' ENGINE AT REST .................................................................................................... 7.4 RUN AND DRIVE ........................................................................................ 7.5 RUN, NO DRIVE ......................................................................................... 7.5 START ........................................................................................................ 7.4 STARTING SYSTEM DESCRIPTION ............................................................ 7.2 TACHOMETER SET-UP ................................................................................ 7.6

Tigercat M724D Mulcher

Engine

STARTING CIRCUIT

CIRCUIT DESCRIPTION - CUMMINS ENGINE

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

With the parking brake ON, the parking brake proximity switch is closed and the drive enable relay (4) is energized through wires 6 and 11.

For engine starting and stopping procedures refer to STARTING ENGINE and STOPPING ENGINE in SECTION 2 of the OPERATOR’S MANUAL.

KEY SWITCH

•

The engine starting circuit is controlled by a proximity switch located on the parking brake lever which prevents the engine from being started when the parking brake is OFF.

•

BULB TEST/ ENGINE SHUTDOWN OVERRIDE SWITCH

•

M724D-26A KEY AND BULB TEST SWITCHES When the key is turned to the START position, voltage is supplied to the start circuit through wire 6 to the contacts of drive enable relay (4) and wire 9 to the start relay (3).

PROXIMITY SWITCH

Voltage is supplied through wire 23 to the coil of the start relay (3), which closes and supplies voltage through wire 16 to the coils of the remote REMOTE START SOLENOID 337-19

FUEL SOLENOID

PARKING BRAKE "OFF" POSITION

••

•

125 AMP FUSE

••

337-20

724D-D47

PARKING BRAKE "ON" POSITION

start solenoid and the fuel solenoid. The start solenoid relay closes and supplies voltage through wire 12 to close the contacts of the start solenoid and supply battery power to the starter to turn the engine. The fuel solenoid contacts also close to supply power through wire 54 to the fuel control valve PULL IN coil during the start procedure.

The parking brake must be in the ON position to allow the engine to start. The engine is started by holding the bulb test/engine override switch in the ON position, turning the key to the START position and then releasing it to the RUN position after the engine starts. The bulb test/engine override switch is also released.

If the engine stalls during operation of the vehicle, the key must be turned to the OFF position to reset the ignition switch before the engine can be restarted.

Refer to START CIRCUIT DIAGRAMS in THIS SECTION.

START AND FUEL SOLENOIDS

During the start procedure the BULB TEST/ SHUTDOWN OVERRIDE SWITCH must be pressed and held to allow current to flow through wires 13, 13C and 76 and activate the HOLDING COIL in the fuel control valve. The switch can be 7.2

Tigercat M724D Mulcher

Engine To set machine in drive mode, place parking brake OFF to de-energize the drive enable relay (4) and allow voltage to flow to drive lock relay (2) along wire 66. Close both doors and press the pilot reset switch. This will energize the pilot shut off relay (1), de-energize the drive lock relay (2) and allow voltage to flow through wire 36 to energize the drive prevent valve solenoid and allow pilot oil to the drive pedals.

For schematic diagrams, showing various stages of the start circuit, refer to START CIRCUIT DIAGRAMS - CUMMINS 'C' ENGINE OPTION in THIS SECTION.

724D-D46

RELAY 6 LOW HYD. OIL LEVEL

RELAY 3 START

DIODE 1 HORN TEST

DIODE 4 BULB TEST

RELAY 2 DRIVE LOCK

DIODE 2 HORN TEST

DIODE 3 BULB TEST

RELAY 1 PILOT LOCK

21019A R0

RELAY 4 DRIVE ENABLE 5A 1 GAUGES 15A 2 SAFETY 10A 3 CONTROLS 10A 4 FUEL 10A 5 RADIO 15A 6 BACK HORN 15A 7 FAN/ACC.

RELAY 5 SAW

20A 8 AUX. 10A 9 AUX. FAN 30A 10 A/C - HEATER 20A 11 LIGHTER 25A 12 F. LIGHTS 25A 13 R. LIGHTS 15A 14 HORN/DOME

RELAYS, DIODES AND FUSES PANEL released after engine oil pressure rises above 10 psi. At this point the engine oil pressure switch contacts open and de-energize the emergency engine shutdown relay (7) allowing current to flow through wires13A and 13B to keep the HOLDING COIL activated.

When the parking brake is OFF, the drive enable relay (4) is de-energized, voltage is not available in wire 9 and therefore the engine cannot be started. This prevents accidental starting of the engine when the parking brake is OFF.

197-5

CAB DOOR SWITCH

It should be noted that with the engine running, the parking brake ON and the drive enable relay energized, voltage is not available in wire 66 to the drive lock relay (2). Because of this, driving the machine is still not possible until both cab doors are closed and the pilot reset switch is pressed.

7.3

Tigercat M724D Mulcher

Engine

START CIRCUIT DIAGRAMS - CUMMINS 'C' ENGINE OPTION START CIRCUIT - AT REST

M724D-12

START CIRCUIT - START MASTER DISCONNECT - ON PARKING BRAKE - ON BULB TEST/OVERRIDE SWITCH - ON IGNITION KEY - START POSITION

M724D-13

7.4

Tigercat M724D Mulcher

Engine

START CIRCUIT DIAGRAMS - CUMMINS 'C' ENGINE OPTION START CIRCUIT - RUN, NO DRIVE MASTER DISCONNECT - ON PARKING BRAKE - OFF PILOT RESET SW. - OFF BULB TEST/OVERRIDE SWITCH - OFF IGNITION KEY - RUN (IGNITION)

M724D-14

START CIRCUIT - RUN AND DRIVE MASTER DISCONNECT - ON PARKING BRAKE - OFF PILOT RESET SW. - ON IGNITION KEY - RUN (IGNITION)

M724D-15

7.5

Tigercat M724D Mulcher ENGINE COOLING SYSTEM

Engine

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

When the coolant reaches operating temperature and the thermostat opens, flow is directed to the top tank of the radiator, across the top of the radiator core and down through the core to the bottom tank and back to the water pump.

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

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

FILLING THE SYSTEM WITH COOLANT The coolant is added through the filler neck in the surge tank and runs slowly down the shunt line.

This coolant fills the bottom radiator hose at the water pump and then fills the radiator from the bottom upwards. The air displaced by the coolant discharges from the radiator top tank through the vent tube to the surge tank. As the radiator is filled, coolant flows through the water pump and engine oil cooler to fill the engine. Coolant will flow out the top radiator hose through the thermostat bypass and into the engine once the top tank of the radiator has filled. The engine vent discharges air directly from the engine to the surge tank.

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

An engine vent discharges air directly from the top of the engine to the surge tank.

ENGINE VENT

SURGE TANK

THERMOSTAT (PARTIALLY OPEN) VENT TUBE AFTER COOLER TOP TANK

CYLINDER HEAD

SHUNT LINE RADIATOR CORE

BYPASS

ENGINE BLOCK

724D-22

ENGINE OIL COOLER

WATER PUMP

COOLANT FLOW DURING OPERATION 7.6

BOTTOM TANK

Tigercat M724D Mulcher

Engine

PRECLEANER - ENGINE AIR INTAKE

TACHOMETER SET-UP

The precleaner is the first defense against foreign objects entering the air intake to the air cleaner filter elements and the engine. This unit draws its air supply through the perforated side engine door where the course outer screen blocks the passage of large particles such as leaves, twigs or pine needles. Inside the precleaner is a turbine fan which spins due to the passage of air over its blades. The blades direct large particles to the outside of the casing, where they are blown out the exhaust port area. The main air stream continues into the air filter assembly for removal of fine dust and particles.

NOTE: A calibrated “electronic photo tachometer” is required for this procedure.

AS THE AIR SPINS, CENTRIFUGAL FORCE SEPARATES FOREIGN MATERIALS FROM THE CLEAN AIR

1. Park machine on level ground, install articulation lock bar, lower attachment to ground, stop engine, pull parking brake ON and block wheels.

2. The magnetic sensor must be properly installed in the flywheel housing of the diesel engine. The end of the sensor is to be set at 0.030” clearance from the flywheel ring gear teeth. To achieve this, thread the sensor down gently until it touches the ring gear teeth then back it out the amount shown below; Cummins Engine = 1/2 turn.

CONTAMINANTS ARE BLOWN OUT OF SPECIAL DISCHARGE PORTS BY HIGH VELOCITY, AIR POWERED ROTOR

Tighten down the lock nut to hold the sensor in place.

3. Air Conditioning/Heater hoses (inside right cab door) may have to be moved out of the way to provide easier access to the back of the tachometer.

• •

4. Place reflecting tape, for electronic tachometer, on crankshaft vibration damper pulley.

• •

THE PRECLEANER HAS SPECIALLY DESIGNED BLADES THAT CAUSE THE INCOMING AIR TO SPIN TURBO 2

5. Start engine, and using electronic photo tachometer on damper pulley, adjust throttle so that the engine is running at a constant 2200 rpm.

6. Set the tachometer on the instrument panel to 2200 rpm using a 5/64” (2mm) allen key in the calibration access hole on the back of the tachometer.

ONLY THE PURIFIED AIR GOES TO THE AIR FILTER

PRECLEANER OPERATION

NOTE: Calibration access hole is on far side of tachometer. Do not short out the electrical wiring under the panel. Use an insulated (plastic) allen key, which is called an “alignment tool” and is available from most electronics parts supply stores.

SERVICE Under normal conditions, the outer screen should be checked every 8 hours for obstructions such as leaves, needles and twigs. This is done by opening the left, rear, upper engine door.

The complete precleaner unit must be removed for inspection and cleaning whenever the air cleaner primary filter element is replaced. This is done by loosening the gear clamp behind the unit and pulling it loose. Check the blades for dirt build-up and clean them. Check the exhaust port area (narrow slots around outside of casing) for dirt and particle build-up. Clean the entire unit.

When installing the unit, ensure that the intake end with the screen is protruding into the hole in the engine door by about 1/4" when the door is closed. Tighten the gear clamp and check to see that the engine door closes properly.

NOTE: Tachometer must be calibrated accurately at high RPM (2200 rpm) The low idle rpm reading on the instrument panel tachometer may be slightly inaccurate.

7. Reduce engine rpm to LOW IDLE and then back up to 2200 rpm on the electronic photo tachometer.

8. Compare instrument panel tachometer against electronic photo tachometer for 2200 rpm. Readjust if necessary.

7.7

Tigercat M724D Mulcher

Engine

7.8

Tigercat M724D Mulcher SECTION 8 - DRIVE JANUARY 2004

CONTENTS - SECTION 8 AXLES .......................................................................................................... 8.42 AXLE LUBRICATION ............................................................................... 8.44 BRAKE BLEEDING .................................................................................. 8.44 BRAKE LINING INSPECTION (REAR AXLE ONLY) ............................... 8.43 DIFFERENTIAL AND DIFFERENTIAL LOCKS ........................................ 8.43 DRAINING THE AXLES ........................................................................... 8.44 FILLING AXLES, ALTERNATIVE METHOD ............................................ 8.45 FILLING THE AXLES ............................................................................... 8.44 REAR AXLE OSCILLATION SHIM ........................................................... 8.46 SERVICE BRAKES (REAR AXLE ONLY) ................................................ 8.43 CIRCUIT DIAGRAM, DRIVE DUAL MOTOR 1-SPEED TRANSMISSION ............................................. 8.25 SINGLE MOTOR 2-SPEED TRANSMISSION ......................................... 8.13 DRIVE LIMITER CONTROL VALVE ............................................................ 8.11 DRIVE PEDAL PILOT VALVE ...................................................................... 8.10 DRIVE PREVENT VALVE ............................................................................ 8.10 DRIVE SHAFT, FRONT, INSTALLATION ................................................... 8.40 HYDROSTATIC DRIVE MOTOR ................................................................... 8.8 DESCRIPTION ........................................................................................... 8.8 DIAGRAM DUAL MOTOR 1-SPEED TRANSMISSION ............................................ 8.8 SINGLE MOTOR 2-SPEED TRANSMISSION ........................................ 8.9 SCHEMATIC .............................................................................................. 8.9 HYDROSTATIC DRIVE PUMP DESCRIPTION ........................................................................................... 8.4 DIAGRAM ................................................................................................... 8.5 SCHEMATIC .............................................................................................. 8.6 HYDROSTATIC DRIVE SYSTEM CIRCUIT DESCRIPTION DUAL MOTOR 1-SPEED TRANSMISSION ............................................ 8.3 SINGLE MOTOR 2-SPEED TRANSMISSION ........................................ 8.2 PRESSURE SETTINGS AND ADJUSTMENTS DUAL MOTOR 1-SPEED TRANSMISSION DRIVE MOTORS .................................................................................. 8.30 DRIVE PUMP ........................................................................................ 8.28 SINGLE MOTOR 2-SPEED TRANSMISSION DRIVE MOTORS .................................................................................. 8.18 DRIVE PUMP ........................................................................................ 8.16 TEST DRIVE DUAL MOTOR 1-SPEED TRANSMISSION ............................................. 8.26 SINGLE MOTOR 2-SPEED TRANSMISSION ......................................... 8.14 TRANSMISSION 1-SPEED (DUAL MOTOR) .............................................. 8.39 TRANSMISSION 2-SPEED (SINGLE MOTOR) ........................................... 8.36 SHIFT LEVER .......................................................................................... 8.37 WHEEL INSTALLATION .............................................................................. 8.48

Tigercat M724D Mulcher

SWASHPLATE, AXIAL PISTON DRIVE PUMP

Drive

LOW PRESSURE RETURN

BENT AXIS PISTON DRIVE MOTOR (LH)

FROM DIESEL ENGINE

TO VEHICLE DRIVE

HIGH PRESSURE SUPPLY

M724D-17

TYPICAL CONTINUOUS CLOSED LOOP HYDRAULIC CIRCUIT SINGLE MOTOR (2-SPEED TRANSMISSION) Hydrostatic drives are used because they offer enhanced operator control of vehicle speed and tractive effort. As well hydrostatic drive systems give flexibility in the positioning of components within the machine when compared to mechanical drive systems.

HYDROSTATIC DRIVE SYSTEM SINGLE MOTOR 2-SPEED TRANSMISSION The primary components of the single motor two speed transmission M724D hydrostatic drive system are a hydraulic pump and a hydraulic motor connected together by two hydrostatic hoses. The pump converts the mechanical power of the diesel engine into hydraulic power. This high pressure flow of hydraulic oil is then transmitted to the hydraulic motor through one connecting hose. The motor then reconverts the hydraulic power back into the mechanical power used to propel the machine. Low pressure hydraulic oil flow then returns from the motor to the pump through the other connecting hose thereby completing a continuous closed loop hydraulic circuit.

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

8.2

Tigercat M724D Mulcher

Drive

BENT AXIS PISTON DRIVE MOTOR (LH)

LOW PRESSURE RETURN

SWASHPLATE, AXIAL PISTON DRIVE PUMP

TO VEHICLE DRIVE

FROM DIESEL ENGINE

BENT AXIS PISTON DRIVE MOTOR (RH)

TO VEHICLE DRIVE

HIGH PRESSURE SUPPLY

M724D-17

TYPICAL CONTINUOUS CLOSED LOOP HYDRAULIC CIRCUIT DUAL MOTOR (1-SPEED TRANSMISSION) Hydrostatic drives are used because they offer enhanced operator control of vehicle speed and tractive effort. As well hydrostatic drive systems give flexibility in the positioning of components within the machine when compared to mechanical drive systems.

HYDROSTATIC DRIVE SYSTEM DUAL MOTOR 1-SPEED TRANSMISSION The primary components of the dual motor one speed transmission M724D hydrostatic drive system are a hydraulic pump and two hydraulic motors connected together by hydrostatic hoses.

The pump converts the mechanical power of the diesel engine into hydraulic power. This high pressure flow of hydraulic oil is then transmitted to the hydraulic motors through one connecting hose. The motors then reconvert the hydraulic power back into the mechanical power used to propel the machine. Low pressure hydraulic oil flow then returns from the motors to the pump through the other connecting hose thereby completing a continuous closed loop hydraulic circuit.

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

8.3

Tigercat M724D Mulcher

Drive

HYDROSTATIC DRIVE PUMP (REXROTH)

displacement angle, the piston pump will produce maximum flow in one direction in the closed loop.

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

The hydrostatic drive pump is mounted at the top center location of the pump drive gearbox. A spline adapter connects the input driveshaft of the pump directly to the output of the gearbox. The gearbox is driven directly by the diesel engine through a flexible coupling.

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

The primary pump is a variable displacement, swashplate, axial piston type. This pump is made variable by slipping the pump pistons against a tiltable swashplate cradle. The volume and direction of oil flow from the piston pump is determined by the angle of this swashplate. When the swashplate is stroked to a maximum RETURN TO TANK LINE

The secondary pump is a fixed displacement, internal gear type which provides charge oil (make-up oil) for the closed loop as well as providing control oil for the regulation of the primary pump.

OPERATING DESCRIPTION The drive pedal pilot valve (drive control valve) directs oil from the charge pump and sends a pressure signal to shift the spool in the swashplate control valve. This changes the position of the control cylinder which is directly 'G1' PORT TO DRIVE LIMITER CONTROL VALVE

'TEST PORT 'G' • QUICK CONNECT

•

••

'B' PORT RELIEF

•

•

5 MM ALLEN KEY 17 WRENCH

• ••

'A' PORT RELIEF 5 MM ALLEN KEY 17 MM WRENCH

•

CHARGE PRESS. RELIEF • 5 MM ALLEN KEY • 17 MM WRENCH

'Yst' PORT TO DRIVE LIMITER CONTROL VALVE PRESSURE PORT 'B'

•

PRESSURE PORT 'A'

••

TO CHARGE PRESSURE FILTER

SUCTION FROM TANK

••

M724D-28

••

DRIVE PUMP - REXROTH 8.4

•

Tigercat M724D Mulcher

Drive avoid stalling the engine while the mulching head cutter is rotating.

connected to the swashplate of the piston pump.

The angle and direction that the swashplate moves determines vehicle speed and direction of travel. The angle and direction that the swashplate moves is directly proportional to the position of the drive pedal. When neither of the drive pedals are depressed, charge pump oil is not supplied to the swashplate. The swashplate therefore remains in the neutral position and no oil is pumped by the piston pump.

The drive pedal pilot valve only functions when the parking brake lever is in the OFF position.

This prevents the machine from being driven when the parking brake ON. A proximity sensor is attached to the parking brake lever. When this lever is in the OFF position, the proximity sensor contacts are open, de-energizing the drive enable relay and energizing the drive prevent valve. With the drive prevent valve energized, drive pedal pilot oil can be directed to either the forward or reverse side of the pump swashplate control valve as required. With the drive prevent valve deenergized, drive pedal pilot oil is directed to both sides of the swashplate control valve, the valve does not move and the pump swashplate angle remains at zero (0o).

The remotely mounted drive limiter control solenoid valve is energized only when both the drive limiter switch and the saw/cutter switch are in the ON position. When the drive limiter solenoid is energized charge oil supplied to the drive pedal pilot valve first passes through the DA control cartridge inside the drive pump. The DA control limits the flow of charge oil to the drive pedal pilot valve in response to a drop in engine rpm due to loading from the mulching head.

Reduced flow of charge oil to the drive pedal limits the drive speed of the machine, reducing the load on the engine and effectively limiting the drop in engine rpm to a factory set range between 1800 rpm and 2200 rpm. The drive limiter function is intended to aid the operator by automatically maintaining correct engine rpm levels during mulching operations in order to

DRIVE SHAFT

CONTROL CYLINDER

The hydrostatic piston pump is equipped with a pressure override (POR) valve to protect the closed loop components from excessive pressure. When the tractive effort requirements of the vehicle are demanding then pressure on the high side of the closed loop can reach maximum.

At this pressure the POR valve signals the swashplate control valve to destroke the swashplate, reducing piston pump flow and maintaining system pressure at the POR setting.

SWASHPLATE CONTROL VALVE PORT 'B'

CHARGE PUMP

PRESSURE OVERRIDE VALVE (POR)

CHARGE PUMP RELIEF 'B' PORT RELIEF

PORT 'B'

PORT 'A'

SPLINED SHAFT SWASHPLATE

AP008-1

CROSS SECTION THRU' PORT PLATE BODY

PORT 'A'

DRIVE PUMP 8.5

'A' PORT RELIEF

AP008-2

Tigercat M724D Mulcher

Drive TO MOTORS (B)

TO DRIVE PEDAL CONTROL VALVE

F

R

P

TO MOTORS (A) POR VALVE

DRIVE LIMITER CONTROL VALVE

CHARGE PUMP RELIEF HIGH PRESSURE RELIEF VALVE 'B' HIGH PRESSURE RELIEF VALVE 'A'

DA CONTROL CARTRIDGE

SWASHPLATE CONTROL VALVE CONTROL CYLINDER

HYDROSTATIC PUMP (PISTON) CHARGE PRESSURE FILTER

CHARGE PUMP (GEAR)

Ma TEST PORT Mb TEST PORT

M724D-20

DRIVE PUMP SCHEMATIC

The POR prevents continuous dumping of high pressure oil across the piston pump high pressure relief valves. This eliminates unnecessary heating of the oil and protects the pump and motor(s) during rapid acceleration and deceleration or when the drive system stalls.

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

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

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

The charge pump continuously introduces oil from 8.6

Tigercat M724D Mulcher

Drive

8.7

Tigercat M724D Mulcher

Drive

HYDROSTATIC DRIVE MOTORS

SOME HOSES REMOVED FOR CLARITY SOME HOSES REMOVED FOR CLARITY

M724D-32

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

SINGLE DRIVE MOTOR 2-SPEED TRANSMISSION

One or two motors are used to drive the feller buncher depending on the transmission option chosen. The motor(s) are mounted to the input side of the transmission. A splined coupling connects the motor shaft to the transmission input shaft.

The angle of the pistons is variable and is changed by an internal control cylinder that receives high pressure oil via the MOTOR's pressure override valve (POR) and a displacement control spool.

Each motor is a variable displacement, bent axis piston type. The motor(s) form a closed loop circuit with the drive pump.

The displacement control spool is operated by pilot pressure from the forward and reverse foot pedals. When sufficient pressure from the pedals is directed to the spool, it shifts against a spring and directs oil past the POR valve to the displacement control cylinder thus decreasing the displacement control of the motor to the minimum setting. Removal of the pressure signal from the

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

•

M724D-33

DUAL DRIVE MOTORS 1-SPEED TRANSMISSION

FLUSHING VALVE

•

ROTATING GROUP

PORT 'M1'

AQ010-5Y

'A'

•

PORT 'B'

•

PORT 'A'

BEGIN OF STROKE ADJUSTING SCREW PORT 'G'

• VIEW 'A'

•

AQ010-1

POR ADJUSTING SCREW

DRIVE SHAFT

•

•

•

PORT 'X'

DUAL DRIVE MOTORS ~ REXROTH (160CC SIZE) 8.8

MINIMUM DISPLACEMENT ADJUSTING SCREW

Tigercat M724D Mulcher

Drive override set point".

FLUSHING VALVE

The MOTOR POR set point must be correctly set for the system to function properly. Refer to DRIVE MOTOR PRESSURE SETTINGS in THIS SECTION .

•

CONTROL CYLINDER

MIN

POR VALVE

•

A minimum displacement adjusting screw on the outside of the motor housing limits the maximum speed of the motor.

DISPLACEMENT CONTROL SPOOL

•

WARNING: Improper adjustment of Minimum displacement adjusting screw can result in motor and transmission failure due to overspeeding.

When installing a new motor always ensure stroke limiting screw is set correctly. Refer to SET MOTOR MINIMUM DISPLACEMENT, in this section.

FROM PEDALS AND SPEED CONTROL FROM PUMP

720C-24

FROM PUMP

A flushing valve is incorporated into the motor.

This valve provides a regulated flow of oil from the low pressure side of the loop in the motor case. This action reduces the possibility of particle build up in the loop by providing a continuous change of oil, it also assists with cooling. This valve is factory set and requires no adjusting.

DRIVE MOTOR SCHEMATIC

foot pedals will cause the displacement control spool to return to the neutral position, shutting off the pressure to the displacement control cylinder thus increasing displacement to maximum.

The spool in the POR valve is moved by system pressure from the high pressure side of the loop.

When the POR spool moves as a result of high pressures it reduces the pressure directed to the displacement control cylinder. The reduced pressure will cause the displacement control piston to move. The point at which the displacement control spool begins to move is known as "begin of stroke set point" or "pressure

NOTE** The term "begin of stroke set point" or "pressure override set point" can also be known as "begin of displacement regulation" or "begin of regulation" or "begin of displacement" or "motor POR". In this manual it will be referred to as MOTOR POR.

•

MAX

FLUSHING VALVE

•

ROTATING GROUP

PORT 'M1'

AQ010-5Y

'A'

•

PORT 'A'

PORT 'B'

•

BEGIN OF STROKE ADJUSTING SCREW PORT 'G'

• VIEW 'A'

•

M724D-01

POR ADJUSTING SCREW

DRIVE SHAFT

•

•

•

PORT 'X'

SINGLE DRIVE MOTOR ~ REXROTH (160CC SIZE) 8.9

MINIMUM DISPLACEMENT ADJUSTING SCREW

Tigercat M724D Mulcher

Drive

DRIVE PEDAL PILOT VALVE

At the same time the regulating spool (2) is moved through the regulating spring (3).

When the regulating stroke begins, there is a connection from port 'P' via hole (8) in the spool and work ports 1 and 2 in the base of the valve, to the swashplate control valve on the drive pump.

Pressure provided by the drive charge pump at ports 1 and 2 is directly proportional to the position of the operator's foot on the foot pedal and the regulating spring characteristic.

DRIVE PREVENT VALVE The drive prevent valve is located under the cab.

This solenoid operated spool valve prevents the machine from being driven either forward or reverse when the parking brake is ON. 1

2

P

UNDERSIDE OF CAB

DRIVE PREVENT VALVE

••

T

DRIVE PILOT VALVE

AU004

This pilot valve is a manually operated directional valve and operates on the same principal as a direct operating pressure reducing valve.

•

Operated by foot, this valve directs oil pressure provided by the drive charge pump, to the swashplate control valve on the drive pump to drive the machine either forward or reverse.

•

5

•

DRIVE PREVENT VALVE

724D-D24

SOLENOID AND CONNECTOR

1

•

• P1

• • •

4 3

• •

•

2

•

SM-29

P2

SPOOL SECTION

•

VALVE BLOCK

• •

PORT 1

8 PORT 2 'P' PORT

AU013-1

WORK PORTS 1, OR 2

SPOOL ARRANGEMENT

V-04

DRIVE PREVENT VALVE

OPERATING DESCRIPTION AU013-2

When the solenoid valve is de-energized (parking brake ON) the spool cross connects the forward and reverse pilot lines causing drive charge pump oil to return to tank in the event the foot control is operated. This prevents the foot control from supplying pressure to the drive pump displacement controller.

