Tigercat M760 MULCHER SERVICE MANUAL - PDF DOWNLOAD

SERVICE MANUAL Tigercat M760 MULCHER ISSUE 2.0, OCTOBER, 2006

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 ......................................................................................................... 11 LIFT BOOM ........................................................................................................ 12 TILT .................................................................................................................... 13 ATTACHMENT DRIVE ....................................................................................... 17 MULCHER DEFLECTOR DOOR ....................................................................... 19

M760SM00

M760 Available Literature Operator's Manual ................................................. Part No. 14673A Service Manual (This Manual) .............................. Part No. 14674A Parts Catalog ......................................................... Part No. 14672A

Tigercat

®

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

Tigercat M760 MULCHER

Introduction

ii

Tigercat M760 Mulcher Tigercat M760 MULCHER

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 M760 Mulcher serial number 760M0101 and up.

The operator's manual will assist the operator with the techniques of proper and safe operation of the M760 Mulcher. There is also important information regarding the safe operation of the saw head. 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.

M760-023

iii

Tigercat M760 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 M760 MULCHER

Introduction

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

IT IS Tigercat POLICY THAT NO CHANGES ARE TO BE MADE TO ITS PRODUCTS INCLUDING DELETIONS OR ADDITIONS OTHER THAN A Tigercat APPROVED OPTION FITTED IN THE FACTORY APPROVED MANNER. Official approval to make changes or install options is only to be undertaken as follows: i) The relevant options for that product must be shown or listed on current Tigercat documentation or literature such as a printed specification sheet, price list, parts manual, or product literature issued by Tigercat. ii) Approved options or product changes authorized in writing by the Tigercat Engineering Manager.

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

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

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

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

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

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

Tigercat Industries Inc.

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Tigercat M760 MULCHER

Introduction

vi

Tigercat M760 Mulcher SECTION 1 - SAFETY OCTOBER, 2006

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 .......................................................................... 1.14 BOOM LIFT LOCK ........................................................................................ 1.14 CAB EXITS ..................................................................................................... 1.9 EMERGENCY CAB EXITS .............................................................................. 1.9 ENGINE ACCESS PANELS ......................................................................... 1.12 FIRE PREVENTION ...................................................................................... 1.16 FIRE PREVENTION GUIDELINES ............................................................. 1.16 WHAT ELSE TO DO BEFORE YOU EXPERIENCE A FIRE ...................... 1.17 WHAT TO DO AFTER A FIRE ................................................................... 1.18 WHAT TO DO IN CASE OF A MACHINE FIRE .......................................... 1.17 HAZARD ZONE .............................................................................................. 1.3 MULCHING OPERATION SAFETY ............................................................... 1.10 PARKING THE MACHINE ............................................................................... 1.8 SAFETY INTERLOCK SWITCHES ON CAB DOORS ..................................... 1.9 SAFETY PRECAUTIONS, GENERAL ............................................................ 1.2 SAFETY PRECAUTIONS, OPERATING ......................................................... 1.6 SAFETY PRECAUTIONS, SERVICING ........................................................ 1.12 SAFETY SYMBOLS ....................................................................................... 1.2 SIGNAL WORDS ............................................................................................ 1.2

Tigercat M760 Mulcher

Safety

SAFETY SYMBOLS

GENERAL SAFETY PRECAUTIONS Remember that safety is a prime responsibility of all.

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

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

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

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

Understanding Signal Words

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

Follow all instructions from safety inspector and supervisors.

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

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

Do not let an untrained person operate the machine.

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

IMPORTANT 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.

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 M760 Mulcher

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

GENERAL SAFETY PRECAUTIONS continued

KEEP BACK 500 FEET

DANGER ROTATING CUTTER

DANGER

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

Thrown debris keep back 500 feet.

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

500 FEET

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

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

500 FEET

500 FEET

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

500 FEET

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

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

M724D-03

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

HAZARD ZONE

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

Do not use the machine foot controls as a step.

DANGER Danger caused by flying debris.

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

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

1.3

Tigercat M760 Mulcher

Safety

GENERAL SAFETY PRECAUTIONS continued Avoid mounting or dismounting the machine in areas with slippery surfaces. If this is not possible clean up or cover slippery surfaces with a nonslip material.

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

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

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

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

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

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

•

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

•

If these are found, Do Not Touch!!!

•

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

•

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

•

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

Machine should be washed completely before and after every major service.

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

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

Check windows and door guards for damage.

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

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

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

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

Check all fluid levels.

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

1.4

Tigercat M760 Mulcher

Safety WARNING WARNING

GENERAL SAFETY PRECAUTIONS continued

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.

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

Approach with extreme caution any area where overhanging electrical power lines are present.

Serious injury or death by electrocution can result if the machine or any of its attachments are not kept a safe distance from these lines.

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

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

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

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

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

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

Read, understand and follow all general safety precautions specified by attachment manufacturer.

1.5

Tigercat M760 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 this manual. Refer to OPERATING MACHINE in SECTION 2 of the OPERATOR'S MANUAL. Before moving the machine to the work site, check to ensure that all doors, panels, and access covers are installed properly and secured.

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

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

Secure loose items in the cab.

1.6

Tigercat M760 Mulcher

Safety

OPERATING SAFETY PRECAUTIONS continued

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

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

NEVER travel across a STEEP slope or side hill:

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

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

•

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

•

Serious injury or death could result from crushing.

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

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

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

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

Use only prearranged and approved signalling practices.

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

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

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

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

1.7

•

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

•

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

Tigercat M760 Mulcher

Safety

OPERATING SAFETY PRECAUTIONS continued

1

•

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

•

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

ENGINE CONTROL MODULE (ECM)

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

•

When parking the machine: •

Park on level ground.

•

Do not park on a hillside or incline.

•

Lower attachment onto level ground.

•

Engage the parking brake.

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.

CAUTION

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.

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

•

Stop the engine and vent the hydraulic tank.

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

•

Release pilot system pressure by performing the following steps:

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

7501-0A

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

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.

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.

1.8

Tigercat M760 Mulcher

Safety SWITCH

OPERATING SAFETY PRECAUTIONS continued

•

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

•

CAB EXITS

ACTUATOR

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

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

INTERLOCK SWITCH (L.H. DOOR SHOWN)

197-5

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

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

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

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

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

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

ALWAYS shut OFF engine before using the escape hatch exit.

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

To operate:

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

Close both doors and press the PILOT RESET switch.

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

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

Once the safety interlock system has been activated, the safety of both the operator and all persons outside the cab becomes the responsibility of the operator.

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

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

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

1.9

Tigercat M760 Mulcher OPERATING SAFETY PRECAUTIONS continued MULCHING OPERATION SAFETY 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.

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

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

Replace all worn cutter tools.

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.

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

FRONT DANGER ZONE

•• 726M-026

REAR DANGER ZONE

•• DANGER ZONES

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

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

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.

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.

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

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

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

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

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

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

•

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

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

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

DO NOT operate without guards.

1.10

Tigercat M760 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 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.

Inspect the rotor for clinging strands often.

1.11

Tigercat M760 Mulcher

Safety

SERVICING SAFETY PRECAUTIONS

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

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

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

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

This machine is equipped with a reversible cooling fan to facilitate cleaning of the charge air cooler, radiator and oil cooler assembly. Exercise care when working in this area with the engine running. If the fan switch in the cab is in the AUTO position, the fan could turn ON and/or go into REVERSE mode without warning.

Prior to welding on any part of the machine, it should be cleaned and a fire extinguisher should be made available at the welding location. Care must be taken in attaching the welding machine grounding clamp so electrical current does not pass through bearings, especially the center joint bearing.

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

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

L.H. SIDE ACCESS PANELS

•

HAND KNOB

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

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

•

• •

M760-025

L.H. ENGINE ACCESS PANELS

1.12

Tigercat M760 Mulcher

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

SERVICING SAFETY PRECAUTIONS continued WARNING

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

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

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

Never use bare hand to check for fluid leaks.

Fluid leaks under pressure may not be visible.

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

Pressure can be maintained in a hydraulic system long after the power source and pump have been shut down. Lower the attachment to the ground, stop engine and relieve trapped pressure from pilot system and brake accumulators before performing work on components, or disconnecting any hoses.

For the procedure on how to RELIEVE PRESSURE, refer to PARKING THE MACHINE in THIS SECTION.

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

1.13

Tigercat M760 Mulcher

Safety

SERVICING SAFETY PRECAUTIONS continued

WARNING

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

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

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

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

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

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

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.

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

WARNING Always allow the cutter blade to come to a COMPLETE STOP before approaching attachment to make adjustments.

1.14

Tigercat M760 Mulcher

Safety

SERVICING SAFETY PRECAUTIONS continued

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

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

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

Dispose of fluids properly.