OPERATING DESCRIPTION In the neutral position the foot pedal is held centered by return spring (4).

When the pedal (1) is operated, the plunger (5) is pushed against the return spring (4).

8.10

Tigercat M724D Mulcher

Drive

When the solenoid valve is energized (parking brake OFF), the spool in the drive prevent valve shifts and blocks the cross connection between the forward and reverse pilot line. This allows the foot control (forward or reverse) to send drive charge pump pressure* to the drive pump displacement controller.

engine rpm to a factory set range between 1800 rpm and 2200 rpm.

The drive limiter function is intended to aid the operator by automatically maintaining correct engine rpm levels during mulching operations in order to avoid stalling the engine while the mulching head cutter is rotating.

DRIVE LIMITER CONTROL VALVE The drive limiter control solenoid valve is energized only when both the drive limiter switch and the saw/cutter switch are in the ON position.

When the drive limiter solenoid is energized charge oil supplied to the drive foot pedal control pedal first passes through the DA control cartridge inside the drive pump.

UNDERSIDE OF CAB

DRIVE LIMITER VALVE

•• •

•• SHUTTLE VALVE

M724D-34

DRIVE LIMITER CONTROL VALVE SOLENOID AND CONNECTOR

M724D-21

•• •• 2

SPOOL SECTION

1 3

•

PORT '3' FROM DRIVE PUMP 'Yst'

PORT '2' TO DRIVE PEDAL 'P'

•• PORT '1' FROM DRIVE PUMP 'G1' AT022 DRIVE LIMITER CONTROL VALVE The DA control limits the flow of charge oil to the drive pedal in response to a drop in engine rpm due to loading from the mulching head. Reduced flow of charge oil to the drive pedal limits the drive speed of the machine, reducing the load on the engine and effectively limiting the drop in

8.11

Tigercat M724D Mulcher

Drive

8.12

Tigercat M724D Mulcher

M724D-17

Drive

DRIVE CIRCUIT - SINGLE MOTOR 2-SPEED TRANSMISSION 8.13

Tigercat M724D Mulcher

Drive

TEST DRIVE

MOTOR PRESSURE OVERRIDE (POR)

SINGLE MOTOR 2-SPEED TRANSMISSION

1. Shift the transmission to HIGH RANGE, turn ON both front and rear differential locks.

Set the throttle control to FULL.

This drive will verify the following: 1. Motor pressure override.

2. Top speed control.

3. Front and rear differential lock functions.

4. Attachment recovery time 5. Boom functions.

6. Parking brake operation.

2. Drive the machine FORWARD at FULL SPEED. Apply the foot brake to slow the machine to approximately half speed but no slower.

3. While doing the above, observe the pressure at 'Mb'. The reading should be 3700 psi (drive motor POR setting). Also observe the pressure reading at 'M1' which should be 1850 psi (half of 'Mb').

REAR CHASSIS RH SIDE 'X' TEST PORT

'M1' TEST PORT

••

Note: This test may have to be done a few times to get a proper reading.

•

TOP SPEED CONTROL: 1. Shift the transmission to HIGH RANGE, turn ON both front and rear differential locks.

Set the throttle control to FULL.

M724D-27X

2. Drive the machine forward at top speed and adjust the throttle control so that the tachometer reads 2200 rpm at top speed.

GAUGE CONNECTIONS

3. With the aid of an assistant drive the machine forward at top speed (speed control lever fully forward) and record the time to complete 5 tire revolutions. This should take 5 seconds maximum.

'TEST PORT 'G' • QUICK CONNECT

•• •

•• GAUGE TEST PORT 'Mb'

If it takes longer than 5 seconds either the MOTOR minimum displacement, MOTOR POR or PUMP charge pressure may be incorrectly set.

GAUGE TEST PORT 'Ma' M724D-28

DRIVE PUMP - REXROTH

Connect one 0 - 5,000 psi gauge to drive motor test port 'M1'. Connect one 0-10,000 psi gauge at the 'Mb' port of the drive pump.

NOTE: Fasten these gauges so that they can be viewed from the operator’s seat in the cab.

DIFFERENTIAL LOCK FUNCTIONS: 1. Bring machine to a full stop, set throttle to IDLE, ensure both front and rear differential lock switches are turned OFF. Steer machine without depressing drive pedal.

Fasten your seat belt and move the machine to a suitable test area, where it can be safely driven at full speed for approximately 150 feet.

All wheels should rotate as machine is being steered. Steer several times, check all wheels.

IMPORTANT: Foot brake must only be applied for 5 -10 seconds followed each time by a minimum 20 second cool down period. Failure to do so will result in 'burn out' of the rear axle brake.

2. Turn only the front differential lock switch ON. While steering the machine, both front wheels should slide instead of rotating. Rear wheels should still rotate.

3. Turn front differential lock switch OFF. 4. Turn only the rear differential lock switch ON. While steering the machine, both rear wheels should slide instead of rotating.

Front wheels should still rotate.

8.14

Tigercat M724D Mulcher

Drive FELLER BUNCHER CONFIGURATION SAW

ATTACHMENT RECOVERY TIME MULCHER

1. Install saw guard and raise felling head 6 inches off ground.

1. Close mulch deflector door and raise mulching head 6 inches off ground.

2. Set throttle control FULL.

2. Set throttle control FULL.

3. Turn saw ON.

3. Turn mulcher ON.

4. For 5500, 5600 and 5700 wide kurf series saws: Observe saw pressure gauge visible through cab window, pressure should rise to 3500-3600 psi. for about 10 seconds, drop to 3100 psi. for about 1215 seconds and then drop to 1200-1800 psi as saw reaches full rpm. From FULL STOP to FULL rpm. should take 30 seconds.

4. For Fecon BH250 mulching head: Observe saw/cutter pressure gauge visible through cab window, the gauge will show an initial value of 4950-5050 psi for about 7 seconds. After a total elapsed time of approximately 7 seconds the gauge reading will drop to approximately 1000-1200 psi and hold, as the rotating cutter has reached full speed.

NOTE: Refer to the Tigercat BUNCHING SAWS OPERATING AND SERVICE MANUAL for setup and servicing procedures.

NOTE: Refer to the MANUFACTURER'S OPERATING AND SERVICE MANUAL for setup and servicing procedures.

CAUTION

BOOM FUNCTIONS

Ensure that all personnel are clear of the attachmment.

MULCHER Test all boom functions for proper operation (lift, tilt, mulch deflector door).

WARNING When leaving the cab to check the rotating cutter/saw blade or other parts of the attachment, observe all safety rules listed in this manual and the attachment manufacturer's manual.

FELLER BUNCHER CONFIGURATION Test all boom functions for proper operation (lift, tilt, accumulating arms, clamp arms).

CHECKING FOR PROPER PARKING BRAKE ADJUSTMENT The parking brake is properly adjusted when resistance is encountered half way through the brake lever’s travel.

Refer to SECTION 9 of THIS MANUAL for adjusting procedure and additional information on brakes.

8.15

Tigercat M724D Mulcher

Drive

DRIVE PUMP PRESSURE SETTINGS AND ADJUSTMENTS

5. Install a limiting block under the foot pedal to limit its movement to 1/3 of its full travel. (The limiting block should measure approximately 1-5/8" high . If there is any difficulty setting pressures the size of the block may need to be reduced slightly.)

SINGLE MOTOR 2-SPEED TRANSMISSION NOTE: Ensure hydraulic oil is at operating temperature. Refer to HYDRAULIC OIL HEATING PROCEDURE in SECTION 5 of THIS MANUAL. NOTE:Relief valves are set by loosening the locknut and turning the adjusting screw OUT (counter-clockwise) to reduce the pressure setting and IN (clockwise) to increase the pressure setting.

1-5/8"

WARNING 189-10X

INSTALL A LIMITING BLOCK UNDER BOTH DRIVE PEDALS

6. Disconnect the parking brake proximity sensor power wire from the sensor.

To prevent injury caused by accidental steering of the machine when setting pressures, make sure the articulation lock bar is held securely in place by the lynch pins provided.

CAUTION Avoid the risk of unintentionally driving the machine with this wire disconnected, the parking brake will be ON without the ability to release it. This will result in overheating of the brakes which could cause a fire in the machine.

1. Park machine on level ground, lower attachment to the ground and set parking brake ON. Install the articulation lock bar and shut off engine.

ADJUST AUXILIARY BRAKE SET-UP CALIPER (ADJUSTING NUT) TO 110 LBF/FT.

7. Turn the pump pressure override valve (POR) adjusting screw IN (clockwise) until lightly seated. Do not over-tighten, or breakage will result. Turn the pump POR valve OUT (counter-clockwise) one half turn.

IMPORTANT

•

Avoid blowing oil over relief longer than 5 seconds, as excessive heating of hydraulic fluid and damage to drive pump can occur.

336-3AX

IMPORTANT

AUXILIARY BRAKE SET-UP CALIPER

2. Adjust auxiliary brake set-up caliper to lock the rotating brake disc. Refer to illustrations to identify your caliper and the proper setting.

To prevent frequent operation of relief valves, it is important that the settings of the high pressure relief valves be substantially higher than the pump POR setting.

3. Connect a 0-1000 psi pressure gauge to the "capped" test port from port 'G' on the drive pump. Connect 0-10000 psi pressure gauges to ports 'Ma' and 'Mb' on the drive pump.

8. With the aid of an assistant hold down the brake pedal and while depressing the FORWARD drive pedal to 1/3 of its full travel set the pump high pressure relief valve 'B' at 'Mb' 5650-5700 psi at FULL throttle.

4. Start the engine and set to FULL throttle. Set charge pressure relief valve to 450 psi at 'G'.

CAUTION The machine should not be able to move while the brake pedal is depressed.

8.16

Tigercat M724D Mulcher

Drive

9. With the aid of an assistant hold down the brake pedal and while depressing the REVERSE drive pedal to 1/3 of its full travel set the pump high pressure relief valve 'A' at 'Ma' 5650-5700 psi at FULL throttle.

12. Shut off the engine. Reconnect the parking brake proximity sensor.

17. Remove all pressure gauges and reinstall all plugs and caps.

10. Remove the limiting block from under the forward and reverse footpedals.

POR VALVE 4 mm ALLEN KEY 13 mm WRENCH

SOME HOSES REMOVED FOR CLARITY

11. With the aid of an assistant hold down the brake pedal and while depressing the FORWARD drive pedal fully adjust the pump POR valve to get a reading at 'Mb' of 5000-5050 psi at FULL throttle.

DRIVE PUMP

M724D-29

'TEST PORT 'G' • QUICK CONNECT

CHARGE PRESSURE RELIEF • 5 MM ALLEN KEY • 17 MM WRENCH

•

HIGH PRESSURE RELIEF VALVE 'B' 5 MM ALLEN KEY 17 WRENCH

• HIGH PRESSURE RELIEF VALVE 'A'

••

M724D-28

••

•

5 MM ALLEN KEY 17 MM WRENCH

••

GAUGE TEST PORT 'Ma' • 3/16" ALLEN KEY • PORT SIZE - 04 ORB

DRIVE PUMP - REXROTH

8.17

•• GAUGE TEST PORT 'Mb' • 3/16" ALLEN KEY • PORT SIZE - 04 ORB

Tigercat M724D Mulcher

Drive

DRIVE MOTOR PRESSURE SETTINGS AND ADJUSTMENTS

A. MOTOR MINIMUM DISPLACEMENT ADJUSTMENT

SINGLE MOTOR 2-SPEED TRANSMISSION

NOTE: Ensure hydraulic oil is at operating temperature. Refer to HYDRAULIC OIL HEATING PROCEDURE in THIS SECTION of the manual.

To set the hydrostatic drive motor pressures and speeds, the following procedure must be performed in the order shown.

1. Park the machine on level ground, lower attachment to the ground and set parking brake ON. Install articulation lock bar an shut off engine.

A. Set the motor minimum displacement.

B. Set the motor begin of displacement control pressure.

C. Set the motor pressure override.

IMPORTANT

WARNING

The adjustment or set-up procedure is a series of steps that must be done in a proper sequence to achieve optimum performance from the machine. Any deviation from the procedures could present a safety hazard, damage components and/or affect the operation of the machine.

To prevent injury caused by accidental steering of the machine when setting pressures, make sure the articulation lock bar is held securely in place by the lynch pins provided.

2. Remove the minimum displacement adjusting screw (largest screw) from the top of motor housing and measure its length.

IMPORTANT • When installing a new or rebuilt motor, ensure minimum displacement screw is set correctly.

• Improper adjustment of min. displacement adjusting screw can result in motor failure due to overspeeding.

• It may be necessary to verify the length of adjusting screw used by removing and measuring the screw.

3. Reinstall the minimum displacement adjusting screw and locknut into the motor housing. For a 90mm long screw, it should be adjusted such that the dimension from the top of the locknut to the end of the exposed screw is 19mm. (For different length screws, measure the length and subtract 71mm from this total length. This is the amount of screw that should be exposed above the locknut.)

(For example: 100mm screw, minus 71mm will leave 29mm above locknut).

REAR CHASSIS RH SIDE

NOTE: Repeat for the other motor.

'M1' TEST PORT

•

M724D-27X

'X' TEST PORT

"X"

••

DIM X

GAUGE CONNECTIONS

8.18

MIN. DISPLACEMENT "X" DIMENSION

Tigercat M724D Mulcher

Drive

B. MOTOR BEGIN OF DISPLACEMENT CONTROL PRESSURE ADJUSTMENT

'TEST PORT 'G' • QUICK CONNECT

••

NOTE: Ensure hydraulic oil is at operating temperature. Refer to HYDRAULIC OIL HEATING PROCEDURE in THIS SECTION of the manual.

••

• GAUGE TEST PORT 'Mb'

GAUGE TEST PORT 'Ma'

1. Park the machine on level ground, lower attachment to the ground and set parking brake ON. Install articulation lock bar an shut off engine.

M724D-28

DRIVE PUMP - REXROTH

3. Connect a 0-1000 psi pressure gauge to the "capped" test port 'G' on the drive pump.

Connect 0-10000 psi pressure gauges to ports 'Ma' and 'Mb' on the drive pump.

Connect one 0-1000psi gauge to the 'X' test port . Connect a 0-5000 psi pressure gauge to the motor test port 'M1'.

2. Adjust auxiliary brake set-up caliper to lock the rotating Brake disc. Refer to illustrations to identify your caliper and the proper setting.

ADJUST AUXILIARY BRAKE SET-UP CALIPER (ADJUSTING NUT) TO 110 LBF/FT.

POR VALVE 4 mm ALLEN KEY 13 mm WRENCH

SOME HOSES REMOVED FOR CLARITY

AUXILIARY BRAKE SET-UP CALIPER

•

FLUSHING VALVE

•

PORT 'M1' • 6 ORB 1/4" ALLEN KEY

•

336-3AX

DRIVE PUMP

M724D-29

••

••

MAXIMUM DISPLACEMENT ADJUSTING SCREW (DO NOT ADJUST) FOR REFERENCE ONLY: DIM. 'X' = 3/8" (9MM) FOR A 50MM LONG SCREW

'A' PORT 'A'

PORT 'B'

• •

•

VIEW 'A'

BEGIN OF DISPLACEMENT ADJUSTING SCREW (DO NOT ADJUST) FOR REFERENCE ONLY: DIM. 'X' = 3/8" (9MM)

M724D-01

MOTOR POR ADJUSTING SCREW

AQ010-5Y

MINIMUM DISPLACEMENT ADJUSTING SCREW - 6MM ALLEN KEY - 19MM WRENCH DIM. 'X' = 3/4" (19MM) FOR A 90MM LONG SCREW

SINGLE DRIVE MOTOR ~ REXROTH (160CC SIZE) 8.19

Tigercat M724D Mulcher

Drive

4. Disconnect the parking brake proximity sensor power wire form the sensor.

MOTOR PRESSURE OVERRIDE ADJUSTING SCREW (POR)

(SOME HOSES REMOVED FOR CLARITY)

CAUTION Avoid the risk of unintentionally driving the machine with this wire disconnected, the parking brake will be ON without the ability to release it. This will result in overheating of the brakes which could cause a fire in the machine.

•

• MINIMUM DISPLACEMENT ADJUSTING SCREW

5. Start the engine and set to FULL throttle.

6. To set the motor pressure override adjustment (POR), it is necessary to temporarily adjust the drive pump pressure override to 3700 psi.

DRIVE MOTOR

320-23

7. With the aid of an assistant hold down the brake pedal and while depressing the REVERSE drive pedal set the pump pressure override (POR) valve to a reading at 'Ma' of 3700 psi at FULL throttle.

• • REVERSE LIMITING SCREW

CAUTION

189-10

The machine should not be able to move while the brake pedal is depressed.

FORWARD LIMITING SCREW

FORWARD AND REVERSE DRIVE PEDALS

9. To set the motor begin of displacement control pressure, it is also necessary to temporarily achieve pressure readings of 125&135 psi pressure reading at 'X' while fully depressing the REVERSE and FORWARD pedals. See steps below.

8. Turn the motor pressure override valve (POR) adjusting screw IN (clockwise) until lightly seated. Do not overtighten.

a. With the aid of an assistant, hold down the brake pedal and while fully depressing the

•

FLUSHING VALVE

•

•

PORT 'M1' • 6 ORB 1/4" ALLEN KEY

MAXIMUM DISPLACEMENT ADJUSTING SCREW (DO NOT ADJUST) FOR REFERENCE ONLY: DIM. 'X' = 3/8" (9MM) FOR A 50MM LONG SCREW

'A' PORT 'A'

PORT 'B'

• •

•

VIEW 'A'

BEGIN OF DISPLACEMENT ADJUSTING SCREW (DO NOT ADJUST) FOR REFERENCE ONLY: DIM. 'X' = 3/8" (9MM)

M724D-01

MOTOR POR ADJUSTING SCREW

AQ010-5Y

MINIMUM DISPLACEMENT ADJUSTING SCREW - 6MM ALLEN KEY - 19MM WRENCH DIM. 'X' = 3/4" (19MM) FOR A 90MM LONG SCREW

SINGLE DRIVE MOTOR ~ REXROTH (160CC SIZE) 8.20

Tigercat M724D Mulcher REVERSE pedal, adjust the stroke limiting screw (located under the pedal) upwards to limit the stroke of the reverse pedal and give a reading of 125 psi at 'X' for 15 seconds. b. With the aid of an assistant, hold down the brake pedal and while fully depressing the FORWARD pedal, adjust the stroke limiting screw (located under the pedal) upwards to limit the stroke of the reverse pedal and give a reading of 135 psi at 'X' for 15 seconds.

Drive 11. With the aid of an assistant, hold down the brake pedal and while fully depressing the REVERSE foot pedal (set to 125 psi at 'X') the motor SHOULD NOT STROKE and a low reading of 800 psi or less should be obtained at 'M1'.

12. With the aid of an assistant, hold down the brake pedal and while fully depressing the FORWARD foot pedal (set to 135psi at 'X') the motor SHOULD STROKE and a high reading of 2000-2500 psi should be obtained at 'M1'.

Note: Notice the difference in pressures for the forward and reverse pedals. These settings are important.

13. If these readings are obtained then the motor begin of displacement setpoint is now between 125-135 psi.

Alternatively the position of the speed control lever can be used to give these pressures with one of the foot pedals fully depressed.

If not then repeat steps 10 to 12 until a correct setpoint is achieved.

When properly set the motor will begin to stroke in the pressure range of 125-135 psi.

This is a critical setting for the smooth and efficient operation of the machine.

15. Check motor to verify that this setting did not changed as the locknuts were tightened.

16. To complete this procedure the drive motor POR must be reset. Refer to MOTOR PRESSURE OVERRIDE (POR) ADJUSTMENT in THIS SECTION.

M724D-02

SPEED CONTROL LEVER

10. With the aid of an assistant, hold down the brake pedal and while fully depressing the FORWARD foot pedal, adjust the motor begin of displacement screw to give a reading at 'M1' of 2000-2500 psi at FULL throttle. This is very difficult to do and takes a little patience. The screw is VERY sensitive.

Get as close as possible.

If the reading is HIGH; turn the motor begin of displacement adjusting screw OUT (counterclockwise) until a correct reading at 'M1' is obtained with the locknut tightened.

If the reading is LOW; turn the motor begin of displacement adjusting screw IN (clockwise) until a correct reading at 'M1' is obtained with the locknut tightened.

Recheck frequently while adjusting by having an assistant release and depress pedals.

NOTE: These settings are turn on/turn off points and should not be confused with pressure settings.

8.21

Tigercat M724D Mulcher

Drive

C. MOTOR PRESSURE OVERRIDE ADJUSTMENT (POR)

'TEST PORT 'G' • QUICK CONNECT

••

NOTE: Ensure hydraulic oil is at operating temperature. Refer to HYDRAULIC OIL HEATING PROCEDURE in THIS SECTION of the manual.

•

••

GAUGE TEST PORT 'Mb'

GAUGE TEST PORT 'Ma'

Note: Steps 1 to 7 were completed in BEGIN OF DISPLACEMENT . If this procedure was just finished move to step 8.

M724D-28

1. Park the machine on level ground, lower attachment to the ground and set parking brake ON. Install articulation lock bar an shut off engine.

DRIVE PUMP - REXROTH

REAR CHASSIS RH SIDE 'M1' TEST PORT

••

'X' TEST PORT

•

WARNING To prevent injury caused by accidental steering of the machine when setting pressures, make sure the articulation lock bar is held securely in place by the lynch pins provided.

M724D-27X

GAUGE CONNECTIONS

4. Disconnect the parking brake proximity sensor power wire form the sensor.

2. Adjust auxiliary brake set-up caliper to lock the rotating Brake disc. Refer to illustrations to identify your caliper and the proper setting.

CAUTION Avoid the risk of unintentionally driving the machine with this wire disconnected, the parking brake will be ON without the ability to release it. This will result in overheating of the brakes which could cause a fire in the machine.

ADJUST AUXILIARY BRAKE SET-UP CALIPER (ADJUSTING NUT) TO 110 LBF/FT.

5. Start the engine and set to FULL throttle.

6. To set the motor pressure override adjustment (POR), it is necessary to temporarily adjust the drive pump pressure override to 4000-4025 psi.

•

7. With the aid of an assistant hold down the brake pedal and while depressing the REVERSE drive pedal set the pump pressure override (POR) valve to a reading at 'Ma' of 4000-4025 psi at FULL throttle.

336-3AX AUXILIARY BRAKE SET-UP CALIPER 3. Connect a 0-1000 psi pressure gauge to the "capped" test port 'G' on the drive pump.

Connect 0-10000 psi pressure gauges to ports 'Ma' and 'Mb' on the drive pump.

Connect one 0-1000psi gauge to the 'X' test port. Connect a 0-5000 psi pressure gauge to the motor test port 'M1'.

CAUTION The machine should not be able to move while the brake pedal is depressed.

8. Readjust the limiting screws on the forward and reverse pedals to get a reading of 450460 psi at 'X' for both forward and reverse.

With the aid of an assistant, hold down the 8.22

Tigercat M724D Mulcher

Drive 10. Release the forward drive pedal and reapply.

Ensure the 'M1' gauge reads 2000-2500 psi (half of Mb).

11. To complete this procedure the drive pump POR must be reset.

• • REVERSE LIMITING SCREW

SOME HOSES REMOVED FOR CLARITY

FORWARD LIMITING SCREW

FORWARD AND REVERSE DRIVE PEDALS brake pedal and while fully depressing the reverse foot pedal, observe the pressure reading at 'X'. It must read 450-460 psi at FULL throttle (the save value as charge pressure) for 15 seconds to ensure that the reading is correct.

189-10

Repeat for the forward drive pedal.

If using the alternative method of adjusting the speed control lever to adjust pressures at 'X' position the speed control lever in the fully forward position and check for an 'X' gauge reading of 450-460 psi when one of the foot pedals is fully depressed.

MOTOR PRESSURE OVERRIDE ADJUSTING SCREW (POR)

(SOME HOSES REMOVED FOR CLARITY)

••

M724D-29

••

DRIVE PUMP

12. With the aid of an assistant hold down the brake pedal and while depressing the FORWARD drive pedal fully adjust the drive pump POR valve to get a reading at 'Mb' of 5000-5050 psi at FULL throttle.

13. Shut off the engine. Reconnect the parking brake proximity sensor.

14. Remove all pressure gauges and reinstall all plugs and caps.

15. Readjust auxiliary brake set-up caliper to its ORIGINAL POSITION (loose and locked).

Friction between the brake caliper and the rotating disc can cause a fire.

•• MINIMUM DISPLACEMENT ADJUSTING SCREW

320-23

POR VALVE 4 mm ALLEN KEY 13 mm WRENCH

DRIVE MOTOR

9. With the aid of an assistant hold down the brake pedal and while depressing the FORWARD drive pedal adjust the motor pressure override to a reading of 2000-2500 psi (half of Mb) at 'M1'.

If the reading is HIGH; turn the motor POR adjusting screw OUT (counter-clockwise) until there is a correct reading of 2000-2500 psi (half of Mb) at 'M1'.

If the reading is LOW ; turn the motor POR adjusting screw IN (clockwise) until there is a correct reading of 2000-2500 psi (half of Mb) at 'M1'.

8.23

Tigercat M724D Mulcher

Drive

8.24

Tigercat M724D Mulcher

M724D-16

Drive

DRIVE CIRCUIT - DUAL MOTORS AND ONE-SPEED TRANSMISSION 8.25

Tigercat M724D Mulcher

Drive

TEST DRIVE

MOTOR PRESSURE OVERRIDE (POR)

DUAL MOTOR 1-SPEED TRANSMISSION

1. Turn ON both front and rear differential locks.

Set the throttle control to FULL.

This drive will verify the following: 1. Motor pressure override.

2. Top speed control.

3. Front and rear differential lock functions.

4. Attachment recovery time 5. Boom functions.

6. Parking brake operation.

2. Drive the machine FORWARD at FULL SPEED. Apply the foot brake to slow the machine to approximately half speed but no slower.

3. While doing the above, observe the pressure at 'Mb'. The reading should be 4000 psi (drive motor POR setting). Also observe the pressure readings at 'LM1' and 'RM1' which should be 2000 psi (half of 'Mb').