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

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

1.15

Tigercat M760 Mulcher

FIRE PREVENTION

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

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

The following guidelines will help to keep your equipment up and running efficiently and keep the risk of fire 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. Inspect the EXHAUST SYSTEM DAILY for any signs of LEAKAGE. Check for worn, cracked, broken, or damaged pipes or muffler. Also check for missing or damaged bolts or clamps. Should any exhaust leaks or defective parts be found, repairs must be made immediately. Engine exhaust leaks can cause fires, DO NOT OPERATE the machine until the exhaust leak is repaired.

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

Safety 5. 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. 6. 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 logging 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 can fall into other areas of the machine and thereby spread a fire.

7. 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.

8. 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.

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

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

11. 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.

1.16

Tigercat M760 Mulcher

Safety

FIRE PREVENTION continued 12. Shut down equipment immediately when a problem is suspected or smoke is detected.

•

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.

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

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

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

16. 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.

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

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

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

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

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

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

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.

•

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

*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.

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.

•

Activate the fire suppression system

•

Radio or call for help (as appropriate).

•

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

•

If you can safely do so, turn OFF battery disconnect switch.

•

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.

*

*

Continued on page 16

1.17

Tigercat M760 Mulcher

Safety •

FIRE PREVENTION continued

*

Continued from page 15

•

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.

Use the PASS method with most extinguishers.

• •

•

•

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

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.

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

•

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

•

Ensure that the machine and all components have cooled down sufficiently after a fire has occurred. Beware of the possibility of coolant or hydraulic hoses rupturing after a fire spraying hot oil or coolant which may result in severe burns.

WHAT TO DO AFTER A FIRE •

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.

*

*NOTE: Dry chemical fire suppression 20229A

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.

TYPICAL 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.

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.

7

using high speed disc saws safely Comments and Instructions cont.

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

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

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

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using high speed disc saws safely

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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

11

using high speed disc saws safely Comments and Instructions cont.

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

UNCUT TREE OR STUMP BACKUP THROW ENGAGEMENT DISTANCE

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

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

FELLING HEAD MOVING INTO LOG

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

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

FELLING HEAD MOVING INTO STUMP (FEED SPEED)

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

12

using high speed disc saws safely Comments and Instructions cont.

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

THROW GAP

FIGURE 12: SAW BLADE THROW GAP

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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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using high speed disc saws safely

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Tigercat M760 Mulcher SECTION 3 - LUBRICATION & MAINTENANCE OCTOBER, 2006

CONTENTS - SECTION 3 AIR CONDITIONING SYSTEM, CHECKING ....... 3.16 APPROVED HYDRAULIC OILS ............................ 3.7 BELT, ENGINE SERPENTINE, REPLACING ..... 3.21 CENTER JOINT LUBRICATION ................................................ 3.17 MAINTENANCE .............................................. 3.17

NEW MACHINE MAINTENANCE FIRST 8 HOURS ............................................... 3.3 FIRST 125 HOURS:~ ........................................ 3.3 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

DRIVE SHAFT SPLINE LUBRICATION, MIDDLE AND REAR ................................................................. 3.22 ELECTRICAL SCHEMATIC SHEET 1 OF 6 ................................................ 3.27 SHEET 2 OF 6 ................................................ 3.28 SHEET 3 OF 6 ................................................ 3.29 SHEET 4 OF 6 ................................................ 3.30 SHEET 5 OF 6 ................................................ 3.31 SHEET 6 OF 6 ................................................ 3.32 EMERGENCY EXITS, CHECK MONTHLY ........... 3.3 ENGINE MAINTENANCE CHART ...................... 3.10 ENGINE SERPENTINE BELT, REPLACING ...... 3.21 FILTERS CHARGE PUMP PRESSURE FILTER ........... 3.12 FUEL FILTER/WATER SEPARATOR ............. 3.11 FUEL TANK STRAINER .................................. 3.11 HYDRAULIC OIL RETURN FILTERS .............. 3.13 SERVICING GUIDELINES OIL FILTERS ................................................ 3.13 FIRE PREVENTION ............................................. 3.3 HYDRAULIC OILS, APPROVED ........................... 3.7 LUBRICATION AND SERVICE POINTS CHART .. 3.9 MACHINE START-UP ......................................... 3.19

PRESSURE/SPEED SETTINGS ........................ 3.33 PRESSURIZED WATER SYSTEM MAINTENANCE .............................................. 3.14 REPLACING ENGINE SERPENTINE BELT ....... 3.21 SCHEDULED MAINTENANCE GENERAL ......................................................... 3.3 8 HOURS .......................................................... 3.4 40 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 SPEED CONTROL LEVER ADJUSTMENT ........ 3.24 START-UP .......................................................... 3.19 STARTUP PROCEDURE AFTER MAINTENANCE .................................. 3.18 TORQUE CHART ................................................ 3.25 TORQUE, FLUID CONNECTIONS ............ 3.34, 3.37 TORQUE SPECIFICATIONS - GENERAL .......... 3.26 TRANSMISSION ................................................ 3.17 CHECK OIL LEVEL ......................................... 3.17 WHEELS, INSTALLING ........................................ 3.2

Tigercat M760 Mulcher

Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE 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.

IMPORTANT!

THE FIRST 100 HOURS:~

Wheels: REPLACE:~

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.

• OIL IN PUMP DRIVE GEARBOX • OIL IN TRANSMISSION • HYD. OIL CHARGE FILTER † :FAN DRIVE (1); TRAVEL (1); CUTTER (1)

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

• HYD. OIL RETURN FILTER †, DOUBLE ELEMENT BOOM/STEER, PILOT SYSTEM

Hour meter ~ maintenance: Check the machine hour meter on a regular basis to determine your scheduled maintenance times.

• HYD. OIL RETURN FILTER †, DOUBLE ELEMENT CASE DRAIN FOR FAN, TRAVEL AND CUTTER

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

• HYD. OIL FILTER †, LOW PRESSURE RETURN

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

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

Tightening points:~ All hydraulic connections Hose clamps

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

Center joint pin securing bolts Transmission securing bolts Engine mounting bolts Pump drive gearbox securing bolts

*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

Axle mounting bolts

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

Wheel retaining bolts Cab securing bolts Pin retainers Any other loose nut, bolt or fitting

3.2

Tigercat M760 Mulcher

Lubrication and Maintenance

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

Clean around filler caps before checking or adding fluids.

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

Plug or cap immediately.

Clean up spills as soon as possible.

Always use clean hydraulic oil and filters.

Drain dirty oil while still warm.

Do not exceed recommended fluid levels.

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

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

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

Inspect the EXHAUST SYSTEM DAILY for any signs of LEAKAGE. Check for worn, cracked, broken, or damaged pipes or muffler.

Also check for missing or damaged bolts or clamps. Should any exhaust leaks or defective parts be found, repairs must be made immediately. Engine exhaust leaks can cause fires, DO NOT OPERATE the machine until the exhaust leak is repaired.

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

Before welding on machine be sure master switch is disconnected and disconnect multi pin connectors on engine CPU and engine wiring harness.

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

Clean away all branches, bark and chips.

Clean up all traces of oil to avoid fires.

Always have a fire extinguisher at hand.

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

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

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.

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

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

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

3. If equipped, read the fire suppression system manual and have the system serviced regularly by qualified personnel.

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

Also refer to FIRE PREVENTION in SECTION 1 of THIS MANUAL for additional information.

3.3

Tigercat M760 Mulcher

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 8 HOURS (EVERY SHIFT):~

EVERY 40 HOURS:~

• CHECK ENGINE OIL LEVEL

• PERFORM 8 HOUR MAINTENANCE

• DRAIN FUEL/WATER SEPARATOR

AND IN ADDITION:~

• CHECK HYDRAULIC OIL LEVEL

• CHECK 1ST STAGE AIR INTAKE, EMPTY DUST CUP AND CHECK TUBES

• CHECK PUMP DRIVE GEARBOX OIL LEVEL WITH DIPSTICK

• DRAIN COMPRESSED AIR TANK

• CHECK TRANSMISSION OIL LEVEL AT DIPSTICK • LUBRICATE TILT AND LIFT CYLINDER ENDS, 8-FITTINGS, PURGE • LUBRICATE LIFT BOOM AND TILT LINKAGE, 9-FITTINGS, PURGE

• LUBRICATE AXLES ~ OUTER BEARINGS 1 FITTING, 4-PLACES, ONE SHOT, HAND GREASE GUN ONLY • LUBRICATE MID DRIVE SHAFT SLIP JOINT* 1-FITTING, *NOTE: LUBRICATE MID DRIVE SHAFT SLIP JOINT WITH MACHINE ARTICULATED

• LUBRICATE CUTTER DRIVE SHAFT BEARINGS. CLEAN:~

• LUBRICATE FRONT DRIVE SHAFT SUPPORT BEARING, 1-FITTING, PURGE

• AIR CONDITIONER CONDENSOR, OIL COOLER, CHARGE AIR COOLER AND RADIATOR BY REVERSING AIR FLOW

• LUBRICATE CENTER JOINT BEARINGS, 2-FITTINGS, PURGE

CHECK:~

• LUBRICATE STEERING CYLINDER ENDS, 4-FITTINGS, PURGE

• FOR LEAKAGE AROUND HYDRAULIC COMPONENTS AND FLEXIBLE HOSES

______________________________________________

• EXHAUST SYSTEM FOR LEAKS. • FOR LOOSE NUTS, BOLTS AND FITTINGS • IF THE WATER SYSTEM HAS BEEN OPERATED, REFER TO PRESSURIZED WATER SYSTEM MAINTENANCE IN THIS SECTION FOR REFILLING AND CHARGING INSTRUCTIONS. • CONDITION AND TENSION OF ACCESSORY DRIVE BELT (FAN BELT).