REAR CHASSIS RH SIDE LM1 TEST PORT

'RM1' TEST PORT

••

••

'X' TEST PORT

Note: This test may have to be done a few times to get a proper reading.

•

TOP SPEED CONTROL: 1. Turn ON both front and rear differential locks.

Set the throttle control to FULL. 2. Drive the machine forward at top speed and adjust the throttle control so that the tachometer reads 2200 rpm at top speed.

M724D-27

GAUGE CONNECTIONS

3. With the aid of an assistant drive the machine forward at top speed (speed control lever fully forward) and record the time to complete 5 tire revolutions. This should take 7 seconds maximum.

'TEST PORT 'G' • QUICK CONNECT

• ••

••

If it takes longer than 7 seconds either the MOTOR minimum displacement, MOTOR POR or PUMP charge pressure may be incorrectly set.

GAUGE TEST PORT 'Mb'

GAUGE TEST PORT 'Ma' M724D-28

DRIVE PUMP - REXROTH

DIFFERENTIAL LOCK FUNCTIONS:

Connect two 0 - 5,000 psi gauges to ports 'LM1' and 'RM1' on the drive motors. Connect one 0-10,000 psi gauge at the 'Mb' port of the drive pump.

1. Bring machine to a full stop, set throttle to IDLE, ensure both front and rear differential lock switches are turned OFF. Steer machine without depressing drive pedal.

NOTE: Fasten these gauges so that they can be viewed from the operator’s seat in the cab.

Fasten your seat belt and move the machine to a suitable test area, where it can be safely driven at full speed for approximately 150 feet.

IMPORTANT: Foot brake must only be applied for 5 -10 seconds followed each time by a minimum 20 second cool down period. Failure to do so will result in 'burn out' of the rear axle brake.

All wheels should rotate as machine is being steered. Steer several times, check all wheels.

2. Turn only the front differential lock switch ON. While steering the machine, both front wheels should slide instead of rotating. Rear wheels should still rotate.

3. Turn front differential lock switch OFF. 4. Turn only the rear differential lock switch ON. While steering the machine, both rear wheels should slide instead of rotating.

Front wheels should still rotate.

8.26

Tigercat M724D Mulcher ATTACHMENT RECOVERY TIME

Drive BOOM FUNCTIONS

MULCHER

MULCHER

1. Close mulch deflector door and raise mulching head 6 inches off ground.

Test all boom functions for proper operation (lift, tilt, mulch deflector door).

2. Set throttle control FULL.

FELLER BUNCHER CONFIGURATION

3. Turn mulcher ON.

Test all boom functions for proper operation (lift, tilt, accumulating arms, clamp arms).

4. For Fecon BH250 mulching head: Observe saw/cutter pressure gauge visible through cab window, the gauge will show an initial value of 4950-5050 psi for about 7 seconds. After a total elapsed time of approximately 7 seconds the gauge reading will drop to approximately 1000-1200 psi and hold, as the rotating cutter has reached full speed.

NOTE: Refer to the MANUFACTURER'S OPERATING AND SERVICE MANUAL for setup and servicing procedures.

CHECKING FOR PROPER PARKING BRAKE ADJUSTMENT The parking brake is properly adjusted when resistance is encountered half way through the brake lever’s travel.

Refer to SECTION 9 of THIS MANUAL for adjusting procedure and additional information on brakes.

CAUTION Ensure that all personnel are clear of the attachmment.

WARNING When leaving the cab to check the rotating cutter/saw blade or other parts of the attachment, observe all safety rules listed in this manual and the attachment manufacturer's manual.

FELLER BUNCHER CONFIGURATION SAW 1. Install saw guard and raise felling head 6 inches off ground.

2. Set throttle control FULL. 3. Turn saw ON. 4. For 5500, 5600 and 5700 wide kurf series saws: Observe saw pressure gauge visible through cab window, pressure should rise to 3500-3600 psi. for about 10 seconds, drop to 3100 psi. for about 1215 seconds and then drop to 1200-1800 psi as saw reaches full rpm. From FULL STOP to FULL rpm. should take 30 seconds.

NOTE: Refer to the Tigercat BUNCHING SAWS OPERATING AND SERVICE MANUAL for setup and servicing procedures.

8.27

Tigercat M724D Mulcher

Drive

DRIVE PUMP PRESSURE SETTINGS AND ADJUSTMENTS

5. Install a limiting block under the foot pedal to limit its movement to 1/3 of its full travel. (The limiting block should measure approximately 1-5/8" high . If there is any difficulty setting pressures the size of the block may need to be reduced slightly.)

DUAL MOTOR 1-SPEED TRANSMISSION NOTE: Ensure hydraulic oil is at operating temperature. Refer to HYDRAULIC OIL HEATING PROCEDURE in SECTION 5 of THIS MANUAL. NOTE:Relief valves are set by loosening the locknut and turning the adjusting screw OUT (counter-clockwise) to reduce the pressure setting and IN (clockwise) to increase the pressure setting.

1-5/8"

WARNING 189-10X

INSTALL A LIMITING BLOCK UNDER BOTH DRIVE PEDALS

6. Disconnect the parking brake proximity sensor power wire from the sensor.

To prevent injury caused by accidental steering of the machine when setting pressures, make sure the articulation lock bar is held securely in place by the lynch pins provided.

CAUTION Avoid the risk of unintentionally driving the machine with this wire disconnected, the parking brake will be ON without the ability to release it. This will result in overheating of the brakes which could cause a fire in the machine.

1. Park machine on level ground, lower attachment to the ground and set parking brake ON. Install the articulation lock bar and shut off engine.

ADJUST AUXILIARY BRAKE SET-UP CALIPER (ADJUSTING NUT) TO 110 LBF/FT.

7. Turn the pump pressure override valve (POR) adjusting screw IN (clockwise) until lightly seated. Do not over-tighten, or breakage will result. Turn the pump POR valve OUT (counter-clockwise) one half turn.

IMPORTANT

••

Avoid blowing oil over relief longer than 5 seconds, as excessive heating of hydraulic fluid and damage to drive pump can occur.

336-3AX

IMPORTANT

AUXILIARY BRAKE SET-UP CALIPER

2. Adjust auxiliary brake set-up caliper to lock the rotating brake disc. Refer to illustrations to identify your caliper and the proper setting.

To prevent frequent operation of relief valves, it is important that the settings of the high pressure relief valves be substantially higher than the pump POR setting.

3. Connect a 0-1000 psi pressure gauge to the "capped" test port from port 'G' on the drive pump. Connect 0-10000 psi pressure gauges to ports 'Ma' and 'Mb' on the drive pump.

8. With the aid of an assistant hold down the brake pedal and while depressing the FORWARD drive pedal to 1/3 of its full travel set the pump high pressure relief valve 'B' at 'Mb' 5650-5700 psi at FULL throttle.

4. Start the engine and set to FULL throttle. Set charge pressure relief valve to 450 psi at 'G'.

CAUTION The machine should not be able to move while the brake pedal is depressed.

8.28

Tigercat M724D Mulcher

Drive

9. With the aid of an assistant hold down the brake pedal and while depressing the REVERSE drive pedal to 1/3 of its full travel set the pump high pressure relief valve 'A' at 'Ma' 5650-5700 psi at FULL throttle.

12. Shut off the engine. Reconnect the parking brake proximity sensor.

17. Remove all pressure gauges and reinstall all plugs and caps.

10. Remove the limiting block from under the forward and reverse footpedals.

POR VALVE 4 mm ALLEN KEY 13 mm WRENCH

SOME HOSES REMOVED FOR CLARITY

11. With the aid of an assistant hold down the brake pedal and while depressing the FORWARD drive pedal fully adjust the pump POR valve to get a reading at 'Mb' of 5000-5050 psi at FULL throttle.

DRIVE PUMP

M724D-29

'TEST PORT 'G' • QUICK CONNECT

CHARGE PRESSURE RELIEF • 5 MM ALLEN KEY • 17 MM WRENCH

•

HIGH PRESSURE RELIEF VALVE 'B' 5 MM ALLEN KEY 17 WRENCH

• HIGH PRESSURE RELIEF VALVE 'A'

••

M724D-28

••

•

5 MM ALLEN KEY 17 MM WRENCH

••

GAUGE TEST PORT 'Ma' • 3/16" ALLEN KEY • PORT SIZE - 04 ORB

DRIVE PUMP - REXROTH

8.29

•• GAUGE TEST PORT 'Mb' • 3/16" ALLEN KEY • PORT SIZE - 04 ORB

Tigercat M724D Mulcher

Drive

DRIVE MOTOR PRESSURE SETTINGS AND ADJUSTMENTS

A. MOTOR MINIMUM DISPLACEMENT ADJUSTMENT

DUAL MOTOR 1-SPEED TRANSMISSION To set the hydrostatic drive motor pressures and speeds, the following procedure must be performed in the order shown.

NOTE: Ensure hydraulic oil is at operating temperature. Refer to HYDRAULIC OIL HEATING PROCEDURE in THIS SECTION of the manual.

A. Set the motor minimum displacement.

Perform this procedure on BOTH MOTORS.

B. Set the motor begin of displacement control pressure.

1. Park the machine on level ground, lower attachment to the ground and set parking brake ON. Install articulation lock bar an shut off engine.

C. Set the motor pressure override.

IMPORTANT WARNING

The adjustment or set-up procedure is a series of steps that must be done in a proper sequence to achieve optimum performance from the machine. Any deviation from the procedures could present a safety hazard, damage components and/or affect the operation of the machine. All adjustments must be performed on BOTH MOTORS.

To prevent injury caused by accidental steering of the machine when setting pressures, make sure the articulation lock bar is held securely in place by the lynch pins provided.

2. Remove the minimum displacement adjusting screw (largest screw) from the top of motor housing and measure its length.

IMPORTANT

3. Reinstall the minimum displacement adjusting screw and locknut into the motor housing. For a 90mm long screw, it should be adjusted such that the dimension from the top of the locknut to the end of the exposed screw is 19mm. (For different length screws, measure the length and subtract 71mm from this total length. This is the amount of screw that should be exposed above the locknut.) (For example: 100mm screw, minus 71mm will leave 29mm above locknut).

• When installing a new or rebuilt motor, ensure minimum displacement screw is set correctly.

• Improper adjustment of min. displacement adjusting screw can result in motor failure due to overspeeding.

• It may be necessary to verify the length of adjusting screw used by removing and measuring the screw.

REAR CHASSIS RH SIDE

NOTE: Repeat for the other motor.

LM1 TEST PORT

••

M724D-27

'RM1' TEST PORT

••

'X' TEST PORT

"X"

•

DIM X

GAUGE CONNECTIONS

8.30

MIN. DISPLACEMENT "X" DIMENSION

Tigercat M724D Mulcher

Drive

B. MOTOR BEGIN OF DISPLACEMENT CONTROL PRESSURE ADJUSTMENT

'TEST PORT 'G' • QUICK CONNECT

••

NOTE: Ensure hydraulic oil is at operating temperature. Refer to HYDRAULIC OIL HEATING PROCEDURE in THIS SECTION of the manual.

••

• GAUGE TEST PORT 'Mb'

GAUGE TEST PORT 'Ma'

Perform this procedure on BOTH MOTORS. 1. Park the machine on level ground, lower attachment to the ground and set parking brake ON. Install articulation lock bar an shut off engine.

DRIVE PUMP - REXROTH

M724D-28

3. Connect a 0-1000 psi pressure gauge to the "capped" test port 'G' on the drive pump.

Connect 0-10000 psi pressure gauges to ports 'Ma' and 'Mb' on the drive pump.

Connect one 0-1000psi gauge to the 'X' test port. Connect a 0-5000 psi pressure gauge to the motor 'LM1' and 'RM1' test ports .

2. Adjust auxiliary brake set-up caliper to lock the rotating Brake disc. Refer to illustrations to identify your caliper and the proper setting.

ADJUST AUXILIARY BRAKE SET-UP CALIPER (ADJUSTING NUT) TO 110 LBF/FT.

POR VALVE 4 mm ALLEN KEY 13 mm WRENCH

SOME HOSES REMOVED FOR CLARITY

••

DRIVE PUMP

M724D-29

•

AUXILIARY BRAKE SET-UP CALIPER

VIEW 'A'

•

PORT 'M1' • 6 ORB 1/4" ALLEN KEY

•

'A'

BEGIN OF DISPLACEMENT ADJUSTING SCREW (DO NOT ADJUST) FOR REFERENCE ONLY: DIM. 'X' = 3/8" (9MM) MOTOR POR ADJUSTING SCREW

•

AQ010-1

PORT 'B'

•

PORT 'A'

MAXIMUM DISPLACEMENT ADJUSTING SCREW (DO NOT ADJUST) FOR REFERENCE ONLY: DIM. 'X' = 3/8" (9MM) FOR A 50MM LONG SCREW

•

336-3AX

AQ010-5Y

MINIMUM DISPLACEMENT ADJUSTING SCREW - 6MM ALLEN KEY - 19MM WRENCH DIM. 'X' = 3/4" (19MM) FOR A 90MM LONG SCREW

DUAL DRIVE MOTOR ~ REXROTH (160CC SIZE) 8.31

Tigercat M724D Mulcher

Drive

4. Disconnect the parking brake proximity sensor power wire form the sensor.

MOTOR PRESSURE OVERRIDE ADJUSTING SCREW (POR)

(SOME HOSES REMOVED FOR CLARITY)

CAUTION Avoid the risk of unintentionally driving the machine with this wire disconnected, the parking brake will be ON without the ability to release it. This will result in overheating of the brakes which could cause a fire in the machine.

• •• MINIMUM DISPLACEMENT ADJUSTING SCREW

5. Start the engine and set to FULL throttle.

6. To set the motor pressure override adjustment (POR), it is necessary to temporarily adjust the drive pump pressure override to 4000-4025 psi.

DRIVE MOTOR

320-23

7. With the aid of an assistant hold down the brake pedal and while depressing the REVERSE drive pedal set the pump pressure override (POR) valve to a reading at 'Ma' of 4000-4025 psi at FULL throttle.

• • REVERSE LIMITING SCREW

CAUTION

189-10

The machine should not be able to move while the brake pedal is depressed.

FORWARD LIMITING SCREW

FORWARD AND REVERSE DRIVE PEDALS

9. To set the motor begin of displacement control pressure, it is also necessary to temporarily achieve pressure readings of 125&135 psi pressure reading at 'X' while fully depressing the REVERSE and FORWARD pedals. See steps below.

8. Turn the motor pressure override valve (POR) adjusting screw IN (clockwise) until lightly seated. Do not overtighten. Do this for both motors.

a. With the aid of an assistant, hold down the brake pedal and while fully depressing

•

VIEW 'A'

•

PORT 'M1' • 6 ORB 1/4" ALLEN KEY

'A'

MOTOR POR ADJUSTING SCREW

•

BEGIN OF DISPLACEMENT ADJUSTING SCREW (DO NOT ADJUST) FOR REFERENCE ONLY: DIM. 'X' = 3/8" (9MM)

•

AQ010-1

PORT 'B'

•

PORT 'A'

MAXIMUM DISPLACEMENT ADJUSTING SCREW (DO NOT ADJUST) FOR REFERENCE ONLY: DIM. 'X' = 3/8" (9MM) FOR A 50MM LONG SCREW

AQ010-5Y

MINIMUM DISPLACEMENT ADJUSTING SCREW - 6MM ALLEN KEY - 19MM WRENCH DIM. 'X' = 3/4" (19MM) FOR A 90MM LONG SCREW

DUAL DRIVE MOTOR ~ REXROTH (160CC SIZE) 8.32

Tigercat M724D Mulcher the REVERSE pedal, adjust the stroke limiting screw (located under the pedal) upwards to limit the stroke of the reverse pedal and give a reading of 125 psi at 'X' for 15 seconds. b. With the aid of an assistant, hold down the brake pedal and while fully depressing the FORWARD pedal, adjust the stroke limiting screw (located under the pedal) upwards to limit the stroke of the reverse pedal and give a reading of 135 psi at 'X' for 15 seconds.

Drive NOTE: These settings are turn on/turn off points and should not be confused with pressure settings.

11. With the aid of an assistant, hold down the brake pedal and while fully depressing the REVERSE foot pedal (set to 125 psi at 'X') the motors SHOULD NOT STROKE and a low reading of 800 psi or less should be obtained at 'LM1' and 'RM1'.

Note: Notice the difference in pressures for the forward and reverse pedals. These settings are important.

12. With the aid of an assistant, hold down the brake pedal and while fully depressing the FORWARD foot pedal (set to 135psi at 'X') the motors SHOULD STROKE and a high reading of 2000-2500 psi should be obtained at 'LM1' and 'RM1'.

Alternatively the position of the speed control lever can be used to give these pressures with one of the foot pedals fully depressed.

13. If these readings are obtained then the motor begin of displacement setpoint is now between 125-135 psi on both motors.

If not then repeat steps 10 to 12 until a correct setpoint is achieved.

When properly set the motors will begin to stroke in the pressure range of 125-135 psi.

This is a critical setting for the smooth and efficient operation of the machine.

15. Check both motors to verify that this setting did not changed as the locknuts were tightened.

M724D-02

SPEED CONTROL LEVER

10. With the aid of an assistant, hold down the brake pedal and while fully depressing the FORWARD foot pedal, adjust the motor begin of displacement screw to give a reading at 'RM1' and 'LM1' of 2000-2500 psi at FULL throttle. This is very difficult to do and takes a little patience. The screw is VERY sensitive. Get as close as possible. Use two gauges and set BOTH MOTORS moving back and forth between the tow motors.

16. To complete this procedure the drive motor POR must be reset. Refer to MOTOR PRESSURE OVERRIDE (POR) ADJUSTMENT in THIS SECTION.

If the reading is HIGH; turn the motor begin of displacement adjusting screw OUT (counterclockwise) until a correct reading at 'RM1' and 'LM1' is obtained with the locknut tightened.

If the reading is LOW; turn the motor begin of displacement adjusting screw IN (clockwise) until a correct reading at 'RM1' and 'LM1' is obtained with the locknut tightened.

Recheck frequently while adjusting by having an assistant release and depress pedals.

8.33

Tigercat M724D Mulcher

Drive

C. MOTOR PRESSURE OVERRIDE ADJUSTMENT (POR)

'TEST PORT 'G' • QUICK CONNECT

••

NOTE: Ensure hydraulic oil is at operating temperature. Refer to HYDRAULIC OIL HEATING PROCEDURE in THIS SECTION of the manual.

•

••

GAUGE TEST PORT 'Mb'

GAUGE TEST PORT 'Ma'

Perform this procedure on BOTH MOTORS. Note: Steps 1 to 7 were completed in BEGIN OF DISPLACEMENT . If this procedure was just finished move to step 8.

DRIVE PUMP - REXROTH

M724D-28

REAR CHASSIS RH SIDE

1. Park the machine on level ground, lower attachment to the ground and set parking brake ON. Install articulation lock bar an shut off engine.

LM1 TEST PORT

•

'RM1' TEST PORT

••

'X' TEST PORT

•

WARNING To prevent injury caused by accidental steering of the machine when setting pressures, make sure the articulation lock bar is held securely in place by the lynch pins provided.

M724D-27

GAUGE CONNECTIONS

4. Disconnect the parking brake proximity sensor power wire form the sensor.

2. Adjust auxiliary brake set-up caliper to lock the rotating Brake disc. Refer to illustrations to identify your caliper and the proper setting.

CAUTION Avoid the risk of unintentionally driving the machine with this wire disconnected, the parking brake will be ON without the ability to release it. This will result in overheating of the brakes which could cause a fire in the machine.

ADJUST AUXILIARY BRAKE SET-UP CALIPER (ADJUSTING NUT) TO 110 LBF/FT.

5. Start the engine and set to FULL throttle.

6. To set the motor pressure override adjustment (POR), it is necessary to temporarily adjust the drive pump pressure override to 4000-4025 psi.

•

336-3AX

7. With the aid of an assistant hold down the brake pedal and while depressing the REVERSE drive pedal set the pump pressure override (POR) valve to a reading at 'Ma' of 4000-4025 psi at FULL throttle.

AUXILIARY BRAKE SET-UP CALIPER

3. Connect a 0-1000 psi pressure gauge to the "capped" test port 'G' on the drive pump.

Connect 0-10000 psi pressure gauges to ports 'Ma' and 'Mb' on the drive pump.

Connect one 0-1000psi gauge to the 'X' test port . Connect a 0-5000 psi pressure gauge to the 'LM1' and 'RM1' motor test ports.

CAUTION The machine should not be able to move while the brake pedal is depressed.

8. Readjust the limiting screws on the forward and reverse pedals to get a reading of 450460 psi at 'X' for both forward and reverse.

With the aid of an assistant, hold down the 8.34

Tigercat M724D Mulcher

Drive 10. Release the forward drive pedal and reapply.

Ensure that both gauges ('LM1' and 'RM1') read 2000-2500 psi (half of Mb).

11. To complete this procedure the drive pump POR must be reset.

• • REVERSE LIMITING SCREW

189-10

SOME HOSES REMOVED FOR CLARITY

FORWARD LIMITING SCREW

FORWARD AND REVERSE DRIVE PEDALS

M724D-29

POR VALVE 4 mm ALLEN KEY 13 mm WRENCH

••

DRIVE PUMP

brake pedal and while fully depressing the reverse foot pedal, observe the pressure reading at 'X'. It must read 450-460 psi at FULL throttle (the save value as charge pressure) for 15 seconds to ensure that the reading is correct.

12. With the aid of an assistant hold down the brake pedal and while depressing the FORWARD drive pedal fully adjust the drive pump POR valve to get a reading at 'Mb' of 5000-5050 psi at FULL throttle.

Repeat for the forward drive pedal.

13. Shut off the engine. Reconnect the parking brake proximity sensor.

If using the alternative method of adjusting the speed control lever to adjust pressures at 'X' position the speed control lever in the fully forward position and check for an 'X' gauge reading of 450-460 psi when one of the foot pedals is fully depressed.

MOTOR PRESSURE OVERRIDE ADJUSTING SCREW (POR)

14. Remove all pressure gauges and reinstall all plugs and caps.

15. Readjust auxiliary brake set-up caliper to its ORIGINAL POSITION (loose and locked).

Friction between the brake caliper and the rotating disc can cause a fire.

(SOME HOSES REMOVED FOR CLARITY)

•

• MINIMUM DISPLACEMENT ADJUSTING SCREW

320-23

DRIVE MOTOR

9. With the aid of an assistant hold down the brake pedal and while depressing the FORWARD drive pedal adjust the motor pressure override to a reading of 2000-2500 psi (half of Mb) at 'RM1' or 'LM1'. This adjustment must be done for both motors.

If the reading is HIGH; turn the motor POR adjusting screw OUT (counter-clockwise) until there is a correct reading of 2000-2500 psi (half of Mb) at 'RM1' or 'LM1'.

If the reading is LOW ; turn the motor POR adjusting screw IN (clockwise) until there is a correct reading of 2000-2500 psi (half of Mb) at 'RM1' or 'LM1'.

8.35

Tigercat M724D Mulcher

Drive

TRANSMISSION

OPERATION

SINGLE MOTOR 2-SPEED TRANSMISSION

Pulling up or pushing down the gearshift lever inside the cab moves the shift lever (1) on the transmission, which moves the shift collar (2), to connect either the LOW gear (3) or the HIGH gear (4) to the output shaft (5).

The two speed manual shift transmission drives both the front and rear axles of the machine.

Power is supplied by the hydrostatic drive motor mounted to the input side of the transmission.

The output shaft transmits power to both the front and rear axles.

Detent balls (6) between the collar and output shaft provide positive feel for the selected range.

This results in either low speed operation , or high speed operation. The mid position is neutral.

A lubrication pump (7) mounted on the front of the transmission and driven off the end of the input shaft (8) provides oil to lubricate the gears and bearings and also the splines of the hydrostatic drive motor. Oil is channelled to these areas via a passageway and a series of crossed drilled holes in the input shaft. Additional lubrication is provided by escaping oil from the input shaft and also oil splashed up on to the gears from the sump in the bottom of the transmission. The oil level in the gearbox must be up to the level marked on the dipstick. For the recommended lubricant refer to SECTION 3 of THIS MANUAL.

NOTE: Shift gears only when the machine is stationary and on level ground. Slight movement of the steering joystick may be required to facilitate shifting from one gear to the next.

The transmission must be in neutral for machine to be towed by another vehicle. For more information on towing, refer to TOWING INSTRUCTIONS in SECTION 2 of the OPERATOR'S MANUAL.

INPUT SHAFT (8)

INPUT SHAFT (8) LUBRICATION PUMP (7)

•

FROM MOTOR

•

LUBRICATION PUMP (7)

•

FROM MOTOR

SHIFT COLLAR (2)

SHIFT COLLAR (2) SHIFT LEVER (1)

SHIFT LEVER (1)

•

DETENT BALLS (6)

• REAR AXLE

•

• •

FRONT AXLE

•

FRONT AXLE

• •

•

OUTPUT SHAFT (5)

REAR AXLE

•

•

OUTPUT SHAFT (5)

LOW GEAR (3)

HIGH GEAR (4)

LOW GEAR (3)

HIGH GEAR (4)

HIGH SPEED OPERATION

LOW SPEED OPERATION 2-SPEED TRANSMISSION 720B15

8.36

Tigercat M724D Mulcher

Drive

TRANSMISSION SHIFT LEVER (2-SPEED TRANSMISSION ONLY)

8

LEVER ADJUSTMENT

•

The 2-speed transmission gear shift lever is located at the right side, behind the seat. Lever UP is HIGH speed, NEUTRAL in the center and DOWN is LOW speed. If required, these positions can be adjusted at the transmission end of the cable.

To shorten or lengthen the cable, remove the cotter pin and the clevis pin and loosen the jam nut, screw the clevis on or off the cable to change the cable length. Tighten the jam nut, replace the clevis pin and cotter pin. The outer cable can be adjusted by adjusting the two jam nuts holding it in the support bracket.

229-20

GEAR SHIFT LEVER

BELLCRANK

HEX NUT 7/16"

CLEVIS CABLE END

CLEVIS SHIFT LEVER "U" BOLT

COTTER PIN

CABLE HOLD DOWN NUT

CLEVIS PIN

CABLE

TRANSMISSION

JAM NUTS

720B23

SHIFT CABLE ADJUSTMENT 8.37

Tigercat M724D Mulcher

Drive

8.38

Tigercat M724D Mulcher

Drive

TRANSMISSION DUAL MOTOR 1-SPEED TRANSMISSION The transmission drives both the front and rear axles of the machine. Power is supplied by two hydraulic motors mounted to the input side of the transmission. The output drive shafts transmit the power to both the front and rear axles.