• CONDUCT AN OVERALL VISUAL INSPECTION. REFER TO DIESEL ENGINE SERVICE MANUAL FOR ADDITIONAL REQUIRED MAINTENANCE AT THIS SCHEDULED TIME PERIOD. ______________________________________________

3.4

Tigercat M760 Mulcher

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 125 HOURS:~

EVERY 250 HOURS:~

• PERFORM 8 HOUR MAINTENANCE

• PERFORM 8 HOUR MAINTENANCE

• PERFORM 40 HOUR MAINTENANCE

• PERFORM 40 HOUR MAINTENANCE

AND IN ADDITION:~

• PERFORM 125 HOUR MAINTENANCE

• LUBRICATE REAR AXLE PIVOT, 2-FITTINGS, PURGE

AND IN ADDITION REPLACE:~

• LUBRICATE REAR DRIVE SHAFT SLIP JOINT 1-FITTING, PURGE

• OIL IN TRANSMISSION

• ENGINE OIL AND CHANGE OIL FILTER

• OIL IN CUTTER GEARBOX

CHECK:-

• CHECK FUEL TANK FILLER SCREEN

• FLUID LEVEL IN BATTERIES UNLESS MAINTENANCE FREE

• ENGINE FUEL FILTER*

• ENGINE COOLANT LEVEL

• FUEL/WATER SEPARATOR FILTER*

• 2ND STAGE AIR INTAKE PRIMARY FILTER

• 2 ND AIR INTAKE PRIMARY FILTER

• ENGINE R.P.M.

• DESSICANT CARTRIDGE IN COMPRESSOR AIR DRYER (FREQUENT USE) ‡

• CASE DRAIN HYDRAULIC OIL FILTER

‡ SEE 500 HRS IF USED INFREQUENTLY

• HYDRAULIC PUMP AND MOTOR SECURING BOLTS

CHECK:-

• TORQUE TIGHTENING POINTS AS PER NEW MACHINE MAINTENANCE

• AIR INTAKE PRECLEANER, CLEAN AS REQUIRED

VISUALLY CHECK FOR DAMAGE TO:-

• CHECK ENGINE AIR FILTER RESTRICTION INDICATOR

• LIFT BOOM AND TILT LINKAGE

*REFER TO DIESEL ENGINE SERVICE MANUAL FOR ADDITIONAL REQUIRED MAINTENANCE AT THIS SCHEDULED TIME PERIOD.

• FRONT AND REAR FRAME • CENTER JOINT AREA

______________________________________________

• ATTACHMENT MAKE REPAIRS IMMEDIATELY VISUALLY INSPECT FOR:• FRAYED ELECTRICAL WIRING AND HYDRAULIC HOSE • WEAR IN ANY OTHER COMPONENTS CLEAN/REPLACE:• AIR CONDITIONER RE-CIRCULATION FILTER • CAB FRESH AIR FILTER REFER TO DIESEL ENGINE SERVICE MANUAL FOR ADDITIONAL REQUIRED MAINTENANCE AT THIS SCHEDULED TIME PERIOD. ______________________________________________

3.5

Tigercat M760 Mulcher

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 500 HOURS:~

EVERY 1000 HOURS:~

• PERFORM 8 HOUR MAINTENANCE • PERFORM 40 HOUR MAINTENANCE

• PERFORM 8 HOUR MAINTENANCE

• PERFORM 125 HOUR MAINTENANCE

• PERFORM 40 HOUR MAINTENANCE

• PERFORM 250 HOUR MAINTENANCE

• PERFORM 125 HOUR MAINTENANCE

AND IN ADDITION REPLACE:~

• PERFORM 250 HOUR MAINTENANCE

• 2 ND STAGE AIR INTAKE SAFETY FILTER

• PERFORM 500 HOUR MAINTENANCE

• HYD. OIL CHARGE PUMP FILTER † :FAN DRIVE (1); TRAVEL (1); CUTTER (1)

AND IN ADDITION REPLACE :~

• HYD. OIL RETURN FILTER † , DOUBLE ELEMENT BOOM/STEER, PILOT SYSTEM

• OIL IN AXLES, FRONT AND REAR

• HYD. OIL RETURN FILTER †, DOUBLE ELEMENT CASE DRAIN FOR FAN, TRAVEL AND CUTTER

• STRAINER IN ACCUMULATOR CHARGE VALVE

• OIL IN PUMP DRIVE GEARBOX

• OIL IN HYDRAULIC RESERVOIR

• DESSICANT CARTRIDGE IN COMPRESSOR AIR DRYER (INFREQUENT USE) ‡

CHECK:~ • CENTER JOINT PIVOT • INTAKE FUEL STRAINER, DRAIN TANK, CLEAN OR REPLACE AS NECESSARY

‡ SEE 250 HRS IF USED FREQUENTLY

REFER TO DIESEL ENGINE SERVICE MANUAL FOR ADDITIONAL REQUIRED MAINTENANCE AT THIS SCHEDULED TIME PERIOD.

CHECK:~ • ALL HYDRAULIC PRESSURES

______________________________________________

• TRANSMISSION MOUNTING; CHECK, RE-TORQUE

EVERY 2000 HOURS:~

• PARKING BRAKE, LUBE AS REQUIRED WITH WD40.

REFER TO DIESEL ENGINE SERVICE MANUAL FOR ADDITIONAL REQUIRED MAINTENANCE AT THIS SCHEDULED TIME PERIOD. ______________________________________________

• PERFORM 8 HOUR MAINTENANCE • PERFORM 40 HOUR MAINTENANCE • PERFORM 125 HOUR MAINTENANCE • PERFORM 250 HOUR MAINTENANCE • PERFORM 500 HOUR MAINTENANCE • PERFORM 1000 HOUR MAINTENANCE AND IN ADDITION REPLACE:~ • ENGINE COOLANT* *REFER TO DIESEL ENGINE SERVICE MANUAL FOR ADDITIONAL REQUIRED MAINTENANCE AT THIS SCHEDULED TIME PERIOD. ______________________________________________

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

3.6

Tigercat M760 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" Note: The use of ALL WEATHER Synthetic oils need not be drained and refilled. ______________________________________________

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 THE 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 THE APPROPRIATE HYDRAULIC OILS LISTED BELOW .

IMPORTANT! DO NOT MIX SYNTHETIC OILS AND MINERAL OILS TOGETHER. USE ONE OF THE FOLLOWING RECOMMENDED MINERAL HYDRAULIC OILS

HYDRAULIC OIL THE FLUID USED TO FILL OR REPLENISH THE HYDRAULIC SYSTEM OF THIS MACHINE MUST MEET JOHN DEERE SPECIFICATIONS TYPE J20C (SUMMER) OR J20D (WINTER).

THE FOLLOWING ARE APPROVED BY Tigercat FOR USE IN THIS MACHINE:

®

CHEVRON CITGO IMPERIAL/ESSO SHELL SUN JOHN DEERE

TRACTOR HYDRAULIC FLUID (SUMMER) TRACTOR HYDRAULIC FLUID (33-310) (SUMMER) HYDRAUL 56 (SUMMER) HYDRAUL 50 (LOW VISC) WINTER) DONAX TD (SUMMER) DONAX TDL (WINTER) SUNFLEET TH FLUID (SUMMER) TYPE J20C (HYGARD) (SUMMER) 11514A R1 TYPE J20D (HYGARD) WlNTER)