The gears and bearings in the transmission are lubricated by splash lubrication inside the case.

The oil level in the transmission must always be kept up to the proper level indicated on the dipstick. Refer SECTION 3 of this manual for the recommended lubricant.

432-1

ONE-SPEED TRANSMISSION SHOWN ENGAGED

TRANSMISSION OIL LEVEL CHECK/FILL

••

CHECK TRANSMISSION OIL LEVEL The transmission disconnect lever is used to shift the transmission between the DRIVE and NEUTRAL positions, e.g. NEUTRAL for towing the machine.

M724D-18

432-3

A short bar is placed through the hole in the lever and pulled upwards to put the transmission into neutral.

For more information on towing, Refer to TOWING INSTRUCTIONS in SECTION 2 of the OPERATOR'S MANUAL.

8.39

ONE SPEED TRANSMISSION SHOWN IN NEUTRAL

Tigercat M724D Mulcher

Drive

FRONT DRIVE SHAFT

nut hand tight only. Be sure to align front and rear yoke in the same plane (see illustration).

Assembly and installation of a front drive shaft assembly.

1. Park machine on level ground, install articulation lock bar, lower felling head to ground, stop engine, pull parking brake ON and block wheels.

NOTE: For this repair, front and rear chassis must be aligned.

2. Remove the upper guards and cover plates and belly pan access door on front chassis.

5. Carefully clamp flat wing of yoke in a vice and torque the large 1 1/4"- 18 UNEF retaining nut to 475-525 lbf-ft. DO NOT CLAMP TUBULAR PART OF DRIVE SHAFT IN VICE. FRONT DRIVE SHAFT AND PILLOW BLOCK BEARING INSTALLATION IN TO MACHINE: 1. Install front drive shaft and pillow block bearing first. Attach front universal, leave pillow block mounting bolts loose and attach grease line.

2. Install mid drive shaft and tighten all universal joints. For torque values, refer to TORQUE CHART in SECTION 3 of THIS MANUAL.

3. Remove the mid drive shaft first by separating the two universal joints.

4. Remove the front drive shaft and pillow block bearing. Remove the grease line from the pillow block bearing, unbolt the bearing from the chassis and separate the front universal joint.

IMPORTANT The mid shaft should not be installed backwards. The large diameter tube end of mid drive shaft must fasten to the universal joint at the transmission.

PILLOW BLOCK BEARING INSTALLATION ONTO FRONT DRIVE SHAFT: 1. Remove the yoke retaining nut and the yoke from the front drive shaft. DO NOT clamp the TUBULAR portion of the drive shaft in a vice during any of the assembly process.

2. Slide the old pillow block bearing off of the drive shaft.

3. Remove the set screw supplied with the bearing and discard.

4. Remove the grease fitting supplied with the new bearing and discard. Care should be taken not to lose the locking pin inside the bearing housing.

3. Care must be taken to correctly align the front and rear chassis before tightening the pillow block bearing bolts. The front drive shaft must line up directly on center with the center steering articulation pin.

NOTE: To align the front and rear chassis, measure the distance between outer axle bearing grease fitting on the front and rear axles on one side of the machine. Then measure the same distance on the other side of the machine. Articulate the machine to get the same reading on both sides.

4. Holding the front and rear chassis and the front drive shaft in alignment, tighten the two pillow block bearing bolts (3/4” UNC x 2”) with hardened washers under heads. Use LOCTITE 242 (blue - removable) and torque to 357 lbf-ft.

5. Make sure that the locking pin is properly positioned inside the bearing housing. Install the 90° grease fitting (from the grease line assembly) to ensure that the locking pin stays properly positioned within the dimple in the outer race of the bearing.

5. Re-install the grease line to the pillow block bearing.

6. Use anti-seize on the shaft. Install the new pillow block bearing with the long extension (set screw side) facing the splined end of the shaft (rear of machine). The bearing must slide freely on the shaft.

3. Install the set screw supplied with the new bearing lining it up with the slot in the shaft.

The bearing must slide freely along the shaft, for the length of the set screw slot.

6. Slowly add grease to the pillow block bearing using a hand grease gun until it starts to leak from the bearing. Be careful not to 'pop' the grease seal by adding grease too rapidly.

NOTE: DO NOT use a power greaser.

Also refer to MIDDLE AND REAR DRIVE SHAFT SPLINE LUBRICATION in SECTION 3 of THIS MANUAL.

4. Use anti-seize on the shaft splines and install the yoke onto the drive shaft. Install retaining 8.40

Tigercat M724D Mulcher

Drive FRONT AXLE

GREASE LINE

SET SCREW UNIVERSALS

PILLOW BLOCK BEARING YOKE RETAINING NUT

FRONT DRIVE SHAFT SLIP SPLINE

DUST CAP FLAT WING OF YOKE YOKE

TRANSMISSION REAR OUTPUT YOKE

SPLINES RELIEF FITTING SEALS

MIDDLE DRIVE SHAFT GREASE FITTING SLIP SPLINE TRANSMISSION FRONT OUTPUT YOKE REAR AXLE

REAR DRIVE SHAFT

SLIP SPLINE SEAL

724D-01

DRIVE SHAFT INSTALLATION 8.41

GREASE FITTING

Tigercat M724D Mulcher

Drive

AXLES Power from the drive motors is transmitted to the front and rear axles via the transmission and the front and rear drive shafts.

The front axle assembly is bolted directly to the front chassis. The rear axle assembly is pivot mounted to the rear chassis, allowing oscillation of the axle.

DRAIN (TOP)

Apart from the mounting, both front and rear axle assemblies are configured in a similar way except that the rear axle has internal service brakes and the front axle has none.

DIFF. LOCK (BTM.)

Each axle assembly consists of an input yoke (1), a spiral bevel gear set (2), a differential gear set (3), hydraulic differential locks (4), inboard multiple wet disk brakes (5) (one each side in rear axle only), inboard planetary final drives (6) (one each side) and axle housings and shafts (7).

FRONT AXLE

26KSM

PIVOT LUBRICATION POINT

DIFF. LOCK (BTM.)

BRAKE

The final drive (6) is an inboard mounted planetary gear arrangement which further reduces speed and increases torque to the axles. The input side receives drive power from the differential via a sun gear shaft. The output side (planetary carrier) is splined on to the axle.

DRAIN (TOP)

The lubricant in both axle assemblies is hydraulic oil. There are drain lines from each axle plumbed to the machine's hydraulic system. These drain lines take care of internal leakage originating from the differential locks, which use the same hydraulic oil as the machine's hydraulic system.

Refer also to AXLE LUBRICATION in THIS SECTION. 1

PIVOT LUBRICATION POINT

REAR AXLE 27KSM

AXLE HYDRAULIC CONNECTIONS

2 4

6

7

3

5 AXL-4X

LATER DESIGN - AXLE ASSEMBLY CROSS SECTION (REAR SHOWN) 8.42

Tigercat M724D Mulcher

Drive

DIFFERENTIAL AND DIFFERENTIAL LOCKS BRAKE DISC

The differentials (3) distribute the power to each side of the axle while allowing the wheels to turn at different speeds. The differential locks (4), in the front and rear axle assemblies, are hydraulically controlled and can be independently turned ON or OFF by switches in the cab.

BACKING PLATE

Placing one or both switches in the ON position, energizes the differential lock control valve solenoid(s) (located on the pilot manifold) and directs pilot oil to the corresponding differential clutch pack assembly pistons to lock the differential(s).

ANNULAR PISTON

ANNULAR BRAKE against the brake disc and traps it between the piston and the backing plate to apply the brakes.

Maximum operating pressure for the brakes is 1000 psi. For information on the hydraulic circuit, refer to SECTION 9 of THIS MANUAL. AXL-BRK

This condition provides positive drive to both wheels of the axle when tractive conditions might otherwise allow one wheel to spin.

IMPORTANT

BRAKE LINING INSPECTION (REAR AXLE ONLY)

Differential locks should only be used when additional traction is needed.

Inspection ports are provided in the differential case and are located on each side of the pivot boss when viewed from the opposite side of the input shaft.

Before inspecting the brakes the axle must be drained. Refer to DRAINING THE AXLES in THIS SECTION.

SERVICE BRAKES (REAR AXLE ONLY) The "wet" disc type service brakes consist of an annular piston, a brake disc with brake facing material, and a brake backing plate. One brake assembly is located on each side of the differential case and before the final drive.

The piston and the backing plate are attached to the case and the brake disc is splined on to the sun gear of the planetary final drive.

•

Remove brake inspection port plugs.

•

Inspect brake linings on both sides of disc.

•

If brake lining material is worn down to the bottom of the oil grooves, brake backing plate and annular piston pressure plate assemblies must be replaced.

When the brake foot control pedal in the cab is depressed, brake pressure oil moves the piston up 1

2 4

6

7

3

5 AXL-3

EARLIER DESIGN - AXLE ASSEMBLY CROSS SECTION (REAR SHOWN) 8.43

Tigercat M724D Mulcher

Drive

BRAKE BLEEDING

AXLE LUBRICATION The axles are allowed to completely fill with oil to the top of the differential case. This hydraulic oil buildup inside the differential case is due to normal internal leakage from the differential locks and is used as lubricant for the differential. The excess oil drains back to the hydraulic tank via the axle drain line.

The rear axle assembly is equipped with two brake bleed screws, one for each side. Brakes must be bled whenever there has been potential for air to enter the system, such as removal of hydraulic lines. Both passages must be bled, one SINGLE BRAKE LINE ACTUATES BOTH BRAKES IN REAR AXLE

BLEED SCREWS

DRAINING THE AXLES Care should be taken when draining the hydraulic oil from the axles, not to also drain the oil from the hydraulic tank. To prevent oil from siphoning from the tank, first remove the hydraulic drain line from the top of the axle to allow air to vent into the axle when the bottom drain plug is removed and oil drains out. The line that is removed must be capped to prevent draining from the hydraulic tank.

SINGLE BRAKE PEDAL

The time to schedule an oil change in the axles is when doing the seasonal oil change on the hydraulic oil tank, as they are part of the overall system and use the same oil.

REAR AXLE ASSEMBLY

AXL-BRK1

DUAL BRAKES (REAR AXLE)

IMPORTANT

at a time.

PROCEDURE

Care should be taken to refill the axle(s) before moving the machine after draining.

1. Place parking brake ON.

FILLING THE AXLES The axles must be filled by pumping oil in through the ports on the front of the differential housing on the front axle and the top left side of the differential housing on the rear axle.

2. Place a clear plastic tube over bleed screw with other end in a container.

3. Start engine and set throttle at IDLE. 4. Loosen bleed screw.

5. With the aid of an assistant push and hold brake pedal down until brake bleeding is complete (no air bubbles in clear plastic tube).

Front Axle: Remove the two pipe plugs on the front face of the differential housing on the front axle, use one to fill the axle with and the other as a breather to allow air to vent out and also to allow oil to exit when the axle is full of oil.

6. Tighten bleed screw when oil is free of air.

7. Release brake foot pedal.

REMOVE BOTH PLUGS, USE ONE FOR FILLING AND ONE FOR BREATHER

8. Repeat above steps for the other bleed screw.

••

724D-D30

8.44

•

FRONT AXLE

Tigercat M724D Mulcher

Drive ALTERNATIVE METHOD OF FILLING AXLES The following alternative method of filling the axles with oil applies when only the axles have been drained of oil and not the hydraulic tank as well. If a major service has been done, the replacement of any major component or the complete machine has been drained of hydraulic oil, refer to START-UP PROCEDURE AFTER MAJOR MACHINE MAINTENANCE in SECTION 3 of THIS MANUAL.

• • CASE DRAIN PLUG

VENT PLUG

1. Ensure the articulation lock pin is installed.

2. With engine at IDLE, parking brake ON, hold foot brake down, bleed brakes in front axle.

3. Turn both differential locks ON and run engine at IDLE for 30 minutes, this procedure will fill the axles with hydraulic oil and purge the air from them at the same time. (axles fill with controlled leakage from diff. locks). If wheels have been removed, operate forward and reverse pedals very slowly to fill axles with oil.

4. Set throttle to IDLE and run each function for 2 minutes to purge air from circuit.

635-P06

REAR AXLE (LEFT SIDE OF MACHINE)

Rear Axle: Remove the two plugs* located on the front left side of the rear axle. To access these plugs remove the hose guard bolted to the axle with three bolts. Tilt the left side of the axle down to facilitate better access. Use the case drain plug to fill the axle and the vent plug* to vent air *NOTE: If ONLY the axles were drained and not the entire hydraulic system, the port from which the drain line was removed will provide the vent and oil will exit from this port when the axle is full of oil. The drain line should remain capped until it is reinstalled.

Care must be taken to ensure that both axles are completely full of oil and that all plugs, fittings and lines are tight.

CAPACITIES For front and rear axle oil fill capacities, refer to the table: SERVICE AND LUBRICATION in SECTION 3 of THIS MANUAL.

5. Set throttle to FULL and run each function again for 2 minutes to flush circuit.

6. With cylinders fully retracted, top up the hydraulic oil reservoir with clean hydraulic oil.

NOTE:If the machine was on wheels, the steer and drive functions would not have been properly purged or flushed. Remove the articulation lock pin and at LOW IDLE, slowly operate the steer function right and left a few times. With the parking brake released and at LOW IDLE, slowly operate the drive function forward and reverse a few times.

NOTE: If possible, allow the machine to stand for 4 to 6 hours before setting any of the operating pressures. This will allow any air bubbles trapped in the oil to escape, this will also be a good time to check for leaks.

8.45

Tigercat M724D Mulcher

Drive

REAR AXLE OSCILLATION SHIM CHECK AND ADJUSTMENT

3.

Set a dial indicator against the input pinion shaft on the input end of the axle.

1. The axle must be securely bolted to the chassis through the axle supports (front and back). Torque all axle mounting bolts. Refer to TORQUE CHART in SECTION 3 of THIS MANUAL. 2. Temporarily disconnect the two grease hoses from the axle pivot to prevent grease pressure from affecting the set-up. Plug hose ends to avoid contamination.

DISCONNECT REAR PIVOT GREASE HOSE

AXLE-05

SET DIAL INDICATOR

4. Using a long pry bar between the chassis and the axle housing pry the axle backward. It may be necessary to tip the axle from side to side to position the axle fully back for a proper reading.

••

AXLE-13

••

AXLE-06

USE LONG PRY BAR

AXLE-07

BETWEEN CHASSIS AND AXLE HOUSING

DISCONNECT FRONT PIVOT GREASE HOSE

724D-D31

8.46

Tigercat M724D Mulcher

Drive 10. Remove the outer cover plate. Carefully remove the centre pivot cover plate from the axle (6 bolts). Care must be taken to ensure that the thrust washer (a round perforated disk) and shims do not fall.

AXLE-10

TIP AXLE SIDE TO SIDE

AXLE-12

REMOVE CENTER PIVOT COVER

SHIMS

•• AXLE-11

TIP AXLE SIDE TO SIDE

••

5. Zero the dial indicator.

6. Using a long pry bar between the chassis and the axle housing pry the axle forward. It may be necessary to tip the axle from side to side to position the axle fully forward for a proper reading.

7. Read the dial indicator. Axle movement should be .004” to .014”. Check the reading twice by repeating steps 4 through 7.

8. If the reading is within the required range go to step 16.

9. If the reading is not within the required range follow steps 10 through 15 to adjust.

THRUST WASHER

AXLE-16

THRUST WASHER AND SHIMS

11. If the measurement was below .004” ADD shims to get the required range. A 0.010” shim will change the reading by 0.010”. Stock shims are 0.010” and 0.040” thick.

12. If the measurement was above .014” REMOVE SHIMS to correct the reading. A 0.010” shim will change the reading by 0.010”. Stock shims are 0.010” and 0.040” thick.

13. Replace the thrust washer.

14. Replace the center pivot front cover plate.

Make sure that the thrust washer and shims do not slide out of place and become damaged.

Torque cover bolts (6) to 80 lbf-ft.

15. Repeat steps 4 to 7 to check the adjustment again. This reading should be checked twice.

16. Reinstall cover plate and grease hoses in the axle pivot, add grease until back pressure is felt.

8.47

Tigercat M724D Mulcher

Drive

WHEEL INSTALLATION NOTE: All wheel installation joints and surfaces should be clean, flat surfaces (free of paint, grease and oil etc.) using grade 8 bolts, hardened washers and standard torque practices.

• Use tapered assembly studs to help with wheel installation. Two or three studs can be used on each side.

2.17" MIN. FULL THREAD

.79" .406" DRILL

.06" X 45° 7/8" - 14 UNF THREAD

20°

2.64" 3.41"

TAPERED ASSEMBLY STUD FOR 7/8" BOLTS AXL-WHL

The tapered assembly stud shown can be fabricated to aid in wheel installation on an axle flange.

•

Thoroughly clean the wheel bolts, washers and the tapped holes in the axle flange.

When cleaning axle wheel flange, be sure to use the proper thread size tap, 7/8" - 14 UNF thread.

• Install the wheel with the aid of the tapered assembly studs.

• Install wheel bolts by hand to insure bolts are not cross threaded.

• Remove assembly studs and install the remaining bolts.

• Torque wheel bolts to the following values: 7/8"-14 UNF torque to 500-550 lbf/ft. lubricated.

WARNING If a power wrench is used, be sure that the wheel bolts are first hand-engaged to prevent stripping. Operate the wrench slowly to prevent damage to the threads.

8.48

Tigercat M724D Mulcher SECTION 9 - BRAKES AND DIFFERENTIAL LOCKS JANUARY 2004

CONTENTS - SECTION 9 AUXILIARY SET-UP CALIPER ...................................................................... 9.4 BRAKES BRAKE ACCUMULATOR ........................................................................... 9.2 CIRCUIT DESCRIPTION ............................................................................ 9.2 CIRCUIT DIAGRAM .................................................................................... 9.3 FOOT CONTROL VALVE ........................................................................... 9.2 DIFFERENTIAL LOCKS CIRCUIT DESCRIPTION ............................................................................ 9.2 CIRCUIT DIAGRAM .................................................................................... 9.3 PARKING BRAKE .......................................................................................... 9.4 AUXILIARY SET-UP CALIPER ................................................................... 9.4 BRAKE CALIPER ASSEMBLY ................................................................... 9.6 CALIPER FLOAT ADJUSTMENT ............................................................... 9.7 CHECKING FOR PROPER ADJUSTMENT ............................................... 9.5 LINING REPLACEMENT ............................................................................ 9.7 PROXIMITY SENSOR ................................................................................ 9.5

Tigercat M724D Mulcher

Brakes and Differential Locks

BRAKE COMPONENTS

BRAKE ACCUMULATOR

For information on bleeding lines, inspecting brake linings and integral parts of the disc brakes, refer to SECTION 8 of THIS MANUAL.

The accumulator is installed to ensure that the brake control remains responsive at all times by maintaining a constant pressure of 750 psi to the brake foot control valve. The brake accumulator holds sufficient pressure for up to five (5) brake applications after the engine stalls or is shut down. Beyond this, the pressure drops substantially.

To release hydraulic pressure in the brake system, refer to RELEASE PILOT SYSTEM PRESSURE in SECTION 5 of THIS MANUAL. BRAKE PEDAL

For further information about the brake accumulator refer to BRAKE ACCUMULATOR in SECTION 5 of THIS MANUAL.

••

CIRCUIT DESCRIPTIONS BRAKE CIRCUIT 213-20

BRAKE PEDAL

A fixed displacement pump supplies oil to the accumulator charge valve. This valve directs oil to the brake accumulator through a check valve located between the pilot and brake accumulators. The oil from the brake accumulator side of the check valve is sent to the brake foot control valve to operate the rear axle brakes.

BRAKE FOOT CONTROL VALVE This pilot valve is a manually operated directional valve and operates on the same principle as a pressure reducing valve.

As the pedal is depressed, pressure from the brake accumulator is sent to the brakes in the rear axle. A reaction piston in the valve senses this increase in brake pressure and relays feedback to the operator, i.e. as brake pressure increases the pedal effort increases proportionately.

For further information on brake accumulator and the accumulator charge valve operation, refer to SECTION 5 of THIS MANUAL. DIFFERENTIAL LOCKS CIRCUIT

A positive stop in the brake valve limits the brake pressure to a preset value. This preset value is determined by the requirements of the brakes in the rear axle, which in this case is 1000 psi. The brake pedal therefore regulates the pressure in the brake lines to 1000 psi maximum.

The differential locks in both the front and rear axles (optional on front axle with a steering wheel) are controlled by switches. The rear differential lock switch is located on the control panel in the cab. The front differential lock switch is located on the left hand (steering) joystick (on instrument panel with a steering wheel). The switches control two solenoid operated pilot valves in ports 'C1' (rear) and 'C5' (front) of the pilot manifold. Placing the front or rear differential lock switch in the ON position energizes the solenoid operated pilot valve which directs pilot oil to the differential lock clutch packs in the corresponding axle to lock the differentials.

Refer also to AXLES-DIFFERENTIAL LOCKS in SECTION 8 of THIS MANUAL.

When the pedal is released, the spool returns to its neutral position and allows the brake cylinders to drain to tank.

T A P

MO-02 MO-01

CROSS SECTION OF VALVE BODY

BRAKE FOOT CONTROL VALVE

9.2

Tigercat M724D Mulcher

M724D-26

Brakes and Differential Locks

BRAKE AND DIFFERENTIAL LOCK CIRCUITS 9.3

Tigercat M724D Mulcher

Brakes and Differential Locks Pulling up on the parking brake lever engages the brake caliper on the brake disc. A proximity sensor mounted on the side of the parking brake

PARKING BRAKE The parking brake lever is located beside the operator’s seat. It is connected by a cable to a main disc brake caliper assembly mounted on the output side of the transmission.

BRAKE CABLE

••

ADJUST AUXILIARY BRAKE SET-UP CALIPER (ADJUSTING NUT) TO 50 LBF-FT.

• PROXIMITY SENSOR

PARKING BRAKE LEVER

AUXILIARY BRAKE SET-UP CALIPER 336-3AX A second AUXILIARY SET-UP CALIPER is used for hydraulic set-up procedures only and is not cable operated. When the auxiliary set-up caliper is not being used the adjusting nut should be loose with the jam nut tightened against it.

Friction between the brake caliper and the rotating disc can cause a fire. Refer to individual pressure setting procedures throughout this manual for further information on the use of the auxiliary brake set-up caliper.

••

••

METAL BAR

••

PARKING BRAKE PROXIMITY SENSOR

337-21

lever is also activated by a metal bar which moves to within 1/8" - 3/16" of the sensor. The proximity sensor activates the drive prevent circuit, to prevent the machine from being driven when the parking brake is ON. Pushing down on the lever releases the brake and de-activates the proximity sensor.

There are two ways to adjust the parking brake to compensate for wear. The first is to use the adjusting knob on the end of the parking brake lever. The second is to adjust the cable clevis at the caliper end of the brake cable.

9.4

Tigercat M724D Mulcher

Brakes and Differential Locks

CHECKING FOR PROPER PARKING BRAKE CABLE ADJUSTMENT

Proximity sensor: A proximity sensor attached to the parking brake has two main functions; When the brake is ON It (1) deactivates the drive prevent circuit to prevent the machine from being driven when the brake is ON and (2) enables the START circuit so that the engine can only be started with the parking brake ON. To drive the machine the parking brake must be OFF, both cab doors closed and the pilot reset button PRESSED.

The parking brake is properly adjusted when Resistance is encountered half way through the brake lever’s travel.

PARKING BRAKE CABLE ADJUSTMENTS Lever end: Turn the knob on the end of the brake lever to increase or decrease braking effect. (Set screw on side of adjusting knob will lock setting) Caliper end: Remove the cotter pin and clevis pin. Loosen the jamnut and thread the clevis on of off the cable to change the cable length. Tighten the jamnut.

The jamnut should provide ¼" of preload to the spring. Replace the clevis pin and cotter pin.

The parking brake proximity sensor should be adjusted so that the distance measured between the end of the sensor and the metal actuating bar of the brake lever is 1/8" with the parking brake in the OFF position. The sensor can be adjusted by loosening the two jamnuts and adjusting the location of the sensor.

The parking brake must be kept properly adjusted at all times and should be lubricated every 500 hours under normal operating conditions.

After making adjustments verify that the sensor will activate the drive prevent circuit when the parking brake is in the OFF position.

Do not allow the sensor and the metal actuating bar make contact with each other.

WARNING All brake adjustments and service must be followed by a test drive using these procedures and then checked for proper caliper "float".

BRAKE CABLE

WASHER (2)

SPRING

CLEVIS NUT (3)

•

COTTER PIN

•

CLEVIS PIN

•

•

•

•

• CALIPER ASSEMBLY

720C-PB5

PARKING BRAKE LEVER

ADJ. NUTS ADJUSTING KNOB

• • •

LOCKING SET SCREW

• •

• DISC

CLEVIS

•

•

•

•

••

TRANSMISSION

METAL BAR

LEVER PARKBRK5

•

PARKING BRAKE ASSEMBLY 9.5

PROXIMITY SENSOR 724D-26

Tigercat M724D Mulcher

Brakes and Differential Locks

REAR CALIPER TORQUE PLATE CARRIER AND LINING ASSEMBLY

CENTER ADJUSTING BOLT

CALIPER MOUNTING NUTS (2)

•

•

• • •

CALIPER MOUNTING BOLTS (2)

•

INNER SEAL (RUBBER)

•

BALL BEARINGS (3)

•

SLEEVES (2)

•

SPRING

•

RUBBER BOOT

•

THRUST WASHER

•

STAINLESS WASHER HARDENED WASHER

• •

•

•

• FRONT CALIPER TORQUE PLATE INNER CAM

•

•

SLEEVE SEAL (2)

RETAINER OUTER CAM

••

OUTER ADJUSTING NUT 720C-PB4

•

LEVER

INNER ADJUSTING NUT

BRAKE CALIPER ASSEMBLY

9.6

Tigercat M724D Mulcher

Brakes and Differential Locks LINING REPLACEMENT 1. Loosen inner and outer locking nuts on the center adjusting bolt just enough to slide each of the caliper torque plates away from the disc and far enough to allow removal of the carrier and lining assemblies. It may be necessary to completely remove one or both nuts from the center adjusting bolt for this procedure.

CALIPER FLOAT ADJUSTMENT 1. Using a feeler gauge, check that a gap (0.010” – 0.060”), referred to as caliper float, exists between the two mounting bolt sleeves and the caliper mounting bracket. There must be a 0.010” to 0.060” caliper float.