USE THE FOLLOWING RECOMMENDED SYNTHETIC HYDRAULIC OIL

CHEVRON...........ALL WEATHER TRACTOR HYDRAULIC FLUID

3.7

Tigercat M760 Mulcher

Lubrication and Maintenance

3.8

LUBRICATION AND SERVICE POINTS

Tigercat M760 Mulcher

Lubrication and Maintenance Tigercat® Model M760 SERVICE AND LUBRICATION POINTS

REFER TO Tigercat OPERATOR'S MANUAL FOR FURTHER INFORMATION

1

COOLING SYSTEM

2

COOLING FAN

3

CENTER JOINT PIVOT

4

ENGINE OIL AND FILTER

5

FUEL FILTER

6

FUEL WATER SEPARATOR

7 8

FUEL CAP SCREEN

9

AIR INTAKE PRECLEANER

CHK

32

8.5

34

9

QTY

USG

LITERS

2000

CAPACITY

D/R

LUB

CHK

CHK

REP REP

2

CHECK MOTION BETWEEN CHASSIS LUGS

1

SEE ENGINE MANUFACTURER'S MAINTENANCE MANUAL

1

DRN

1 CHK CHK

1

CLEAN OR REPLACE AS NECESSARY

1

DRAIN TANK, CLEAN OR REPLACE AS NECESSARY

CHK

10 1ST STAGE AIR INTAKE

DESCRIPTION

MIXTURE; 40% DISTILLED WATER, 60% ANTIFREEZE (GM 6035M SPEC.) REFER TO ENGINE MANUAL FOR RECOMMENDED ADDITIVE CLEAN COOLING CORES BY

BY REVERSING AIR FLOW

CHK

INTAKE FUEL STRAINER

11 2 ND STAGE AIR INTAKE PRIMARY FILTER 12 2 ND STAGE AIR INTAKE SAFETY FILTER 13 HYDRAULIC OIL FILTER BOOM/STEER/PILOT 14 HYDRAULIC OIL FILTER CASE DRAIN

1000

500

250

125

40

SERVICE EVERY

8

125

SERVICE POINT NO.

FIRST ITEM

CHECK FOR BLOCKAGE BY LARGE DEBRIS

CHK

REP

1

REP † REP †

2

REMOVE DUST CUP AND EMPTY CHECK TUBES FOR BLOCKAGE CHECK RESTRICTION INDICATOR ON INTAKE PIPE AT FULL ENGINE RPM CHECK FILTER CONDITION INDICATOR AT SAFETY ELEMENT WITH ENGINE OFF DOUBLE FILTER ELEMENT

2

DOUBLE FILTER ELEMENT

CHK REP

REP † REP †

CHK

1

15 HYDRAULIC OIL FILTER CHARGE PRESSURE: DRIVE, CUTTER, FAN 16 HYDRAULIC OIL FILTER LOW PRESSURE RETURN

REP †

REP †

3

3-SINGLE ELEMENT FILTERS

REP †

REP †

1

SINGLE FILTER ELEMENT

17 PUMP DRIVE GEARBOX

D/R

CHK

18 TRANSMISSION

D/R

CHK

D/R D/R

7.3

1.9

5.7

1.5

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 SEE MULCHER MANUFACTURERS MAINTENANCE MANUAL FOR SERVICE INFORMATION

19 MULCHER HEAD

20 AXLES:

FRONT REAR

21 HYDRAULIC RESERVOIR ‡

D/R D/R CHK

D/R 340

22 PARKING BRAKE

23 ACCUMULATOR CHARGE VALVE STRAINER 24 A/C & HEATER FILTERS 25 COMPRESSED AIR TANK DRAIN 26 COMPRESSED AIR DRYER

53 14.2 31 8.2

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

90

‡ TIGERCAT RECOMMENDS REGULAR FLUID SAMPLING TO DETERMINE OIL AND COMPONENT CONDITION REFER TO SECTION 2 OF OPERATOR'S MANUAL. APPLY WD-40 TO BOTH SIDES OF SLIDE AND CLEVIS PIN ON HANDLE.

CHK LUB REP CHK DRN

*

*

REP REP 760M LUBECHART.XLS

3.9

1 CLEAN OR REPLACE AS NECESSARY PULL DRAIN VALVE CABLE TO PURGE WATER REPLACE DESSICANT CARTRIDGE:* OCCASIONAL USE, EVERY 500 HRS * FREQUENT USE, EVERY 250 HRS

Tigercat M760 Mulcher

Lubrication and Maintenance

CATERPILLAR 3176/3196 INDUSTRIAL DIESEL ENGINE MAINTENANCE INFORMATION CONSULT OPERATOR'S MANUAL FURTHER INFORMATION

3.10

Tigercat M760 Mulcher

Lubrication and Maintenance 11. Lubricate the gasket on top of the new filter with clean engine oil and prefill the filter with clean fuel.

FILTERS - REMOVE AND REPLACE

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.

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.

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

FUEL TANK STRAINER

FUEL FILTER/WATER SEPARATOR This 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.

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

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.

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

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.

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.

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

2. Drain the fuel tank. (plug in bottom)

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

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

Changing or cleaning the strainer:

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

Changing the filter:

7. Clean the water sediment bowl.

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.

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.

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

3.11

Tigercat M760 Mulcher

Lubrication and Maintenance

HYDROSTATIC CHARGE PUMP PRESSURE FILTER These single full flow filters, are mounted in the output side of the hydrostatic charge pumps for the Fan, Propel and Cutter drive systems. For service and replacement intervals see SERVICE AND LUBRICATION CHART in THIS SECTION.