If adjustment is required; Loosen the two caliper mounting locknuts (behind the mounting bracket), adjust the two caliper mounting bolts and re-torque the two locking nuts to 100 to 120 lbf-ft, while holding the bolts from turning.

2. Collapse the lining retraction spring (sheet metal spring) and remove it from assembly.

3. Slide both torque plates away from the disc, move the carrier and lining assemblies out of the pockets and remove them from the brake assembly by sliding them sideways.

2. Loosen the two inner and outer locking nuts on the center adjusting bolt.

3. Rotate the caliper actuating lever to the 5:00 o’clock position (as viewed from the front of the machine looking towards the back). This lever has six possible positions. Lift the lever off of the pins on the back of the outer cam.

Hold the cam from moving and rotate the lever to the desired position and place it back on to the pins on the back of the cam.

4. Apply a coating of "anti-seize" to the outside of the two sleeves and slide the torque plates back and forth along the sleeves to ensure that "anti-seize" gets into bores of caliper plates.

5. Install new carrier and lining assemblies into each caliper torque plate.

4. Tighten the inner adjustment nut until firm contact is made with the brake disc by the linings. Torque to 100 in-lbs (8 lbf-ft) and then back off 4 to 5 flats. Check that disc is free to rotate.

6. Re-install the retraction spring into the assembly. The feet on the spring must be properly located into the holes in both lining carrier assemblies.

7. See previous procedure: caliper float adjustment to complete adjustment of new brake linings.

5. Tighten outer locknut against inner adjustment nut to hold this lining clearance adjustment in place (45 to 55 lbf-ft).

CALIPER MOUNTING NUTS

MOUNTING BRKT.

CALIPER "FLOAT"

MOUNTING SLEEVES

REAR TORQUE PLATE

FRONT TORQUE PLATE

CALIPER MOUNTING BOLTS LEVER INNER ADJ. NUT OUTER ADJ. NUT

PARKBRK3

BRAKE CALIPER

9.7

Tigercat M724D Mulcher

Brakes and Differential Locks

9.8

Tigercat M724D Mulcher SECTION 10 - OIL COOLER/RADIATOR AND CROSS-FLOW FAN JANUARY 2004

CONTENTS - SECTION 10 CHECK MAXIMUM FAN SPEED FORWARD AND REVERSE ................................. 10.12 CIRCUIT DIAGRAM, CROSS-FLOW FAN ................................................................ 10.11 CIRCUIT DIAGRAM, OIL COOLER ............................................................................. 10.5 COOLING SYSTEM, ENGINE ................................... SEE SECTION 7 IN THIS MANUAL CROSS-FLOW FAN CIRCUIT DIAGRAM ................................................................. 10.11 CROSS-FLOW FAN WITH ELECTRONIC FAN DRIVE CONTROL ........................... 10.6 ELECTRONIC FAN DRIVE CONTROL (FDC) CHECK FOR TEMPERATURE SENSOR FAILURE ............................................... 10.15 CHECK MINIMUM FAN SPEED WITH A/C "ON" AND NO A/C D .......................... 10.15 CHECK VARIABLE FAN SPEED WHEN CONTROLLED BY ENGINE .................. 10.16 CHECK VARIABLE FAN SPEED WHEN CONTROLLED BY HYDRAU ................. 10.17 ENGINE COOLING SYSTEM .................................... SEE SECTION 7 IN THIS MANUAL FAN COOLING CIRCUIT DESCRIPTION ................................................................. 10.10 FAN DRIVE MOTOR .................................................................................................... 10.9 FAN DRIVE MOTOR INSTALLATION ......................................................................... 10.9 FAN DRIVE PUMP ....................................................................................................... 10.6 FAN DRIVE PUMP PRESSURE, CHECK .................................................................. 10.14 FAN PUMP FORWARD AND REVERSE MAX. DISPLACEMENT SET .................... 10.12 FAN SPEED, MAX. FORWARD AND REVERSE ...................................................... 10.12 FDC CONTROL ........................................................................................................... 10.8 HYDRAULIC OIL TANK ............................................................................................... 10.4 OIL COOLER ............................................................................................................... 10.2 OIL COOLER AND RADIATOR INSTALLATION ......................................................... 10.3 OIL COOLER CIRCUIT DESCRIPTION ...................................................................... 10.2 OIL COOLER CIRCUIT DIAGRAM .............................................................................. 10.5 TROUBLE-SHOOTING GUIDE FDC. OPERATION ................................................................................................. 10.18 OVERHEATING PROBLEMS ................................................................................. 10.18

Tigercat M724D Mulcher

Oil Cooler/Radiator and Cross-flow Fan

OIL COOLER/RADIATOR

OIL COOLER

The hydraulic oil cooler and engine radiator are mounted side by side as an assembly. The assembly is mounted longitudinally in the rear RADIATOR

•

••

OIL COOLER

••

RADIATOR

•• FAN DRIVE PUMP

••

ENGINE, FRONT

••

FAN DRIVE MOTOR

A/C CONDENSER

LEFT SIDE OF MACHINE

•• •

724D-D32

•

RADIATOR/OIL COOLER & A/C CONDENSER RIGHT SIDE OF MACHINE

FAN DRIVE PUMP COUPLING 724D-D33

FAN DRIVE

For detailed cleaning procedures, refer to CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR in SECTION 2 of the OPERATOR’S MANUAL. OIL COOLER CIRCUIT DESCRIPTION

724D-D12

HINGED A/C CONDENSER

chassis to provide cross flow ventilation. The A/C condenser core is mounted in front of these two units and on hinges to facilitate cleaning. The cooling fan is mounted behind the oil cooler/ radiator assembly and draws air from the left side of the machine. The air passes through the oil cooler/radiator and A/C condenser core and exhausts on the right side of the machine.

The fan drive system is reversible to facilitate cleaning by blowing air in the opposite direction through the cooling assembly This cooling assembly must be checked daily for accumulation of debris.

The oil cooler is situated down stream from the boom control valve. The boom control valve receives hydraulic oil from both the boom section of the boom/steer gear pump. The control spool sections of this valve are all "open center" type, therefore oil surplus to requirements is allowed to pass through the valve to the outlet section of the valve and then return to tank via the oil cooler.

Cooling of the oil occurs as air is drawn over the oil cooler cooling fins. Cooled oil then passes through the dual head return filter and into the hydraulic tank.

A check valve, installed in the line at the dual head filter, prevents the tank from being drained in the event that the boom valve drain line (routed through the center joint area) is damaged.

The complete oil cooler/radiator/A-C condenser/ fan drive assembly is rubber isolation mounted to reduce the transmission of noise and to isolate the components from vibration.

Refer to SECTION 7 for information on the ENGINE COOLING SYSTEM. 10.2

Tigercat M724D Mulcher

Oil Cooler/Radiator and Cross-flow Fan SURGE TANK

••

OIL COOLER 'OUT' CONNECTION TO DOUBLE FILTER A/C CONDENSER

RADIATOR

OIL COOLER

•

••

••

• •

FAN SHROUD FAN FINGER GUARD

••

RADIATOR AND OIL COOLER MOUNTS

•

•• •

••

RADIATOR TOP TUBE ENGINE CONNECTIONS

•• FAN MOTOR

•

FAN DRIVE SUPPORT

•• RADIATOR BOTTOM TUBE

724D-05

OIL COOLER AND RADIATOR INSTALLATION 10.3

NOTE: REGULARLY CHECK FOR DEBRIS ACCUMULATION BETWEEN RADIATOR/ OIL COOLER AND A/C CONDENSER

Tigercat M724D Mulcher

Oil Cooler/Radiator and Cross-flow Fan

HYDRAULIC OIL TANK Under normal operating conditions the hydraulic oil tank will become pressurized due to the warming of the hydraulic oil and the influence of outside ambient temperatures.

A check valve preset to 10 psi will ensure that the pressure in the tank does not rise beyond that point.

HYDRAULIC OIL HAND FILL PUMP Oil may be added to the system by means of the hand fill pump. For filling instructions, refer to HYDRAULIC HAND FILL PUMP in SECTION 2 of the OPERATOR’S MANUAL.

CASE DRAIN / PILOT FILTER PRIMARY RETURN FILTERS

RESERVOIR

SECONDARY RETURN FILTERS

••

••

••

••

•

• DRIVE PUMP CHARGE PRESSURE FILTER, DRIVE

•

• FUEL FILTER

HAND FILL PUMP

•• ATTACHMENT PUMP BOOM/STEER PUMP

•• M724D-30

•• PUMPS 10.4

••

Tigercat M724D Mulcher

M724D-19

Oil Cooler/Radiator and Cross-flow Fan

OIL COOLER CIRCUIT 10.5

Tigercat M724D Mulcher

Oil Cooler/Radiator and Cross-flow Fan

ENGINE, FRONT

• • DRAIN FROM CHARGE PRESSURE FILTER

FAN DRIVE PUMP

SYSTEM PRESSURE PORT 'A'

DRAIN LINE TO PUMP PORT 'L2'

•• •

•

•

•• ••

•• SYSTEM PRESSURE PORT 'B'

CHARGE OIL FROM PRESSURE FILTER

FAN DRIVE MOTOR

FAN DRIVE PUMP COUPLING 724D-D35

RIGHT SIDE OF MACHINE

FAN DRIVE COUPLING TO ENGINE

CROSS-FLOW FAN WITH ELECTRONIC FAN DRIVE CONTROL (FDC) The cross-flow fan is driven by a dedicated closed loop hydraulic system consisting of a variable displacement drive pump and a fixed displacement fan drive motor. The cooling fan is mounted behind the oil cooler/radiator assembly and draws air from the left side of the machine. The air passes through the oil cooler/radiator and A/C condenser core and exhausts on the right side of the machine.

By reversing the direction of air flow (CLEAN) dust and debris are forced out of the radiator, oil cooler, A/C condenser cores. The fan drive is controlled electronically by the FDC system.

For additional information regarding the operation of the cross flow fan refer to FAN CONTROL and CLEANING A/C CONDENSER AND OIL COOLER/RADIATOR in SECTION 2 of THE OPERATOR'S MANUAL.

'M2' RETURN TANK PORT

'M1' TEST PORT (FORWARD RELIEF) 'M2' TEST PORT (REVERSE RELIEF)

• •• REVERSE MAXIMUM DISPLACEMENT ADJUSTING SCREW

•

'A'

• 'B'

•• 724D-D37

FAN DRIVE PUMP

FAN DRIVE PUMP The fan drive pump is located at the front of the engine, just below the cooling system assembly.

The fan drive pump is accessible from the right front engine access panels. A splined adapter connects the input drive shaft of the pump directly to the engine.

The fan drive pump is actually two separate hydraulic pumps contained in one common housing and driven by the same input drive shaft.

10.6

Tigercat M724D Mulcher

Oil Cooler/Radiator and Cross-flow Fan

SWASHPLATE

DRIVE SHAFT

PISTON(S)

•

VALVE PLATE

•

•

• AP117-1

The primary pump is a variable displacement, swashplate axial piston pump. This pump is made variable by slipping the pump pistons against a tiltable swashplate cradle. The volume and direction of oil flow from the piston pump is determined by the angle of this swashplate.

When the swashplate is stroked to a maximum displacement angle, the piston pump will produce maximum flow in one direction in the closed loop.

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

The fan drive pump is equipped with two high pressure relief valves. These relief valves are factory set and non-adjustable.

The pump is equipped with an electronic controller which receives signals from the electronic fan displacement control unit (FDC) to control the movement of the swashplate.

CHARGE PUMP

FAN DRIVE PUMP The secondary pump of the fan drive pump is the charge pump which is a fixed displacement internal gear pump which provides charge oil (make-up oil) for the fan drive pump and motor in the closed loop fan drive circuit. Charge flow also provides cooling for the circuit and pressure for the pump control system.

The fan drive charge pump is equipped with a charge pressure relief valve to maintain the charge pressure. The charge pressure relief valve is adjustable.

Refer to FAN DRIVE PUMP PRESSURE VERIFICATION AND ADJUSTMENT in THIS SECTION. For information regarding charge pressure filter replacement, refer to HYDROSTATIC CHARGE PUMP PRESSURE FILTERS in SECTION 3 of THIS MANUAL

For additional information on the FDC control, refer to FDC CONTROL in THIS SECTION.

10.7

Tigercat M724D Mulcher

Oil Cooler/Radiator and Cross-flow Fan SENSOR

EMERGENCY SHUTDOWN RELAY (7)

•

••

••

••

•

FDC OVERRIDE RELAY (8) FDC OVERRIDE RELAY (9)

A/C OFF RELAY (10)

•

A/C FDC SWITCH RELAY (11)

FDC PROCESSING MODULE

••

724D-D38

FDC PROCESSING MODULE AND RELAYS FDC CONTROL

M724D-31

ENGINE COOLANT TEMPERATURE SENSOR When the engine coolant temperature reaches 191°F the sensor on the engine in conjunction with the FDC control will send a signal to the controller on the pump to move the swashplate and start to turn the fan very slowly. The fan speed is infinitely variable from zero up to a maximum of 2200 rpm fan speed @2200 rpm engine speed. As the temperature of the coolant increases so does the speed of the fan up to the maximum 2200 rpm fan speed @2200 rpm engine speed. At this point the engine coolant temperature will be 201°F, or higher.

This control consists of an electronic processing module (FDC), a three position FAN switch in the operator's cab CLEAN/AUTO/FULL ON, and two temperature sensors, one to sense engine coolant temperature and the other to sense hydraulic oil temperature.

CLEAN

AUTO

HYDRAULIC OIL TANK

••

FULL ON

•• SENSOR

•• • •• • CROSS FLOW FAN SWITCH

M724D-26

CROSS FLOW FAN SWITCH

When the switch is in the AUTO position, the fan will operate completely in an automatic mode. It will start, speed up, slow down or stop all based on the temperature of the engine coolant and/or the temperature of the hydraulic oil.

•

724D-D39

HYDROSTATIC DRIVE CHARGE PRESSURE FILTER

HYD. OIL TEMPERATURE SENSOR

The temperature sensor in the hydraulic tank operates in a similar manner to the engine coolant temperature sensor but independently and with a different temperature range of 131°F - 153°F. This sensor will turn the fan ON at 131°F. As the temperature of the hydraulic oil increases, the speed of the fan will also increase to a maximum 2200 rpm fan speed @2200 rpm engine speed, at this point the temperature of the hydraulic oil will be 153°F, of higher.

10.8

Tigercat M724D Mulcher

Oil Cooler/Radiator and Cross-flow Fan FAN DRIVE MOTOR

CAUTION Before placing the fan switch in the CLEAN position make sure that there are no personnel on the left side of the machine in the area where the fan will expel debris When the switch is in the AUTO position and the fan is stopped due to low engine coolant or hydraulic oil temperatures, turning ON the A/C will immediately turn the cooling fan to run at 1200 rpm fan speed @ 2200 rpm engine speed. This is to ensure that sufficient air flow is available for the cab A/C even while the machine is still warming up.

The fan drive motor is a fixed displacement axial piston motor. The fan drive motor is driven by hydraulic flow and pressure from the fan drive pump and in turn directly drives the cross-flow fan.

ASSEMBLY NOTE: Before re-installing a fan drive motor, pack spline area of fan hub and motor shaft with multi-purpose lithium grease.

See Fig. 630B-10.

When the switch is in the FULL ON position, the FDC system is overridden and the fan will run at FULL speed for cooling regardless of coolant or oil temperatures.

When the switch is in the CLEAN position, the FDC system will signal the controller on the pump to move the pump swashplate in the opposite direction, reversing the flow of oil in the hydrostatic closed loop and turn the fan in reverse. The FDC control will also turn the air conditioning system OFF for as long as the fan switch is in the CLEAN position. The amount of time that the switch is held in the CLEAN position need not be more than 20 30 seconds.

FAN DRIVE MOTOR

324-10

FILL HATCHED AREA WITH MULTI-PURPOSE LITHIUM GREASE AS SHOWN PRIOR TO INSTALLING MOTOR DO NOT FILL THIS AREA WITH GREASE

•• •

•

•

• •

•

• •

•

MOTOR

BOLT

WASHER

RETAINING RING

FAN SHAFT

• BEARINGS

FAN SUPPORT 630B-10

FAN DRIVE MOTOR INSTALLATION

10.9

FAN

o

o

At

r.

Tigercat M724D Mulcher

Oil Cooler/Radiator and Cross-flow Fan

FAN COOLING CIRCUIT DESCRIPTION

With the switch in the FULL ON position, the FDC system is overridden and the fan will run at FULL speed for cooling regardless of coolant or oil temperatures.

The fan "cooling" circuit is a closed loop hydraulic system consisting of a variable displacement pump, a fixed displacement motor and a pressure filter.

Current flows through the fan switch to energize the coil of RELAY (8) this will disconnect the FDC (battery +) terminal and shut down the FDC module. Current will flow via a 75 ohm resistor to the FORWARD coil in the pump controller to move the pump swashplate and start to turn the fan forward at FULL speed, 2200 rpm fan speed @2200 rpm engine speed. Current also flows to energize the coil of RELAY (9). This will connect the 'A' side of the pump controller FORWARD coil to ground and at the same time disconnect the pump controller FORWARD coil from the FDC FWD "-" terminal.

The fan drive pump includes an integral charge pump which provides charge oil (make-up oil) for closed loop system. Charge flow also provides cooling for the circuit and pressure for the pump control system.

Charge oil is filtered prior to entering the loop by the charge pressure filter. The accumulation of excess oil in the pump and motor cases, caused by controlled internal leakage is return to the hydraulic tank via the pump tank port 'L2'.

The fan drive pump is equipped with an electronic controller which receives signals from the electronic fan control module (FDC) to control the operation of the pump.

With the fan switch in the AUTO position, current flows through RELAY '8' to the FDC control module BATTERY (+) terminal to power the FDC module. In this mode the FDC module has full control over the operation of the cooling fan. The fan will start, speed up, slow down or stop all based on the temperature of the engine coolant and/or the temperature of the hydraulic oil.

When the switch is in the CLEAN position, current flows through terminals 30 and 87A of the FDC RELAY (8) to the BATTERY (+) to power the FDC module. Current also flows through the fan switch via a 47 ohm resistor to the REVERSE coil in the pump controller to move the pump swashplate in the opposite direction and run the fan in reverse and at FULL speed. Current also flows to energize the coil of RELAY (10) and remove current from the A/C BINARY switch to turn off the air conditioning while the fan is running in REVERSE.

In addition if the cab air conditioning system is turned ON before the engine coolant or hydraulic oil has reached operating temperature, current will flow to energize RELAY (11) and connect the (+) and (-) A/C terminals on the FDC module. This will run the cooling fan at half speed.

When the temperature of the engine coolant reaches 191°F the sensor on the engine will send a signal to the FDC module. The FDC module will then send current to the FORWARD coil in the pump controller to move the pump swashplate and start to turn the fan very slowly. As the temperature increases so does the speed of the fan up to a maximum of 2200 rpm fan speed @2200 rpm engine speed. at this point the engine coolant temperature will be 201°F, or higher.

Hydraulic oil temperature is also monitored in the same way and will engage the fan independently of the engine cooling sensor if the hydraulic oil temperature reaches 131°F. first. This sensor will turn the fan ON at 131°F, as the temperature of the hydraulic oil increases, the speed of the fan will also increase to a maximum of 2200 rpm fan speed @2200 rpm engine speed, at this point the temperature of the hydraulic oil will be 153°F, or higher.

10.10

Tigercat M724D Mulcher

724D-07

Oil Cooler/Radiator and Cross-flow Fan

CROSS-FLOW FAN CIRCUIT 10.11

Tigercat M724D Mulcher

Oil Cooler/Radiator and Cross-flow Fan

CHECK MAXIMUM FAN SPEED FORWARD AND REVERSE

SENSOR

PUMP FORWARD AND REVERSE MAXIMUM DISPLACEMENT SETTINGS

••

NOTE: A calibrated "electronic photo tachometer" is required for this procedure.

1. Park the machine on level ground. Parking brake ON, attachment on ground and engine OFF. 2. Check that the forward displacement limiter adjusting screw (bottom) is set to 0.435" and the reverse displacement limiter adjusting screw (top) is set to 0.370", (dimension 'X').

M724D-31

ENGINE COOLANT TEMPERATURE SENSOR HYDRAULIC OIL TANK

•

"X"

•• • SENSOR

DIM X

DISPLACEMENT LIMITER ADJUSTING SCREW "X" DIMENSION

COUPLING TO ENGINE

'M2' RETURN TANK PORT

'M1' TEST PORT (FORWARD RELIEF) 724D-D39

'M2' TEST PORT (REVERSE RELIEF)

• REVERSE MAXIMUM DISPLACEMENT ADJUSTING SCREW 5/32' ALLEN KEY 1/2" WRENCH

••

••

3. Place a piece of reflecting tape on the fan hub.

••

5. Adjust the throttle control until the engine is running at 2200 rpm.

4. Start the engine. Leave the parking brake ON.

FAN DRIVE PUMP

CHARGE PRESSURE RELIEF ADJUSTING SCREW

'M3' TEST PORT (CHARGE PRESSURE) REMOTE MOUNTED

SHOWN WITH HOSES REMOVED FOR CLARITY 346-1

•

••

HYD. OIL TEMPERATURE SENSOR

If adjustment is required:

•• 724D-D37

HYDROSTATIC DRIVE CHARGE PRESSURE FILTER

FORWARD MAXIMUM DISPLACEMENT ADJUSTING SCREW 5/32' ALLEN KEY 1/2" WRENCH

••

FAN DRIVE PUMP - REAR VIEW 10.12

Tigercat M724D Mulcher

Oil Cooler/Radiator and Cross-flow Fan 8. If adjustment is required due to incorrect readings: a. Stop engine. The engine should not be running when adjustments are being made to the fan drive pump. b. Adjust the forward maximum displacement adjusting screw; Loosen jamnut and turn screw counterclockwise to increase speed and clockwise to decrease fan speed. Set to 2100-2200 rpm.

MANUAL SHIFT LEVER ON PUMP CONTROLLER SHOWN IN FULL FORWARD POSITION 724D-D43 6. Using the manual shift lever on the pump controller, shift the pump to full forward (UP) and measure the fan speed with the electronic photo tachometer, it should be 2200 rpm.

NOTE: Always start with adjusting screw turned in to less than 'X' dimension and then start to unscrew in one 1/2 turn increments. One full turn of the adjusting screw will raise/lower the fan speed by 315 rpm. c. Adjust the reverse maximum displacement adjusting screw; Loosen jamnut and turn screw counterclockwise to increase speed and clockwise to decrease fan speed. Set to 1700-1800 rpm. See NOTE in (b). d. Tighten jamnut (s) and re-check the forward and reverse fan speed as in steps 4 - 8 above. e. Continue with step 8 until correct forward and reverse fan speeds are obtained.

724D-D42

MANUAL SHIFT LEVER ON PUMP CONTROLLER SHOWN IN FULL REVERSE POSITION

7. Using the manual shift lever on the pump controller, shift the pump to full reverse (down) and measure the fan speed, it should be 1700-1800 rpm.

10.13

Tigercat M724D Mulcher

Oil Cooler/Radiator and Cross-flow Fan

CHECK FAN DRIVE PUMP PRESSURE: WARNING

1. Operate machine to raise hydraulic oil to operating temperature (120°F - 140°F).

Monitor hydraulic oil temperature and engine coolant temperatures closely when the fan motor is disconnected. Stop engine if the hydraulic oil temperature rises above 160°F and the engine coolant temperature above 200 °F.

2. Park the machine on level ground. Parking brake ON, attachment on ground and engine OFF. 3. Install two 0-5000 psi gauges on 'M1' and 'M2' test ports. Install one 0-500 psi gauge on fan charge pressure 'M3' test port.

COUPLING TO ENGINE

RETURN TANK PORT

•

'M1' TEST PORT (FORWARD RELIEF)

6. Adjust the throttle control until the engine is running at 2200 rpm.

'M2' TEST PORT (REVERSE RELIEF)

7. Verify that the fan drive charge pump pressure, 'M3' gauge, reads 200-210 psi.

8. If necessary adjust the charge pump pressure using the charge pressure adjusting screw.

• REVERSE MAXIMUM DISPLACEMENT ADJUSTING SCREW 5/32' ALLEN KEY 1/2" WRENCH

5. Start the engine. Leave the parking brake ON.

CHARGE PRESSURE RELIEF ADJUSTING SCREW

••

••

'M3' TEST PORT (CHARGE PRESSURE) REMOTE MOUNTED

••

•

FAN DRIVE PUMP

724D-D37

REAR CHASSIS RH SIDE

SHOWN WITH HOSES REMOVED FOR CLARITY FAN CHARGE PRESSURE 'M3' TEST PORT M724D-27

•

GAUGE CONNECTIONS

4. Disconnect the main hoses going into the fan motor and plug using two 12 ORS plugs.

DISCONNECT MAIN HOSES AND PLUG WITH 12 ORS PLUGS.

••

••

346-1

••

FAN DRIVE PUMP - REAR VIEW

9. Adjust engine speed to 1000 rpm.

10. Shift the pump to full forward using the hand lever on the pump. Verify that the 'M1' gauge reading is 3700-3900 psi. Note the pressure has a tendency to drop slightly while holding the lever shifted fully, this is acceptable.

11. Shift the pump to full reverse using the hand lever on the pump. Verify that the 'M2' gauge reading is 3700-3900 psi. Note the pressure has a tendency to drop slightly while holding the lever shifted fully, this is acceptable.

12. If 'M1' and 'M2' gauge readings are incorrect contact Tigercat Customer Service for more information as the relief valves are not adjustable.

13. Reconnect hoses to fan motor.

324-10

FAN DRIVE MOTOR

14. Check for hydraulic oil leaks. Stop the engine and remove gauges from test port connections.

10.14

Tigercat M724D Mulcher

Oil Cooler/Radiator and Cross-flow Fan

ELECTRONIC FAN DRIVE CONTROL (FDC)

If the readings taken compare favourably with the reading shown in the chart then the sensor is OK.

CHECK FOR TEMPERATURE SENSOR FAILURE: An Ohms meter and an infrared temperature probe (heat gun) are required for this test.

Both the engine coolant and hydraulic oil temperature sensors may be checked for faulty operation by performing a "resistance" check. This involves checking the resistance value of the sensor across the sensor terminals with the coolant or hydraulic oil at a specific temperature level.

10. If the temperature sensor is faulty the resistance reading on the Ohms meter will most likely be zero.

11. Replace sensor and/or reconnect wires.

12. Perform the same test with the Hydraulic oil temperature sensor using the same chart.

HYDRAULIC OIL TANK

The check may be performed without removing the sensor. Use the chart below as a guide for temperature to resistance values.

SENSOR RESISTANCE CHECK TEMP. OHMS 120°F (49°C) 796 ± 5% 140°F (60°C) 561 ± 5% 160°F (71°C) 395 ± 8% 180°F (82°C) 279 ± 8% 200°F (93°C) 196 ± 8% 220°F (104°C) 138 ± 8%

••

•• •

SENSOR

724D-D39

HYDROSTATIC DRIVE CHARGE PRESSURE FILTER

HYD. OIL TEMPERATURE SENSOR

SENSOR

CHECK MINIMUM FAN SPEED WITH A/C "ON" AND NO A/C DURING CLEAN MODE

••

NOTE: A calibrated "electronic photo tachometer" is required for this procedure.

1. Ensure that engine coolant and hydraulic oil temperatures are well below the normal operating temperatures of 191°F coolant and 131°F hydraulic oil throughout entire test or fan will rotate and test will be invalid.

M724D-31

ENGINE COOLANT TEMPERATURE SENSOR 1. Disconnect wires from FDC engine coolant temperature sensor.

2. Place a piece of reflecting tape on the fan hub.

2. Start the engine. Leave the parking brake ON.

4. Set throttle control to 2200 rpm.

3. Set throttle control to IDLE (1000 rpm).

5. Place FAN switch in AUTO position.

4. Place A/C switch in OFF position.

6. Place A/C switch in ON position.

5. Place FAN switch in AUTO position.

7. Use a photo-tachometer to measure the speed of rotation of the fan blade, it should be 1140-1200 rpm.

3. Start the engine. Leave the parking brake ON.

8. Stop engine when engine coolant temperature gauge in cab reads close to a value shown in the above chart.

7. Aim the heat gun at the coolant pipe close to the temperature sensor and take a temperature reading, note the reading.

8. With the help of an assistant press and hold the fan switch in the CLEAN position and visually check clutch on A/C compressor. It should be disengaged and compressor not running.

8. Connect the Ohms meter to the two terminals on the temperature sensor and note resistance value.

9. When the CLEAN switch is released the clutch on the A/C compressor should engage and the compressor should be running.

9. Use the SENSOR RESISTANCE CHECK chart and compare readings.

10.15

Tigercat M724D Mulcher

Oil Cooler/Radiator and Cross-flow Fan

CHECK VARIABLE FAN SPEED WHEN CONTROLLED BY ENGINE COOLANT TEMPERATURE: NOTE: A calibrated "electronic photo tachometer" is required for this procedure.

10. Use the photo-tachometer to measure the rpm. of the fan at this temperature of 201°F, it should be 2100-2200 rpm.

1. Complete TEMPERATURE SENSOR FAILURE VERIFICATION test.

2. Place a piece of reflecting tape on the fan hub.

3. Place A/C switch in OFF position.

4. Cover only the radiator portion of the cooling assembly with cardboard.

5. Start engine. Leave paring brake ON. 6. Set throttle control to 2200 rpm and raise engine coolant temperature to 170°F-180°F on gauge.

11. Remove the cardboard from the radiator.

12. The engine coolant temperature will start to decrease. Verify that the fan speed decreases relative to the decrease in the engine coolant temperature. NOTE, This will happen quickly and can be verified visually without the use of the photo-tachometer.

13. The fan speed should slow down and settle at 800-840 rpm with engine speed of 2200 rpm and engine coolant temperature steady at 195°F, with a 195°F thermostat.

14. Replace FDC processing module if this test fails.

IMPORTANT NOTE: Monitor hydraulic oil temperature closely throughout test. Abort test if hydraulic oil temperature climbs above 131°F. Operator should be instructed to activate functions for 5 seconds and then release for 5 seconds to avoid overheating of valve by hydraulic oil as it passes over the reliefs during the following procedures.

7. Operate RH JOYSTICK to raise boom to upper limit and hold joystick in BOOM UP position for 5 seconds and then release for 5 seconds (see IMPORTANT NOTE) This will impose a load on the engine and cause the engine coolant temperature to rise.

••

724D-D38

8. Observe the engine coolant temperature gauge during this process, when the gauge settles down and reads a steady temperature and then begins to rise, the fan should begin to slowly rotate. The engine coolant temperature should be approximately 191°F. 9. Continue with step (7) to increase the engine coolant temperature to 201°F while at the same time verifying that the rpm of the fan increases proportionally with the increase in temperature of the engine coolant.

10.16

FDC PROCESSING MODULE

FDC PROCESSING MODULE

Tigercat M724D Mulcher

Oil Cooler/Radiator and Cross-flow Fan

CHECK VARIABLE FAN SPEED WHEN CONTROLLED BY HYDRAULIC OIL TEMPERATURE: NOTE: A calibrated "electronic photo tachometer" is required for this procedure.

11. Use the photo-tachometer to measure the rpm of the fan at this temperature of 153°F, it should be 2200 rpm. with an engine speed of 2200 rpm

1. Complete the TEMPERATURE SENSOR FAILURE VERIFICATION test.

2. Place a piece of reflecting tape on the fan hub.

3. Disconnect wire from the FDC engine coolant temperature sensor and install a spare sensor of the same type on the sensor wires. Suspend the spare sensor in a cooler location so that it is not in contact with any hot engine parts. This is necessary to prevent the engine coolant temperature sensor from interfering with this hydraulic oil temperature sensor test.

4. Place A/C switch in OFF position.

12. Remove the cardboard from the oil cooler.

13. The hydraulic oil temperature will start to decrease. Verify that the fan speed decreases relative to the decrease in the hydraulic oil temperature. NOTE, This will happen quickly and can be verified visually without the use of the photo-tachometer.

14. The fan should stop rotating at approximately 131°F. 15. If the test was successful, remove the spare engine coolant sensor and re-connect the sensor wires to the FDC sensor in the hydraulic tank 16. Replace FDC processing module if this test failed.

5. Cover only the oil cooler portion of the cooling assembly with cardboard.

6. Start engine. Leave paring brake ON. 7. Set throttle control to 2200 rpm and raise hydraulic oil temperature to 131°F on gauge.

IMPORTANT NOTE: Monitor engine coolant temperature closely throughout test. Abort test if engine coolant temperature climbs above 200°F. Operator should be instructed to activate functions for 5 seconds and then release for 5 seconds to avoid overheating of valve by hydraulic oil as it passes over the reliefs during the following procedures.

••

724D-D38

8. Operate RH JOYSTICK to raise boom to upper limit and hold joystick in BOOM UP position for 5 seconds and then release for 5 seconds (see IMPORTANT NOTE) This will cause the hydraulic oil temperature to rise.

9. Observe the hydraulic oil temperature gauge during this process, when the gauge settles down and reads a steady temperature and then begins to rise, the fan should begin to slowly rotate. The hydraulic oil temperature should be approximately 131°F. 10. Continue with step (8) to increase the hydraulic oil temperature to 153°F while at the same time verifying that the rpm of the fan increases proportionally with the increase in temperature of the hydraulic oil.

10.17

FDC PROCESSING MODULE

FDC PROCESSING MODULE

Tigercat M724D Mulcher

Oil Cooler/Radiator and Cross-flow Fan

TROUBLE-SHOOTING GUIDE FOR F.D.C. OPERATION SYMPTOM A The fan will not operate when the FAN switch is in the AUTO position.

B The fan will not rotate in reverse direction

C The fan operates in the wrong direction when FAN switch is in AUTO position.

D The fan operates in the

E

wrong direction when the FAN switch is NOT in the AUTO position.

The fan will not go to FULL rpm using FULL ON (OVERRIDE) position on FAN switch.

F The fan will not CLEAN (PURGE).

G The fan operates in FULL ON (OVERRIDE) forward direction when FAN switch is in AUTO position; both hydraulic oil & engine coolant temperatures are cold.

INSPECT

CORRECTION/REPAIR

FDC supply power fuse is blown.

FDC supply power wire is damaged.

Replace fuse; 15 AMP rating Repair damaged section of wire with correct gage wire, and route/guard wire to prevent future damage.

Replace FDC Replace complete coil assembly in EDC.

Faulty FDC. Check condition of forward coil, Check resistance is 20 Ohms across terminals A and B of pump controller (EDC).

Check all wire 17 connections between the FAN switch and the EDC pump controller.

Check 47 Ohms resister in wire 17 at terminal strip Check condition of reverse coil (resistance 16 Ohms) across terminals C and D of pump controller (EDC).

Locate wires at pump connector, check wire-to-terminal locations as follows: A=91, B=88A, C=17, D=G81.

Check FAN switch wire-to-terminal connections, should be as follows: 39=1, 26A=2B, 17 & 89 = 3.

Diode & resistor orientation between wires 88 & 88A incorrect.

Connection for diode &/or resistor between wires 88 & 88A damaged.

Reverse resistor connection may be damaged.

Temperature sensor (hydraulic oil & engine coolant) electrical connectors are not properly installed onto temperature sensors.

Frayed or corroded wires at temperature sensor(s).

Failed temperature sensor(s), check resistance value; see THIS SERVICE MANUAL.

Re-connect wires.

Replace 47 Ohms resister Replace complete coil assembly

Remove & reinstall wires at pump connector for wire-to-terminal locations as follows: A=91, B=88A, C=17, D=G81.

Remove & reinstall wires on the selector switch as follows: 39=1, 26A=2B, 17 & 89 = 3.

Correct diode &/or resistor location/orientation between wires 88 & 88A Repair damaged connection, or replace damaged diode/resistor Repair/replace damaged connection/resistor; 47 Ohms Ensure proper connections between electrical connector and temperature sensor(s) Repair or replace as required Replace temperature sensor(s) if required

TROUBLESHOOTING.DOC/PDF

TROUBLE-SHOOTING GUIDE FOR OVERHEATING PROBLEMS The following is a list of problems that would cause a Mulcher to overheat. All items are equally important and each must be considered.

1.

2.

3.

4.

5.

6.

7.

8.

9.

Dirty Radiator Low Coolant Level Low Oil Level Dirty Air Filter Improper Grade of Fuel Faulty Thermostats Faulty Coolant Pump Coolant Gauge Malfunction Defective Water Pump (Belt)

10.

11.

12.

13.

14.

15.

16.

17.

10.18

Air Recirculation Gaps between Radiator & Shroud Fan Engagement inlo Shroud Corroded Coolant Passages Excess Fuel Delivery from Injection Pump Incorrect lnjection Pump Timing Internal Failure of Deaeration System Operator Induced Problem

Tigercat M724D Mulcher SECTION 11- STEERING AND CENTER JOINT JANUARY 2004

CONTENTS - SECTION 11 CENTER JOINT ADJUSTMENT ........................................................................................ 11.10 CHECKING ............................................................................................. 11.10 DIAGRAM ............................................................................................... 11.11 GREASE SEALS .................................................................................... 11.11 LUBRICATION ........................................................................................ 11.10 MAINTENANCE ...................................................................................... 11.10 CIRCUIT DESCRIPTION ............................................................................. 11.6 CIRCUIT DIAGRAM ..................................................................................... 11.7 JOYSTICK CONTROL VALVE..................................................................... 11.5 PRESSURE SETTINGS .............................................................................. 11.8 SAFETY ....................................................................................................... 11.8 STEER RELIEF VALVE ............................................................................... 11.4 STEER VALVE ............................................................................................. 11.4 CROSS SECTION .................................................................................... 11.4 DESCRIPTION ......................................................................................... 11.4 OPERATING DESCRIPTION ................................................................... 11.4 STEER/BOOM PUMP .................................................................................. 11.2

Tigercat M724D Mulcher STEER/BOOM PUMP

Steering and Center Joint OUTLET

This is a double gear pump mounted to the lower left output pad of the pump drive gearbox. The pump drive shaft is connected to the gearbox via a splined adapter.

DRIVEN (IDLER) GEAR

DRIVE GEAR

•

•

The shaft end section of the pump supplies hydraulic oil for the boom functions. The cover end section of the pump supplies hydraulic oil for the steering, brake and differential lock functions and oil to the pilot circuit.

The operation of a typical external gear pump (so called because the gear teeth are on the external surface of the hub) is shown in Figure gear1.

A gear pump carries oil from the inlet to the outlet in the spaces between gear teeth. The pumping chamber is formed by the gears, the pump housing, and side plates. One of the two gears is the drive gear and is connected to the drive shaft.

The other idler gear is driven by the drive gear.

INLET GEAR1

SHAFT END SECTION (BOOM)

•

AP130-1

TYPICAL GEAR PUMP

COVER END SECTION (STEER)

•

STEER/BOOM PUMP

11.2

Tigercat M724D Mulcher STEER RELIEF VALVE

Steering and Center Joint

The steer relief valve is located between the steer pump and the steer valve. The steer relief valve protects the steer pump and steer circuit from over pressurizing. Relief oil is directed back to tank via a return filter.

The relief valve is adjusted by loosening the locknut and turning the hex head screw. Turning the hex head screw clockwise increases the TEST PORT

••

STEER RELIEF (2500 PSI) - 1/2" WRENCH - 9/16" WRENCH

•• •

ADJUSTING SCREW

LOCKNUT

• TANK

RPGC

PRESSURE 724D-D04

STEER RELIEF VALVE

RELIEF CARTRIDGE

pressure setting and counter-clockwise decreases the pressure setting. Once the pressure is set correctly, tighten the locknut and re-check the pressure setting. A gauge test port is provided at the relief valve.

11.3

Tigercat M724D Mulcher STEER VALVE

Steering and Center Joint

The steer valve is a control valve which consists of an open center spool section, an inlet section and an outlet section. Cartridge type relief valves are installed in both work ports of the spool section.

OPERATING DESCRIPTION Oil from the boom/steer pump (via the accumulator charge valve) enters the inlet section of the steer valve, passes through the open center spool section and back to tank via the outlet section.

Shifting the spool directs oil from the steer pump to the steer cylinders.

The port relief valves in the steer valve also function as anti-cavitation relief valve. The return oil from the port relief valves is diverted back to tank via the tank passage in the spool section and the outlet section.

For a detailed description of port relief valves, refer to RELIEF VALVES in SECTION 18 of THIS MANUAL.

The open center spool has three positions. A spring in the spool end cap holds the spool in the center neutral position. The spool is shifted one way or the other by pilot pressure applied to either end of the spool.

RELIEF VALVE PORT 'A'

PARALLEL PASSAGE

WORK PORT BRIDGE

LOAD CHECK VALVE

RELIEF VALVE PORT 'B'

B

A

SPOOL SPOOL CENTERING SPRING TANK PASSAGE

90136-3

THRU' NEUTRAL PASSAGE

STEERING VALVE CROSS SECTION

11.4

Tigercat M724D Mulcher JOYSTICK CONTROL VALVE

Steering and Center Joint OPERATING DESCRIPTION

This pilot valve is a manually operated directional control valve and operates on the same principle as a direct operating pressure reducing valve.

Operated by hand this valve directs pilot pressure to the steer control valve pilot end caps. The spool valve then shifts from its centre position and directs pump flow to operate the corresponding cylinder.

In the neutral position the joystick lever is held centered by return spring (4).

When the lever (1) is operated, the plunger (5) is pushed against the return spring (4).

At the same time the regulating spool (2) is moved through the regulating spring (3).

When the regulating stroke begins, there is a connection from port 'P' via hole (8) in the spool and work port 2 or 4 in the base of the valve, to the steer valve pilot end caps.

Pressure provided by the steer/boom pump via the pilot manifold at ports 2 and 4 of the joystick valve is directly proportional to the operator position of the joystick and the regulating spring characteristic. Moving the joystick to the right will steer the machine to the right and moving the joystick to the left will steer the machine to the left. The steering joystick cannot move forward or back due to stops installed in these plunger ports.

RR-12

JOYSTICK PILOT VALVE

•

•

5

• •

4 3

• •

•

2

•

1

•

'P' PORT WORK PORTS 2 OR 4

AU013-2

SPOOL ARRANGEMENT

AU013-1

11.5

Tigercat M724D Mulcher STEER CIRCUIT DESCRIPTION

Steering and Center Joint

Two steer cylinders are used to steer the machine. Operating oil is supplied from the fixed displacement boom/steer pump, via steer relief valve and the accumulator charge valve, to the steer valve. The steer valve controls the flow of oil to and from the steering cylinders. The steering joystick supplies pilot oil to shift the spool in the steer valve.

Moving the joystick to the LEFT directs pilot oil to the "A" port pilot end cap of the steer control valve, this shifts the spool in the control valve and allows oil to flow from the steer pump (via the accumulator charge valve) to the two steer cylinders and steer the machine LEFT. Moving the joystick to the RIGHT directs pilot oil to the "B" port pilot end cap of the steer valve and steers the machine RIGHT. Return oil from the cylinders flows back to the steer valve and is directed back to tank through the outlet section of the steer valve.

The steering "speed" is controlled by the amount the joystick is moved to the right or left. A small movement of the joystick will turn the machine slowly and a large movement of the joystick will turn the machine very rapidly. Relief valves are installed on both ports of the steer valve to prevent over pressurizing of the steer cylinders when the control spool is in the center position.

The steer relief valve is the steer circuit main relief valve. It is set lower than the steer valve port reliefs and is installed in the line between the boom/steer pump and the accumulator charge valve. This protects the system by preventing system pressure from rising above the preset value. Higher system pressures will cause the steer relief valve to direct oil back to tank.

NOTE: Hydraulic lines to the steer cylinders must be cross connected to allow the machine to steer while being towed by another vehicle. For complete towing information, refer to TOWING INSTRUCTIONS in SECTION 2 of the OPERATOR'S MANUAL.

11.6

Tigercat M724D Mulcher

M724D-22

Steering and Center Joint

STEER CIRCUIT DIAGRAM 11.7

Tigercat M724D Mulcher STEERING PRESSURE SETTINGS NOTE: Refer to RELIEF VALVE ADJUSTING PROCEDURE in SECTION 18 of THIS MANUAL.

Steering and Center Joint 1. Park the machine on level ground, lower the attachment to the ground and set the parking brake ON. Install articulation lock bar, block wheels and stop engine.

Before starting this procedure, read the following safety precautions:~ • Wear safety glasses and safety shoes when working on or around machine.

• Never stand in the articulating zone of the machine during set-up. Always stand on the side opposite to the direction in which the machine is being steered.

• Be aware of machine pinch points that could cause injury. Never place body parts within the range of motion of moving parts.

• Be sure to use lynch pins when installing articulation lock bar. Vibration and the motion of steering could work retaining pins upward.

ARTICULATION LOCK BAR

WARNING To prevent injury caused by accidental steering of the machine when setting pressures, make sure the articulation lock bar is held securely in place by the lynch pins provided.

2. Install a 0-5000 psi pressure gauge to the steer relief valve gauge test port .

3. Turn the steer relief valve adjusting screw all the way in and then back out two turns.

4. Turn both steer valve port relief adjusting screws on steer valve out until spring pressure is relieved.

RETAINING PIN

•• LYNCH PIN

••

•• 195-24

INSTALL ARTICULATION LOCK BAR

11.8

Tigercat M724D Mulcher

Steering and Center Joint

5. Start the engine and set the throttle control to IDLE. 6. Ensure that the hydraulic oil temperature is between 120°F - 140°F.

IMPORTANT Avoid blowing oil over relief longer than 5 seconds, as excessive heating of hydraulic fluid and damage to boom/steer pump can occur.

7. While attempting to steer the machine to the RIGHT, set the port 'B' relief on the steer valve to 3200 psi.

PORT 'B' RELIEF

PORT 'A' RELIEF

A B

LEFT

RIGHT

STEER VALVE

AT055

8. While attempting to steer the machine to the LEFT, set the port 'A' relief to 3200 psi.

9. Turn steer relief valve all the way out.

TEST PORT

STEER RELIEF (2500 PSI) - 1/2" WRENCH - 9/16" WRENCH

•

•• ••

ADJUSTING SCREW

LOCKNUT

•• TANK

RPGC

PRESSURE 724D-D04

STEER RELIEF

RELIEF CARTRIDGE

10. Move the throttle control to the FULL position.

11. While attempting to STEER the machine either RIGHT or LEFT, set the steer relief valve pressure to 2500 psi.

12. Remove pressure gauge and wipe up any excess oil in test port area.

13. Remove the articulation lock bar and place it in the storage position.

11.9

Tigercat M724D Mulcher

Steering and Center Joint

CENTER JOINT MAINTENANCE OF CENTER JOINT Maintenance in this area is usually limited to: a) Regular lubrication of the two center joint grease fittings (items 11) to purge the pivot bearings of debris and water. Refer to SCHEDULED MAINTENANCE in SECTION 3 of THIS MANUAL for lubrication intervals.

Use only high quality, lithium based EP2 grease containing molybdenum disulphide.

4. Partially depress the plunger end of the dial indicator against the bottom surface of the front chassis upper lug 'B' as close to center pin as possible. Zero the dial indicator.

5. Fully loosen only the 6 bottom pin retainer bolts (item 2) that were torqued in step 2.

DIAL INDICATOR PLUNGER

b) Visually checking the center joint pivot for looseness every 1000 hours. With an observer on the ground, keeping well clear of the center joint area, perform the following test to check for looseness of center joint.

B

••

••

REAR CHASSIS

DIAL INDICATOR FRONT CHASSIS

1. Have operator lift the attachment off the ground and then rapidly raise and lower head several times to "bounce" machine.

DIAL INDICATOR BASE

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

267-17

• A

CHECK PRELOAD

6. The dial indicator should now show a change of 0.008" to 0.012" between lug 'A' and 'B'.

This is the proper bearing preload setting.

FRONT CHASSIS

CHECK FOR MOVEMENT IN THIS JOINT AREA

267-8

A change of less than 0.008" indicates that the bearing preload is too low. No change on the dial indicator is the result of a loose center joint. In these cases, proceed to CENTER JOINT PRELOAD ADJUSTMENT.

REAR CHASSIS

1000 HOUR CHECK

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

CHECKING THE CENTER JOINT PRELOAD 1. Park the machine on level ground. Set parking brake ON and shut off engine.

CENTER JOINT PRELOAD ADJUSTMENT Before making any adjustments to the center joint, please follow CHECKING THE CENTER JOINT BEARING procedure in THIS SECTION. With dial indicator still in place; 7. Remove all bottom pin retainer bolts (item 2), the bottom pin retainer plate (item 3) and all of the shims in the shim pack (items 10).

CAUTION: Keep upward pressure on the bottom pin (item 9) and do not allow pin to fall out from bearing. These pivot pins are very heavy, block the pin in place if necessary.

2. Torque the 6 top and 6 bottom retainer bolts (items 1 and 2) to 282 - 310 lbf-ft.

3. Place the magnetic base of a dial indicator on the top surface of the front chassis lower lug 'A' as close to the center pin as possible.

8. Remove the thinnest shim from the pack.

9. Reinstall the remaining shims, the retainer plate and the bolts. Leave the bolts loose.

10. Zero the dial indicator again and torque the 6 bottom bolts in sequence to 282 - 310 lbf-ft.

11.10

Tigercat M724D Mulcher

Steering and Center Joint

11. A change of 0.008" to 0.012" should register on the dial indicator.

ORIENTATION OF GREASE SEALS The pivot bearings (item 4) are sealed on both sides by grease seals (items 5 and 6). These seals have proven to have a long life.

This is the proper bearing preload setting. a) If change in dial indicator reading is greater than 0.012", the shim removed (in step 8) was not thin enough. Obtain a thinner shim and put it back into the shim pack (item 9).

If replacement becomes necessary, new seals must be installed in the proper orientation. Refer to the center joint diagram and follow these guidelines for correct installation;

b) If the change in the dial indicator reading is less than 0.008", another shim will have to be removed. Repeat steps 7 through 11, removing additional shims but only the thinnest shim each time, until the change in the reading on dial indicator is within the proper range. c) It is possible that the total thickness of two shims is too great and a single shim, of lesser thickness than these two, must be removed.

TORQUE TO 282 - 310 LBF-FT. NO LOCTITE REQUIRED

•

The two seals installed on either side of the top bearing must be installed with the seal garter spring facing UP.

•

The two seals installed on either side of the bottom bearing must be installed with the seal garter spring facing DOWN.

Apply Loctite (blue - removable) or equivalent and torque the six bolts (item 7) for the bearing retainer plate (item 8) to 80 - 88 lbf-ft.

1

•

GREASE SEALS WITH SPRINGS FACING UPWARD

REAR CHASSIS 11

• •

• FRONT CHASSIS • 6

• • •

726B09

• • •

10 3

2 TORQUE TO 282 - 310 LBF-FT. NO LOCTITE REQUIRED

4 5

• GREASE SEALS WITH SPRINGS FACING DOWN

9

• CENTER JOINT 11.11

8 7 TORQUE TO 80 - 88 LBF-FT. USE LOCTITE (REMOVABLE)

Tigercat M724D Mulcher

Steering and Center Joint

11.12

Tigercat M724D Mulcher SECTION 12 - LIFT BOOM JANUARY 2004

CONTENTS - SECTION 12 BOOM LIFT LOCK ....................................................................................... 12.6 BOOM VALVE ASSEMBLY PROCEDURE ....................................................................... 12.8 CROSS SECTION OF SPOOL SECTION ................................................ 12.3 OPERATING DESCRIPTION ................................................................... 12.2 RELIEF VALVES .......................... SEE SECTION 18 - CLAMPS WITH SAW CIRCUIT DIAGRAM ..................................................................................... 12.5 JOYSTICK CONTROL VALVE..................................................................... 12.2 OPERATING DESCRIPTION ................................................................... 12.2 PRESSURE SETTINGS .............................................................................. 12.6 PUMP, DESCRIPTION BOOM/STEER PUMP ................................... SEE SECTION 11 - STEERING SAFETY ....................................................................................................... 12.6

Tigercat M724D Mulcher BOOM JOYSTICK VALVE

Lift boom OPERATING DESCRIPTION

This pilot valve is a manually operated directional control valve and operates on the same principle as a direct operating pressure reducing valve.

Both joysticks and the foot control valves use similar spool arrangements This joystick control valve directs pilot pressure to the boom valve pilot end caps. The corresponding spool valve then shifts from its centre position and directs pump flow to operate the corresponding cylinder.

In the neutral position, the joystick lever is held centered by return spring (4).

When the lever (1) is operated, the plunger (5) is pushed against the return spring (4).

At the same time, the regulating spool (2) is moved through the regulating spring (3).

When the regulating stroke begins, there is a connection from port 'P' via the hole (8) in the spool and work ports 1, 2, 3 or 4 in the base of the valve, to the boom valve pilot end caps.

Pressure provided by the steer/boom pump via the pilot manifold at ports 1, 2, 3 and 4 of the joystick valve is directly proportional to the operator position of the joystick and the regulating spring characteristic.

BOOM VALVE The boom valve consists of four open center spool sections and one inlet section. Each spool section is pilot operated. An outlet section directs return oil back to tank. The control valve is located on the front chassis above the front axle and behind the cover plate.

OPERATING DESCRIPTION

RR-12

Oil enters the inlet section and is allowed to pass through the four spool sections and back to tank via the outlet section. Each of these spool sections has a self centering 3-position spool which is open centered. A spring in the spool end cap holds the spool in the center neutral position.

The spool is shifted by pilot pressure being applied to either end of the spool. Shifting the spool directs oil to operate any one of the four functions (or all at the same time if required but with reduced flow to each).

JOYSTICK PILOT VALVE

•

•

5

• •

4 3

• •

•

2

•

1

To prevent over pressurizing of the operating circuits, each work port in the valve sections has a port relief valve.

•

A main relief valve is installed in the inlet section of the valve. The inlet main relief valve controls the lift spool section and is set lower than the lift up port relief valve. All relief valves are the same type (anti-cavitation relief valve). For a detailed description of these relief valves, refer to RELIEF VALVES in SECTION 18 of THIS MANUAL.

'P' PORT WORK PORTS 2 OR 4

AU013-2

SPOOL ARRANGEMENT

AU013-1

12.2

Tigercat M724D Mulcher

Lift boom

TILT CLAMP ARM

LIFT 'DOWN' PORT RELIEF (2200 PSI)

LIFT 'UP' PORT RELIEF (2900 PSI)

ACCUMULATOR ARM/ MULCH DEFLECTOR DOOR

LIFT BOOM

•

•

INLET GAUGE TEST PORT

•

•

MAIN RELIEF (2600 PSI)

•

INLET SECTION

BOOM CONTROL VALVE

M724D-02

RELIEF VALVE PORT 'A'

PARALLEL PASSAGE

LOAD CHECK VALVE

A

WORK PORT BRIDGE

RELIEF VALVE PORT 'B'

B

PILOT END CAP PILOT END CAP

90136-3

SPOOL CENTERING SPRING

SPOOL TANK PASSAGE

THRU' NEUTRAL PASSAGE

CROSS SECTION OF SPOOL SECTIONS

12.3

Tigercat M724D Mulcher CIRCUIT DESCRIPTION

Lift boom

Two cylinders are used to raise and lower the attachment. The boom cylinders receive oil from a fixed displacement pump via the LIFT spool section in the boom valve. The lift spool section in the boom valve is pilot operated at both ends.

Pilot oil from the boom (right hand) joystick control valve in the operator's cab shifts the spool.

The spool directs oil from the pump to either end of the cylinders and from the cylinders back to tank via the oil cooler and primary return double filter.

The boom valve is located on the front chassis above the front axle, behind the cover plate.

12.4

Tigercat M724D Mulcher

Lift boom

LIFT BOOM CIRCUIT M724D-24

12.5

Tigercat M724D Mulcher PRESSURE SETTINGS NOTE: Refer to RELIEF VALVE ADJUSTING PROCEDURE in section 18 of THIS MANUAL. Before starting this procedure, read the following safety precautions:~ • Never reach between boom crank arms or link arms during machine set-up.

• Wear safety glasses and safety shoes when working on shears.

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

1. Park machine on level ground. Completely raise lift boom and install lift boom cylinder lock over one of the two cylinder rods with the open side at the bottom and wide end up against the keeper plate bolt heads. Install retaining bolt and locknut through center hole. Slowly lower boom until lock is securely held in place.

WARNING

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

4. Turn the boom inlet main relief adjusting screw all the way IN. 5. Turn both lift spool section port relief valve adjusting screws OUT until spring pressure is relieved then turn adjusting screws one full turn IN. 6. Start the engine, and set the throttle control to the IDLE position.

IMPORTANT During the following procedures, DO NOT hold ANY function control for LONGER THAN 5 SECONDS. 7. Ensure that the hydraulic oil temperature is between 120°F - 140°F. 8. While holding the joystick in the LIFT UP position (fully extended), check gauge pressure reading.

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

• Always install 'T' handle retainer bolt • Use only to support boom and cutting head • Do not use to set hydraulics pressures 2. Set parking brake ON. Install articulation lock bar, block wheels and stop engine.

WARNING

If less than 2900 psi, lower boom to rest against lock, stop engine and readjust LIFT UP port relief. Repeat above procedure until a gauge reading of 2900 psi is obtained.

IMPORTANT Approach the gauge reading slowly and deliberately by turning the adjusting screw in a little at a time. The pressure setting must not exceed the above value.

To prevent injury caused by accidental steering of the machine when setting pressures, make sure the articulation lock bar is held securely in place by the lynch pins provided.

3. Connect a 0 - 5000 psi pressure gauge (with at least 4' of hose) to the boom control valve inlet test port.

12.6

Tigercat M724D Mulcher

Lift boom

9. Remove lift boom cylinder lock. It is not designed to withstand high forces created by the hydraulic system. Never use this cylinder lock to set boom down port relief.

10. While holding the joystick in the LIFT DOWN position (fully retracted), check gauge pressure reading. Front wheels may lift off ground.

If less than 2200 psi, release pressure in rod end of lift cylinders and allow attachment to sit on the ground. Stop engine and readjust LIFT DOWN port relief. Repeat above procedure until a gauge reading of 2200 psi is obtained.

11. Stop engine, unscrew inlet main relief adjusting screw three(3) full turns.

12. Start engine and move the throttle control to the FULL position.

IMPORTANT Never run engine at full throttle with main relief turned all the way in.

13. While holding the joystick in the LIFT UP position (fully extended), check gauge pressure reading.

If less than 2600 psi, release pressure in base end of lift cylinders and allow attachment to sit on the ground. Stop engine and readjust the inlet main relief. Repeat above procedure until a gauge reading of 2600 psi is obtained.

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

12.7

Tigercat M724D Mulcher BOOM VALVE ASSEMBLY PROCEDURE

Lift boom

4. Position end section on last spool section as shown and hand tighten tie rod nuts.

1. Lay out valve components on a clean, flat working surface. The inlet assembly will include an "O" ring, a load check poppet and a load check spring. Tools required for basic valve assembly include a 3/4" and 11/16" wrench and a torque wrench with thin wall sockets.

5. Position valve assembly with the mounting pads of the end sections on a flat surface. To obtain proper alignment of end sections relative to the spool sections, apply downward pressure to the end sections and snug the tie rod nuts to 10 lbf-ft.

Torque the two 11/16" nuts at 45-50 lbf-ft.

2. Assemble tie rod nuts to one end of each tie rod with one or two threads showing. Insert tie rods through rod holes in inlet section (larger diameter rod at top). Lay inlet section on end with tie rods up. Place the "O" ring in position within the groove.

Torque the 3/4" nut at 70-80 lbf-ft.

6. Install auxiliary valves and plugs and torque to proper values.

3. Place first spool section ("O" ring side facing up) on the inlet section. Position "O" ring in to groove and insert load check poppet (nose down) and spring (behind poppet) into load check cavity as shown. Repeat this procedure for each spool section. The load check springs are compressed by the following sections during assembly.

12.8

Tigercat M724D Mulcher SECTION 13 - TILT JANUARY 2004

CONTENTS - SECTION 13 BOOM LIFT LOCK ....................................................................................... 13.4 CIRCUIT DESCRIPTION ............................................................................. 13.2 CIRCUIT DIAGRAM ..................................................................................... 13.3 CONTROL VALVES ..................................................................................... 13.2 PRESSURE SETTINGS .............................................................................. 13.4 SAFETY ....................................................................................................... 13.4

Tigercat M724D Mulcher

TILT 'IN' PORT RELIEF (2900 PSI)

Tilt

•

TILT

TILT 'OUT' PORT RELIEF (2900 PSI)

•

CLAMP ARM ACCUMULATOR ARM/ MULCH DEFLECTOR DOOR

LIFT BOOM INLET GAUGE TEST PORT

•

•

•

MAIN RELIEF (2600 PSI)

INLET SECTION

M724D-02

BOOM CONTROL VALVE

CONTROL VALVES

CIRCUIT DESCRIPTION

For a complete description of the boom valve, refer to BOOM VALVE in SECTION 12 of THIS MANUAL.

Two cylinders are used to tilt the attachment forward and back. The cylinders receive oil from the fixed displacement boom/steer pump via the TILT spool section in the boom control valve. The tilt spool section in this control valve is pilot operated at both ends. It receives pilot oil from the boom joystick control valve in the operator's cab to shift the spool. The spool directs oil from the pump to either end of the cylinders and from the cylinders back to tank via the oil cooler and primary return double filter.

For a complete description of the boom joystick pilot valve, refer to JOYSTICK CONTROL VALVE in SECTION 12 of THIS MANUAL.

The boom valve is located on the front chassis above the front axle, behind the cover plate.

13.2

Tigercat M724D Mulcher

M724D-23

Tilt

TILT CIRCUIT 13.3

Tigercat M724D Mulcher PRESSURE SETTINGS NOTE: Refer to RELIEF VALVE ADJUSTING PROCEDURE in SECTION 18 of THIS MANUAL. Before starting this procedure, read the following safety precautions:~ • Never reach between boom crank arms or link arms during machine set-up.

• Wear safety glasses and safety shoes when working on shears.

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

1. Park machine on level ground. Completely raise lift boom and install lift boom cylinder lock over one of the two cylinder rods with the open side at the bottom and wide end up against the keeper plate bolt heads. Install retaining bolt and locknut through center hole.

Slowly lower boom until lock is securely held in place.

WARNING

Tilt 4. Turn the boom inlet main relief adjusting screw all the way IN. 5. Turn both tilt spool section port relief valve adjusting screws OUT until spring pressure is relieved then turn adjusting screws one full turn IN. 6. Start the engine, and put the throttle control to the IDLE position.

7. Ensure that the hydraulic oil temperature is between 120°F - 140°F. 8. While holding the joystick in the TILT OUT position (fully extended), check gauge pressure reading.

If less than 2900 psi, lower attachment to the ground, stop engine and readjust TILT OUT port relief. Repeat above procedure until a gauge reading of 2900 psi is obtained.

IMPORTANT During the following procedures, DO NOT hold ANY function control for LONGER THAN 5 SECONDS. 9. While holding the joystick in the TILT IN position (fully retracted), check gauge pressure reading.

If less than 2900 psi, lower attachment to the ground. Stop engine and readjust TILT IN port relief. Repeat above procedure until a gauge reading of 2900 psi is obtained.

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

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

IMPORTANT Approach the gauge reading slowly and deliberately by turning the adjusting screw in a little at a time. The pressure setting must not exceed the above value.

2. Set parking brake ON. Install articulation lock bar, block wheels and stop engine

WARNING To prevent injury caused by accidental steering of the machine when setting pressures, make sure the articulation lock bar is held securely in place by the lynch pins provided.

3. Connect a 0 - 5000 psi pressure gauge (with at least 4' of hose) to the inlet test port.

10. Stop engine, unscrew inlet main relief adjusting screw 3 full turns.

11. Start engine and move the throttle control to the FULL position.

IMPORTANT Never run engine at full throttle with main relief turned all the way in.

12. While holding the joystick in the TILT IN position, check gauge pressure reading.

If less than 2600 psi, lower attachment to the ground. Stop engine and readjust the inlet main relief. Repeat above procedure until a gauge reading of 2600 psi is obtained.

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

13. Remove pressure gauge and wipe up any excess oil from test port area.

13.4

Tigercat M724D Mulcher SECTION 17 - ATTACHMENT DRIVE JULY 2003

CONTENTS - SECTION 17 ATTACHMENT MOTOR .................. SEE ATTACHMENT MANUFACTURER'S MANUAL ATTACHMENT PUMP ................................................................................................. 17.2 CIRCUIT DESCRIPTION ............................................................................................. 17.4 CIRCUIT DIAGRAM ..................................................................................................... 17.5 CONTROL VALVE, CUTTER OPERATING DESCRIPTION ................................................................................... 17.3 PRESSURE SETTINGS MULCHER ATTACHMENT (MULCHER CONFIGURATION) ................................... 17.6 SAW ATTACHMENT (FELLER BUNCHER CONFIGURATION) .............................. 17.9 SAFETY ............................................................................................................. 17.6, 17.9

Tigercat M724D Mulcher

Attachment drive

ATTACHMENT PUMP PUMP CONTROL VALVE PRESSURE COMPENSATOR VALVE

••

STANDBY VALVE

• M724D-21

•• MAXIMUM DISPLACEMENT ADJUSTING SCREW

••

ATTACHMENT PUMP M724D-22

The attachment pump is an axial-piston variable displacement pump controlled by a load sense and pressure compensated pump control. The pump control is mounted directly onto the pump and has a STANDBY pressure adjustment and a PRESSURE COMPENSATOR adjustment.

PUMP CONTROL PRESSURE COMPENSATOR VALVE

The STANDBY pressure valve is part of the pump's loadsensing control. The loadsensing controls pump displacement starting from a zero pump flow condition. If no flow is demanded, only the "standby" pressure required by the system is maintained by the pump.

Until system pressure reaches the pressure compensator setting, the compensator valve will be in the "return" position blocking oil flow to the swashplate control piston leaving the pump at maximum displacement.

ATTACHMENT PUMP

The pump is mounted to the lower right output pad of the pump drive gearbox. The pump drive shaft is connected to the gearbox via a splined adapter.

M724D-27

NOTE: It is important to note that pressure settings and maximum displacement settings for the attachment pump are different for mulching head attachments and saw attachments (feller buncher configuration). Refer to PRESSURE SETTINGS MULCHER and PRESSURE SETTINGS FELLER BUNCHER SAW in THIS SECTION. Refer also to CONVERTING MULCHER TO FELLER BUNCHER CONFIGURATION and CONVERTING FELLER BUNCHER CONFIGURATION TO MULCHER in SECTION 3 of THIS MANUAL.

ATTACHMENT PUMP SCHEMATIC

••

ATTACHMENT PUMP PRESSURE COMPENSATOR VALVE

INPUT SHAFT

••

ATTACHMENT PUMP ~ SIDE VIEW

17.2

Tigercat M724D Mulcher CUTTER CONTROL VALVE

Attachment drive TO ATTACHMENT MOTOR(S)

M724D-28

FROM ATTACHMENT PUMP

CUTTER CONTROL VALVE SCHEMATIC CUTTER CONTROL VALVE The cutter control valve consists of a steel body which houses valve cartridges. The first cartridge combines a solenoid operated control valve and pilot operated check valve. The second is a relief valve cartridge.

The cutter control valve controls the flow of oil from the attachment pump to the attachment motor(s).

CUTTER CONTROL VALVE MAIN RELIEF ADJUSTING SCREW

TEST PORT 'GP'

M724D-05

(2) Transmits a pressure signal via the 'COMP' port to the attachment pump control causing the attachment pump to provide flow to the attachment motor.

The RELIEF VALVE is included to protect the pump in case of failure of the pressure compensator valve on the pump. Oil is diverted to tank via the 'TANK' port.

The RELIEF VALVE is adjusted by loosening the locknut and turning the adjusting screw clockwise to increase the pressure value and counterclockwise to decrease the value. It must be set at least 350 psi higher than the pressure compensator valve setting on the pump.

••

TEST PORT 'GM'

pressure, via internal porting, causes the CHECK VALVE to open and allow system pressure via the 'M' port to reach the attachment motor.

•• •• CUTTER CONTROL VALVE

OPERATING DESCRIPTION When the SOLENOID VALVE is de-energized (saw/cutter switch in OFF position), oil entering the 'P' port is blocked by the CHECK VALVE preventing flow to the attachment motor.

When the SOLENOID VALVE is energized, (saw/ cutter switch ON) the spool in the control valve shifts and:

Two gauge test ports 'GP' and 'GM' are provided for attaching pressure gauges when checking pressures.

For a complete description of the circuit and pressure setting instructions, refer to PRESSURE SETTINGS: PUMP AND CUTTER CONTROL VALVE. NOTE: It is important to note that pressure settings for the cutter control valve are different for mulching head attachments and saw attachments (feller buncher configuration). Refer to PRESSURE SETTINGS MULCHER and PRESSURE SETTINGS FELLER BUNCHER SAW in THIS SECTION. Refer also to CONVERTING MULCHER TO FELLER BUNCHER CONFIGURATION and CONVERTING FELLER BUNCHER CONFIGURATION TO MULCHER in SECTION 3 of THIS MANUAL.

(1) Allows system pressure to reach the back side of the PILOT OPERATED CHECK VALVE. This 17.3

Tigercat M724D Mulcher ATTACHMENT CIRCUIT DESCRIPTION The attachment is driven by variable displacement hydraulic motor(s). A variable displacement hydraulic pump mounted on the pump drive gearbox supplies oil flow to the motor(s) via the cutter control valve. The cutter control valve is solenoid operated with a built in relief and controls the flow of hydraulic oil from the attachment pump to the attachment motor(s).

The saw/cutter switch on the control panel in the cab is used to turn the attachment ON or OFF. It is a 2 position switch controlling the flow of electrical current via a relay to the cutter control valve solenoid.

IMPORTANT To maximize pump and motor life, do not shut the engine off until the cutter has come to a complete stop.

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

• Always stop cutter with engine at idle.

NOTE: The attachment will not run unless both cab doors are closed and the pilot reset switch is pressed to activate the pilot system.

For additional information, refer to SAW/CUTTER SWITCH and PILOT RESET SWITCH in SECTION 2 of the OPERATOR'S MANUAL. With the saw/cutter switch in the OFF position, the cutter control valve solenoid is de-energized preventing oil flow to the motor. The oil is redirected, via internal ports in the pump, to the PRESSURE COMPENSATOR valve and the STANDBY valve mounted on the back of the pump. When pressure builds up to the standby pressure setting the spool in the STANDBY valve shifts to direct oil to the control piston of the pump swashplate, moving it to the neutral position. In this condition the pump flow is reduced to a minimum.

Attachment drive valve back to the STANDBY valve on the pump to prevent the STANDBY spool from shifting. This will override the standby pressure setting and allow the attachment pump to build up pressure.

When the pressure (system pressure) builds up to the attachment pump's pressure compensator valve setting the spool in the pump pressure compensator valve shifts to direct oil to the opposite end of the pump swashplate control piston. The piston moves the swashplate to the near neutral position, this will cut back the flow of oil from the pump while at the same time maintaining system pressure and continuing to turn the cutter. As the cutter gains momentum system pressure will drop below the pump pressure compensator valve setting.

This system results in a lower horsepower requirement and reduces heat generation since the pump reduces output rather than dumping hydraulic oil over relief valves.

Some attachments are equipped with variable displacement motors which adjust displacement in response to system pressure.

For explanation of attachment motor, refer to ATTACHMENT MANUFACTURER'S MANUAL. NOTE: It is important to note that pressure settings for both the attachment pump and the cutter control valve are different for mulching head attachments and feller buncher saw attachments. Refer to PRESSURE SETTINGS MULCHER and PRESSURE SETTINGS FELLER BUNCHER SAW in THIS SECTION. Refer also to CONVERTING MULCHER TO FELLER BUNCHER CONFIGURATION and CONVERTING FELLER BUNCHER CONFIGURATION TO MULCHER in SECTION 3 of THIS MANUAL.

With the saw/cutter switch in the ON position, the cutter control valve solenoid is energized directing the flow of oil to unseat a PILOT OPERATED CHECK VALVE in the cutter control valve. This allows high pressure oil to flow from the attachment pump to the attachment motor(s).

Pilot oil is also directed from the cutter control 17.4

Tigercat M724D Mulcher

Attachment drive

ATTACHMENT CIRCUIT DIAGRAM M724D-01

17.5

Tigercat M724D Mulcher PRESSURE SETTINGS ATTACHMENT PUMP MULCHER ATTACHMENT: NOTE: Refer to RELIEF VALVE ADJUSTING PROCEDURE in SECTION 18 of THIS MANUAL. Before starting this procedure, read the following safety precautions:~ •

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

•

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

•

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

•

Do not, under any circumstances, overspeed the rotating cutter RPM.

•

A slowly rotating cutter can crush bones.

Beware of pinch points when rotating cutter by hand.

•

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

•

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

•

Mulcher door opens and closes quickly.

Keep clear of its operating range.

•

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

•

Keep mulcher door closed whenever possible during setup.

•

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

•

Check torque on cutter tool mounting bolts before starting cutter.

For more safety information refer to SECTION 1 of THIS MANUAL.

Attachment drive NOTE: When converting a machine from Feller Buncher configuration to Mulcher configuration ensure that attachment pump maximum displacement is reset for mulcher configuration before setting pressures. Refer to CONVERTING FELLER BUNCHER CONFIGURATION TO MULCHER - RESET ATTACHMENT PUMP MAXIMUM DISPLACEMENT in SECTION 3 of THIS MANUAL. 1. Park machine on level ground, close mulcher door and lower mulching head to the ground.

Adjust depth shoes or rest depth shoes on firm blocks so that the rotating cutter is approximately 6" off the ground. Set parking brake ON. Install articulation lock bar, block wheels and stop engine.

WARNING To prevent injury caused by accidental steering of the machine when setting pressures, make sure the articulation lock bar is held securely in place by the lynch pins provided.

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

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

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

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

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

7. Keep mulcher head 6" off the ground (15 cm).

WARNING WARNING

Workers on the ground should stand behind the wheels of the machine to provide an added barrier to thrown objects.

Always allow the rotating cutter to coast to a COMPLETE STOP before approaching mulching head to make adjustments.

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

17.6

Tigercat M724D Mulcher

Attachment drive PUMP CONTROL VALVE

•• • M724D-03

M724D-21

CUTTER/SAW PRESSURE GAUGE

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

MAXIMUM DISPLACEMENT ADJUSTING SCREW

ATTACHMENT PUMP PRESSURE COMPENSATOR VALVE

9. Start the engine and raise hydraulic oil temperature to 120°F - 140°F.

STANDBY VALVE

10. Set throttle control to 1200 rpm.

••

11. Measure standby pressure with saw/cutter switch in the OFF position. Gauge should read 600 psi, if not, adjust standby valve on the saw pump pressure compensator valve.

••

12. Stop engine.

M724D-22

13. Install two 0-5000 psi pressure gauges in test ports 'GM' and 'GP' on cutter control valve.

CUTTER CONTROL VALVE MAIN RELIEF ADJUSTING SCREW

TEST PORT 'GP'

NOTE: Close both doors and press pilot reset switch to operate the saw/cutter.

18. Loosen locknut and adjust pressure compensator valve adjusting screw on the attachment pump to a setting of 5800psi on 'GP' test port. This is a temporary adjustment until the mulcher head spike relief has been set

•

TEST PORT 'GM'

PUMP CONTROL

• •

19. Adjust the mulcher head spike relief valve pressure lower to approximately 5800 psi on 'GM' gauge, a hissing sound will be heard as oil begins to pass over the relief and there will be a change in the sound of the engine.

Immediately place the the saw/cutter switch in the OFF position to minimize heating of the hydraulic oil.

NOTE: Refer to RELIEF VALVE ADJUSTING PROCEDURE in THIS SECTION.

M724D-05

CUTTER CONTROL VALVE

14. Screw main relief valve adjusting screw on cutter control valve all the way IN. 15. Screw the mulcher head spike relief valve all the way IN. 16. Start the engine and set throttle control to 1200 rpm.

17. Place the saw/cutter switch in the ON position.

20. Turn the pressure compensator valve adjusting screw OUT one turn to ensure oil is not heated by flowing over the relief valve.

21. Loosen locknut and adjust pressure compensator valve adjusting screw on the attachment pump to a setting of 5500psi on 'GP' test port. This is a temporary adjustment until the cutter control main relief valve has been set.

17.7

Tigercat M724D Mulcher

Attachment drive

22. Place the saw/cutter switch in the ON position.

23. Adjust the cutter control valve main relief valve pressure to approximately 5500 psi on 'GM' gauge, a hissing sound will be heard as oil begins to pass over the relief and there will be a change in the sound of the engine.

Immediately place the the saw/cutter switch in the OFF position to minimize heating of the hydraulic oil.

NOTE: Refer to RELIEF VALVE ADJUSTING PROCEDURE in THIS SECTION. 24. Turn the pressure compensator valve adjusting screw OUT one turn to ensure oil is not heated by flowing over the relief valve.

25. Place the saw/cutter switch in the ON position.

NOTE: Close both doors and press pilot reset switch to operate the saw/cutter.

26. Set pressure compensator valve on attachment pump to 5000 psi on 'GP' gauge.

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

27. Place the saw/cutter switch in the OFF position. Stop engine and remove block from rotating cutter. Remove pressure gauges and wipe up any excess oil.

NOTE: Some attachments are equipped with variable displacement motor(s) which may require adjustment. Other attachments are equipped with fixed displacement motor(s) which require no adjustment.

For explanation of attachment motor, refer to ATTACHMENT MANUFACTURER'S MANUAL. SET MOTOR POR (BEGIN OF DISPLACEMENT REGULATION) If applicable - applies only to variable displacement attachment motor(s).

SET MOTOR MINIMUM DISPLACEMENT If applicable - applies only to variable displacement attachment motor(s).

Refer to the attachment manufacturer's own OPERATOR AND MAINTENANCE MANUAL for this information.

17.8

Tigercat M724D Mulcher PRESSURE SETTINGS ATTACHMENT PUMP SAW ATTACHMENT NOTE: Refer to RELIEF VALVE ADJUSTING PROCEDURE in SECTION 18 of THIS MANUAL. Before starting this procedure, read the following safety precautions:~ •

Never assume that other workers are aware of disc saw dangers.

•

Do not point the discharge side of the saw toward people, vehicles, buildings, or the machine.

•

Guards, wear plates and covers must be properly attached during operation of saw blade.

•

Do not, under any circumstances, overspeed the saw blade RPM.

•

Be aware that the saw blade is virtually silent as it coasts to a stop.

•

A slowly rotating blade can crush bones.

Beware of pinch points when rotating blade by hand.

•

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

•

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

•

Clamp and Accumulator arms open and close very rapidly. Keep clear of their operating range.

•

Wear safety shoes and safety glasses when working on saws.

•

Keep clamp and accumulator arms closed whenever possible during setup.

•

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

•

Check torque on saw blade mounting bolts and tooth mounting bolts before starting saw.

•

Install saw blade locking pin, except when setting motor "begin of stroke" and blade RPM.

WARNING Always allow the blade to coast to a COMPLETE STOP before approaching saw head to make adjustments.

Attachment drive NOTE: When converting a machine from Mulcher configuration to Feller Buncher configuration ensure that attachment pump maximum displacement is reset for mulcher configuration before setting pressures. Refer to CONVERTING MULCHER CONFIGURATION TO FELLER BUNCHER CONFIGURATION - RESET ATTACHMENT PUMP MAXIMUM DISPLACEMENT in SECTION 3 of THIS MANUAL.

DANGER DO NOT operate saw before adjusting the attachment pump maximum displacement.

Attachment pump maximum displacement is significantly lower for the saw attachment (33 gpm) than for the mulcher attachment (78 gpm).

Attachment pump maximum displacement must be lowered to prevent overspeeding of the saw blade. Overspeeding of the saw blade may result in serious injury or death.

Overspeeding may also result in component damage or subsequent malfunction.

1. Park machine on level ground, lower saw head to approximately 6" off the ground, set parking brake ON. Install articulation lock bar, block wheels and stop engine.

WARNING To prevent injury caused by accidental steering of the machine when setting pressures, make sure the articulation lock bar is held securely in place by the lynch pins provided.

2. Remove all guards and check that the area in and around the saw blade is free of loose objects (wood, stones, nuts, bolts, etc.).

Make sure all tools and spare parts are removed from the saw head area.

3. Rotate blade slowly by hand and check for "runout " and "wobble ".

4. Check the torque on both the saw blade mounting bolts and the saw tooth mounting bolts.

5. Properly install the saw blade guard using all hardware provided. Guard must be secure.

6. Block saw blade from rotating as outlined in saw head manufacturer’s manual.

17.9

Tigercat M724D Mulcher 7. Clear area under the saw of all loose dirt, stones, wood and debris.

WARNING

Attachment drive CUTTER CONTROL VALVE MAIN RELIEF ADJUSTING SCREW

•

Workers on the ground should stand behind the wheels of the machine to provide an added barrier to thrown objects.

WARNING Do not stand above or below the felling head and lift boom or between the boom and front chassis during this procedure.

8. Keep saw head 6" off the ground (15 cm) for the remaining steps of this procedure.

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

TEST PORT 'GM'

•

TEST PORT 'GP'

M724D-05

CUTTER CONTROL VALVE

17. Place the saw/cutter switch in the ON position.

NOTE: Close both doors and press pilot reset switch to operate the saw/cutter.

10. Start the engine and raise hydraulic oil temperature to 120°F - 140°F. 11. Set throttle control to 1200 rpm.

•

PRESSURE COMPENSATOR VALVE

• ••

MAXIMUM DISPLACEMENT ADJUSTING SCREW

ATTACHMENT PUMP

M724D-21 M724D-03

CUTTER/SAW PRESSURE GAUGE

12. Measure standby pressure with saw/cutter switch in the OFF position. Gauge should read 600 psi, if not, adjust standby valve on the saw pump pressure compensator valve.

13. Stop engine.

14. Install two 0-5000 psi pressure gauges in test ports 'GM' and 'GP' on cutter control valve.

15. Screw in main relief valve adjusting screw on cutter control valve all the way IN. 16. Start the engine and set throttle control to 1200 rpm.

POR. VALVE

STANDBY VALVE

•• •• PRESSURE COMPENSATOR VALVE

M724D-22

18. Loosen locknut and adjust pressure compensator valve adjusting screw on the attachment pump to a setting of 3900 psi on 'GP' test port. This is a temporary adjustment until the cutter control main relief valve has been set.

17.10

Tigercat M724D Mulcher

Attachment drive

19. Adjust the cutter control valve main relief valve pressure lower to approximately 3900 psi on 'GM' gauge, a hissing sound will be heard as oil begins to pass over the relief and there will be a change in the sound of the engine.

Immediately place the the saw/cutter switch in the OFF position to minimize heating of the hydraulic oil.

NOTE: Refer to RELIEF VALVE ADJUSTING PROCEDURE in THIS SECTION. 20. Turn the pressure compensator valve adjusting screw OUT one turn to ensure oil is not heated by flowing over the relief valve.

21. Place the saw/cutter switch in the ON position.

NOTE: Close both doors and press pilot reset switch to operate the saw/cutter.

22. Set pressure compensator valve on attachment pump to 3650 psi on 'GP' gauge.

23. Place the saw/cutter switch in the OFF position. Stop engine and remove block from blade. Remove pressure gauges and wipe up any excess oil.

NOTE: Some attachments are equipped with variable displacement motor(s) which may require adjustment. Other attachments are equipped with fixed displacement motor(s) which require no adjustment.

For explanation of attachment motor, refer to ATTACHMENT MANUFACTURER'S MANUAL. SET MOTOR POR (BEGIN OF DISPLACEMENT REGULATION) If applicable - applies only to variable displacement attachment motor(s).

SET MOTOR MINIMUM DISPLACEMENT If applicable - applies only to variable displacement attachment motor(s).

Refer to the attachment manufacturer's own OPERATOR AND MAINTENANCE MANUAL for this information.

17.11

Tigercat M724D Mulcher

Attachment drive

17.12

Tigercat M724D Mulcher SECTION 18 - CLAMPS WITH SAW ATTACHMENT JANUARY 2004

CONTENTS - SECTION 18 BOOM LIFT LOCK ....................................................................................... 18.6 BOOM VALVE .............................................................................................. 18.2 OPERATING DESCRIPTION ................................................................... 18.3 SPOOL SECTION DIAGRAM ................................................................... 18.3 CIRCUIT DESCRIPTION ............................................................................. 18.4 CIRCUIT DIAGRAM ..................................................................................... 18.5 CONTROL VALVES ..................................................................................... 18.2 PILOT LINE PRESSURES ......................... SEE SECTION 5 - PILOT SYSTEM PRESSURE SETTINGS .............................................................................. 18.6 RELIEF VALVES ADJUSTING PROCEDURE ...................................................................... 18.9 OPERATION ............................................................................................. 18.8 SAFETY ....................................................................................................... 18.6 SPOOL SECTION DIAGRAM ...................................................................... 18.3

Tigercat M724D Mulcher CONTROL VALVES

Clamps with saw attachment

The clamp and accumulating arm circuits are controlled by a clamp foot control valve, two solenoid operated pilot valves in the pilot manifold (accumulator) and a pilot operated boom valve.

NOTE: The clamp and accumulating arm circuits apply only to machines which have been converted to feller buncher configuration by replacing the mulching attachment with a saw attachment. For machines with a mulcher attachment refer to SECTION 19 of THIS MANUAL. For more information and instructions about converting a mulcher to feller buncher configuration refer to CONVERTING MULCHER TO FELLER BUNCHER CONFIGURATION in SECTION 3 of THIS MANUAL.

pilot valve, refer to FOOT CONTROL VALVE in SECTION 8 of THIS MANUAL. BOOM VALVE The boom valve is located on the front chassis above the front axle and behind the cover plate.

One of the four spool sections is used to open and close the clamp and a second spool section to open and close the accumulating arm.

The inlet section receives oil from the fixed displacement boom pump.

All four spools in the valve are open center type.

Each spool section is pilot operated. An outlet section directs return oil back to tank.

Cartridge type port relief valves are installed in both work ports of the clamp spool section and both work ports in the accumulator spool section.

The inlet section has a single main relief valve.

For a complete description of the pilot manifold refer to SECTION 5 of THIS MANUAL. For a complete description of the foot operated

CLAMP 'CLOSE' PORT RELIEF (3200 PSI)

CLAMP 'OPEN' PORT RELIEF (1100 PSI) [CLAMP

TILT

ACCUMULATOR 'CLOSE' PORT RELIEF (3200 PSI)

•

CLAMP ARM

•

ACCUMULATOR ARM/ MULCH DEFLECTOR DOOR

• ACCUMULATOR 'OPEN' PORT RELIEF (3200 PSI)

•

LIFT BOOM INLET GAUGE TEST PORT

•

•

•

MAIN RELIEF (2600 PSI)

INLET SECTION

BOOM CONTROL VALVE

M724D-02

TIGERCAT DW5000, DW5600 AND SW5700 BUNCHING SAWS KOEHRING WATEROUS 20" DISC SAWS

18.2

Tigercat M724D Mulcher

Clamps with saw attachment

These reliefs protect the circuits (pumps) from high pressures during operation.

Shifting the spool(s) directs oil from the fixed displacement Boom/Steer Pump to the clamp and accumulating cylinders.

OPERATING DESCRIPTION

The relief valves installed in the inlet and spool sections of the boom valve protect the pump in case of failure of the POR valve on the pump.

Oil from the fixed displacement boom/steer pump enters the inlet section of the boom valve and is allowed to pass through the four open center spool sections and back to tank via the outlet section.

All of the relief valves on the boom valve divert oil to tank via the tank passages in the spool sections and the outlet section of the boom valve.

They also function as anti-cavitation relief valves.

The open centered spools in all of the sections have three positions and are self centering. A spring in the spool end cap holds the spool in the center neutral position.

The spools are shifted one way or the other by pilot oil pressure being applied to either end of the spool.

RELIEF VALVE PORT 'A'

PARALLEL PASSAGE

LOAD CHECK VALVE

A

WORK PORT BRIDGE

RELIEF VALVE PORT 'B'

B

PILOT END CAP

PILOT END CAP SPOOL CENTERING SPRING

SPOOL TANK PASSAGE THRU' NEUTRAL PASSAGE

90136-3

CROSS SECTION OF CLAMP SPOOL SECTION

18.3

Tigercat M724D Mulcher CLAMPS WITH SAW ATTACHMENT

Clamps with saw attachment

Tigercat DW5000, DW5500, DW5600 and SW5700 Bunching Saw Heads.

KOEHRING WATEROUS 20" SAW HEADS. NOTE: Circuit using a Tigercat attachment (with single clamp and accumulator arms) is described below. Circuit is identical for Koehring Waterous attachments but there are dual clamp and accumulator arms.

CIRCUIT DESCRIPTION The clamp and accumulating arms are operated by separate cylinders. A fixed displacement pump supplies oil to the cylinders via two spool sections in the boom valve.

The clamp arm is operated by the clamp foot control valve (left side of cab floor). The left pedal is used to OPEN and the right pedal to CLOSE. Pressing the CLAMP OPEN pedal directs pilot oil to shift the spool in the clamp spool section.

Pressing the CLAMP CLOSE pedal directs pilot oil to the opposite end of the spool to shift it in the opposite direction. The spool directs oil from the pump to either end of the clamp arm cylinder to open or close the arm. Return oil is directed back to tank via the oil cooler.

The accumulating arm is operated by a 3 position thumb switch OPEN/CLOSE (self centering to OFF) located on the right joystick control. The switch operates two solenoid pilot valves on the pilot manifold which direct pilot oil to the accumulator spool section of the boom control valve, to shift the spool. The spool directs oil from the pump to either end of the accumulating arm cylinder to open or close the arm. Return oil is directed back to tank via the oil cooler and dual head primary return oil filter.

18.4

Tigercat M724D Mulcher

Clamps with saw attachment

ACCUMULATING AND CLAMP ARMS CIRCUIT Tigercat DW5000, DW5600, and SW5700 Bunching Saws Koehring Waterous 20" Disc Saws M724D-25

18.5

Tigercat M724D Mulcher PRESSURE SETTINGS SAW CLAMP AND ACCUMULATOR

Clamps with saw attachment 2. Set parking brake ON. Install articulation lock bar, block wheels and stop engine

NOTE: Refer to RELIEF VALVE ADJUSTING PROCEDURE in THIS SECTION. Before starting this procedure, read the following safety precautions:~ • Never reach between boom crank arms or link arms during machine setup.

• Wear safety glasses and safety shoes when working on shears.

WARNING To prevent injury caused by accidental steering of the machine when setting pressures, make sure the articulation lock bar is held securely in place by the lynch pins provided.

• Keep clamp and accumulator arms closed whenever possible during setup.

WARNING

• Clamp and accumulator arms open and close very rapidly, always keep clear of operating area.

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

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

NOTE: This procedure assumes that a Tigercat Bunching Saw Head is used. Follow same procedure for Koehring Waterous 20" Saw Head. Refer to illustration of LIFT BOOM CONTROL VALVE on page 2 for orientation and pressure value references .

1. Park machine on level ground. Completely raise lift boom and install lift boom cylinder lock over one of the two cylinder rods with the open side at the bottom and wide end up against the keeper plate bolt heads. Install retaining bolt and locknut through center hole. Slowly lower boom until lock is securely held in place.

WARNING

TO SET CLAMP AND ACCUMULATOR OPEN AND CLOSE RELIEF VALVES:3. Connect a 0 - 5000 psi pressure gauge (with at least 4' of hose) to the inlet test port on of the boom control valve.

4. Turn the boom inlet main relief adjusting screw all the way IN. 5. Turn the port relief valve adjusting screws on both the accumulator and clamp spool sections of the control valve OUT until spring pressure is relieved then turn adjusting screws one full turn IN. 6. Start the engine, and put the throttle control to the IDLE position.

7. Ensure that the hydraulic oil temperature is between 120°F - 140°F.

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

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

During the following procedures, DO NOT hold ANY function control for LONGER THAN 5 SECONDS.

IMPORTANT Avoid blowing oil over relief longer than 5 seconds, as excessive heating of hydraulic fluid and damage to boom pump can occur.

IMPORTANT Approach the gauge reading slowly and deliberately by turning the adjusting screw in a little at a time. The pressure setting must not exceed the above value.

18.6

Tigercat M724D Mulcher

Clamps with saw attachment

8. While holding the left foot pedal down in the CLAMP OPEN position (cylinder fully retracted), check gauge pressure reading.

If less than 1100 psi, stop engine and readjust clamp open port relief. Repeat above procedure until a gauge reading of 1100 psi is obtained.

9. While holding the right foot pedal down in the CLAMP CLOSE position (cylinder fully extended), check gauge pressure reading.

If less than 3200 psi, stop engine and readjust clamp close port relief. Repeat above procedure until a gauge reading of 3200 psi is obtained.

10. While holding the right joystick thumb switch to the left in the ACCUMULATING ARM OPEN position (accumulator cylinder fully retracted), check gauge pressure reading.

If less than 3200 psi, stop engine and readjust accumulator open port relief. Repeat above procedure until a gauge reading of 3200 psi is obtained.

11. While holding the right joystick thumb switch to the right in the ACCUMULATING ARM CLOSE position (accumulator cylinder fully extended), check gauge pressure reading.

If less than 3200 psi, stop engine and readjust accumulator close port relief. Repeat above procedure until a gauge reading of 3200 psi is obtained.

12. Stop engine, unscrew inlet main relief adjusting screw 3 full turns.

IMPORTANT Never run engine at full throttle with main relief turned all the way in.

13. Start engine and move the throttle control to the FULL position.

14. While holding the joystick thumb switch in the ACCUMULATING ARM OPEN position, check gauge pressure reading.

If less than 2600 psi, stop engine and readjust inlet main relief. Repeat above procedure until a gauge reading of 2600 psi is obtained.

15. Remove pressure gauge and wipe up any excess oil from test port area.

SET PILOT LINE PRESSURES: NOTE: Refer to SECTION 5 of THIS MANUAL.

18.7

Tigercat M724D Mulcher

Clamps with saw attachment ANTI-CAVITATION RELIEF VALVE

VALVE POPPET

T P

This valve is used as a MAIN and PORT relief valve in the boom control valve and the steer control valve.

Operation Step 1.

T

STEP 1 PILOT POPPET

‘P’ represents a high pressure area and ‘T’ represents tank. Under normal operation, ‘P’ is below the relief pressures, the valve poppet is firmly seated and oil cannot flow to tank.

T

Step 2.

P

STEP 2

T SEATING POPPET

Step 3.

T P

STEP 3

When the pressure at ‘P’ reaches the relief valve setting, the pilot poppet unseats and allows oil in the inner cavity to flow to tank, thus lowering the pressure in the cavity between the pilot poppet and the other poppets.

T

As a result of the opening of the pilot poppet, the seating poppet moves back, due to the pressure drop caused by oil flow through the bore of the seating poppet, and seats against the pilot poppet. This shuts off the flow of oil through the seating poppet and the cavity pressure now drops to tank pressure.

Step 4.

VALVE POPPET

T P

STEP 4

T VALVE POPPET

Step 5.

T P

STEP 5

T CHECK POPPET

When pressure ‘P’ drops the pilot poppet closes and then the seating poppet moves back to its original position and permits oil pressure to flow into the cavity behind the valve poppet. As the seating poppet moves back it comes in contact with the valve poppet and its spring force plus the oil pressure cause the valve poppet to move back to the closed position.

As an anti-void or check valve.

T P

ANTI-VOID CHECK OPERATION

As the seating poppet began to move away from the valve poppet, the valve poppet began to open under the effect of the pressure at P thus allowing a large volume of flow to tank. The drop in pressure behind the valve poppet when the seating poppet seats on the pilot poppet ensures full opening of the valve poppet.

T

The anti-void unit supplies oil to the pressure area ‘P’ when its pressure drops below the pressure in the tank gallery of the valve. The valve then acts as a free flow check valve and prevents cavitation. In this condition, the pressure at ‘P’ is lower than at ‘T’ and due to the shape of the check poppet, the pressure forces cause the poppet to unseat, allowing oil to flow from ‘T’ to ‘P’.

18.8

Tigercat M724D Mulcher

Clamps with saw attachment ANTI-CAVITATION RELIEF VALVE ADJUSTING PROCEDURE For relief valve with adjusting screw

ANTI-CAVITATION RELIEF VALVE ADJUSTING PROCEDURE For relief valve with adjusting nut ADJUSTING NUT

•

JAMNUT

ADJUSTING SCREW

•

JAMNUT

• •

RELIEF VALVE 51055-2

RELIEF VALVE

WITH ADJUSTING NUT

51055-20

WITH ADJUSTING SCREW

1.

Loosen jamnut.

1.

Loosen jamnut.

2.

Turn adjusting nut to obtain desired pressure reading on gauge.

2.

Turn adjusting screw to obtain desired pressure reading on gauge.

3.

Lock jamnut against adjusting nut, making sure the adjusting nut does not turn.

3.

5.

Re-check relief setting.

Lock jamnut against relief valve body, making sure the adjusting screw does not turn.

5.

Re-check relief setting.

For complete step-by-step pressure setting procedures of circuits using these relief valves, refer to appropriate sections in THIS MANUAL.

For complete step-by-step pressure setting procedures of circuits using these relief valves, refer to appropriate sections in THIS MANUAL.

18.9

Tigercat M724D Mulcher

Clamps with saw attachment

18.10

Tigercat M724D Mulcher SECTION 19 - MULCH DEFLECTOR DOOR JANUARY 2004

CONTENTS - SECTION 19 BOOM LIFT LOCK ........................................................................................ 19.6 BOOM VALVE .............................................................................................. 19.2 CROSS SECTION OF SPOOL SECTION .................................................. 19.3 OPERATING DESCRIPTION ..................................................................... 19.3 RELIEF VALVES ............................. SEE SECTION 18 - CLAMPS WITH SAW CIRCUIT DESCRIPTION ................................................................................ 19.4 CIRCUIT DIAGRAM ....................................................................................... 19.5 CONTROL VALVES ...................................................................................... 19.2 PILOT LINE PRESSURES ............................ SEE SECTION 5 - PILOT SYSTEM PRESSURE SETTINGS ................................................................................ 19.6 SAFETY ....................................................................................................... 19.6 SPOOL SECTION DIAGRAM ........................................................................ 19.3

Tigercat M724D Mulcher CONTROL VALVES

Mulch deflector door BOOM VALVE

The mulch deflector door circuit is controlled by two solenoid operated pilot valves in the pilot manifold (mulch deflector door) and a pilot operated boom valve.

The boom valve is located on the front chassis above the front axle and behind the cover plate.

One of the four spool sections is used to open and close the mulch deflector door.

NOTE: The clamp section of the boom valve is not used for mulcher applications. For machines which have been converted to feller buncher configuration refer to CLAMPS WITH SAW SECTION 18 of THIS MANUAL. For more information and instructions about converting a mulcher to a feller buncher refer to CONVERTING MULCHER TO FELLER BUNCHER CONFIGURATION in SECTION 3 of THIS MANUAL.

The inlet section receives oil from the fixed displacement boom pump.

For a complete description of the pilot manifold refer to SECTION 5 of THIS MANUAL.

All four spools in the valve are open center type.

Each spool section is pilot operated. An outlet section directs return oil back to tank.

Cartridge type port relief valves are installed in both work ports in the mulch deflector door spool section. The inlet section has a single main relief valve. These reliefs protect the circuits (pumps) from high pressures during operation.

For a complete description of the foot operated pilot valve, refer to FOOT CONTROL VALVE in SECTION 8 of THIS MANUAL.

CLAMP ARM SECTION NOT USED FOR MULCHER APPLICATION

TILT • MULCH DEFLECTOR DOOR 'CLOSE' PORT RELIEF (1000 PSI)

•

CLAMP ARM

ACCUMULATOR ARM/ MULCH DEFLECTOR DOOR

MULCH DEFLECTOR DOOR 'OPEN' PORT RELIEF (1000 PSI)

•

LIFT BOOM INLET GAUGE TEST PORT

•

•

•

MAIN RELIEF (2600 PSI)

INLET SECTION

M724D-02

BOOM CONTROL VALVE - MULCHER ATTACHMENT

19.2

Tigercat M724D Mulcher

Mulch deflector door

OPERATING DESCRIPTION

Shifting the spool(s) directs oil from the fixed displacement Boom/Steer Pump to the mulch deflector door cylinder.

Oil from the fixed displacement boom/steer pump enters the inlet section of the boom valve and is allowed to pass through the four open center spool sections and back to tank via the outlet section.

The relief valves installed in the inlet and spool sections of the boom valve protect the pump in case of failure of the POR valve on the pump.

The open centered spools in all of the sections have three positions and are self centering. A spring in the spool end cap holds the spool in the center neutral position.

All of the relief valves on the boom valve divert oil to tank via the tank passages in the spool sections and the outlet section of the boom valve.

They also function as anti-cavitation relief valves.

The spools are shifted one way or the other by pilot oil pressure being applied to either end of the spool.

RELIEF VALVE PORT 'A'

PARALLEL PASSAGE

LOAD CHECK VALVE

A

WORK PORT BRIDGE

RELIEF VALVE PORT 'B'

B

PILOT END CAP

PILOT END CAP SPOOL CENTERING SPRING

SPOOL TANK PASSAGE THRU' NEUTRAL PASSAGE

90136-3

CROSS SECTION OF SPOOL SECTION

19.3

Tigercat M724D Mulcher CIRCUIT DESCRIPTION

Mulch deflector door

The mulch deflector door is operated by a cylinder.

A fixed displacement pump supplies oil to the cylinder via the mulch deflector door spool section in the boom valve.

The mulch deflector door is operated by a 3 position thumb switch OPEN/CLOSE (self centering to OFF) located on the right joystick control. The switch operates two solenoid pilot valves on the pilot manifold which direct pilot oil to the mulch deflector door spool section of the boom control valve, to shift the spool. The spool directs oil from the pump to either end of the mulch deflector door cylinder to open or close the mulch deflector door. Return oil is directed back to tank via the oil cooler and dual head primary return oil filter.

19.4

Tigercat M724D Mulcher

Mulch deflector door

MULCH DEFLECTOR DOOR CIRCUIT m724d-25

19.5

Tigercat M724D Mulcher PRESSURE SETTINGS MULCH DEFLECTOR DOOR

Mulch deflector door WARNING

NOTE: Refer to RELIEF VALVE ADJUSTING PROCEDURE in SECTION 18 of THIS MANUAL.

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

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

• Wear safety glasses and safety shoes when working on shears.

• Keep mulch deflector door closed whenever possible during setup.

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

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

NOTE: This procedure assumes that a Fecon BH250 mulching head is used. Refer to illustration of BOOM CONTROL VALVE on page 2 for orientation and pressure value references .

1. Park machine on level ground. Completely raise lift boom and install lift boom cylinder lock over one of the two cylinder rods with the open side at the bottom and wide end up against the keeper plate bolt heads. Install retaining bolt and locknut through center hole. Slowly lower boom until lock is securely held in place.

TO SET MULCH DEFLECTOR DOOR OPEN AND CLOSE RELIEF VALVES:3. Connect a 0 - 5000 psi pressure gauge (with at least 4' of hose) to the inlet test port on of the boom control valve.

4. Turn the boom inlet main relief adjusting screw all the way IN. 5. Turn the port relief valve adjusting screws on the mulch deflector door spool section of the control valve OUT until spring pressure is relieved then turn adjusting screws one full turn IN. 6. Start the engine, and put the throttle control to the IDLE position.

7. Ensure that the hydraulic oil temperature is between 120°F - 140°F.

IMPORTANT During the following procedures, DO NOT hold ANY function control for LONGER THAN 5 SECONDS.

WARNING

IMPORTANT Avoid blowing oil over relief longer than 5 seconds, as excessive heating of hydraulic fluid and damage to boom pump can occur.

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

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

IMPORTANT Approach the gauge reading slowly and deliberately by turning the adjusting screw in a little at a time. The pressure setting must not exceed the above value.

2. Set parking brake ON. Install articulation lock bar, block wheels and stop engine.

WARNING To prevent injury caused by accidental steering of the machine when setting pressures, make sure the articulation lock bar is held securely in place by the lynch pins provided.

19.6

Tigercat M724D Mulcher

Mulch deflector door

8. While holding the right joystick thumb switch to the left in the MULCH DOOR OPEN position (mulch deflector door cylinder fully retracted), check gauge pressure reading.

If less than 1000psi, stop engine and readjust mulch deflector door open port relief. Repeat above procedure until a gauge reading of 1000 psi is obtained.

9. While holding the right joystick thumb switch to the right in the MULCH DOOR CLOSE position (mulch deflector door cylinder fully extended), check gauge pressure reading.

If less than 1000 psi, stop engine and readjust mulch deflector door close port relief. Repeat above procedure until a gauge reading of 1000 psi is obtained.

10. Stop engine, unscrew inlet main relief adjusting screw 3 full turns.

11. Start engine and move the throttle control to the FULL position.

IMPORTANT Never run engine at full throttle with main relief turned all the way in.

12. While holding the joystick thumb switch in the MULCH DOOR OPEN position, check gauge pressure reading.

If less than 2600 psi, stop engine and readjust inlet main relief. Repeat above procedure until a gauge reading of 2600 psi is obtained.

13. Remove pressure gauge and wipe up any excess oil from test port area.

SET PILOT LINE PRESSURES: NOTE: Refer to SECTION 5 of THIS MANUAL.

19.7

Tigercat M724D Mulcher

Mulch deflector door

19.8