RETURN FILTERS BOOM, STEER & PILOT

•• ••

Changing the filter:

•

••

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

RETURN FILTERS CASE DRAIN

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. Prefill the new filter with clean hydraulic oil and apply hydraulic oil to the gasket surface.

CHARGE PRESSURE FILTERS - DRIVE, CUTTER & FAN

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

M760-012

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

9. Start the engine and check for leaks.

•• LOW PRESSURE RETURN FILTER

M760-013

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 M760 Mulcher

Lubrication and Maintenance

HYDRAULIC FILTER SERVICING GUIDELINES FOR M760 MULCHERS

HYDRAULIC OIL RETURN FILTERS There are four identical full return flow, spin-on filter elements mounted on dual filter heads with built-in differential pressure bypass valves. For service and replacement intervals see SERVICE AND LUBRICATION CHART in THIS SECTION. Changing the filters:

IMPORTANT

1. Park machine on level ground, install articulation lock pin, lower cutting head 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 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 Tigercat spin-on filter element is supplied with two gaskets enclosed. This machine uses the round section 'O' ring gasket for all four return filters. The square section gasket should be discarded.

FILTER HEAD

• • GASKET

• FILTR_SEALS 2

FILTER ELEMENT

'O' RING GASKET INSTALLATION

z 'O' Ring Gasket Remove used gasket and clean gasket seat in head.

Apply clean oil to new gasket surfaces.

Install new gasket on inside lip of filter.

Screw on new filter until gasket makes contact.

Tighten filter until top edge makes metal to metal contact with filter head. (approximately 1 1/2 additional turns after gasket contact) 7. Start the engine and check for leaks.

3.13

NEVER PRE-FILL ANY HYDRAULIC FILTERS ON M760 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.

Tigercat M760 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 de-pressurizing 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

••

••

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

•

726D-44

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.

•• PRESSURE GAUGE

196-9A

PRESSURIZED WATER SYSTEM

3. Close water shut off valve.

PRESSURIZED WATER SYSTEM

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

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.

SYSTEM TEST: 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.

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.

3.14

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

Tigercat M760 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.

3.15

Tigercat M760 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.

CAUTION

AIR CONDITIONING TOTAL SYSTEM VOLUME R134a Refrigerant

PAG Oil

2 LBS. 12 OZ.

7 OZ.

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.

• 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 and receiver drier are accessed from the left side engine compartment. The evaporator core is accessed on the left hand side of the machine.

CHECK A/C CONDENSER CORE

Use this checklist to maintain system between service intervals. a.

Check and adjust compressor drive belt tension.

b.

Check air intake filters and clean as required.

c.

Check the condenser core for dirt and debris.

Clean as required. Refer to CLEANING A/C CONDENSER AND COOLING ASSEMBLY in SECTION 2 of the OPERATOR'S MANUAL.

•

RECEIVER/ DRYER

•

d. Check the evaporator core and the inside of the A/C housing for dirt and debris. Clean as required.

760M-026

CHECK A/C CONDENSER CORE

e. Run air conditioning system for 3 - 5 minutes. f.

CAUTION

Check to see that compressor clutch will engage.

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 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.

3.16

Tigercat M760 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.

M760-017

CHECK TRANSMISSION OIL LEVEL

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

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

REAR CHASSIS

FRONT CHASSIS

CHECK FOR MOVEMENT IN THIS JOINT AREA

•

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 SECTION 11 of the SERVICE MANUAL for more information..

3.17

Tigercat M760 Mulcher

Lubrication and Maintenance

START-UP PROCEDURE AFTER MAJOR MACHINE MAINTENANCE This procedure should be followed: •

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.

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.

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

3.18

Tigercat M760 Mulcher

Lubrication and Maintenance

MACHINE START-UP

CAUTION

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

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

NOTE: When the attachment is attached, re-torque all teeth (See attachment manual).

INSTALL A 0-1000 PSI. GAUGE AT ‘M3’ PORT.

1. Ensure the articulation lock bar is installed.

••

DISCONNECT MULTI PIN CONNECTOR

••

DRIVE CHARGE PRESSURE SET AT 340-370 PSI @ 2100 RPM

••

•

DRIVE PUMP

M760-019

M760-018

DISCONNECT MULTI PIN CONNECTOR 2. Disconnect the engine multi pin connector (prevents engine starting).

5. Install a 0-1000 psi. gauge on drive pump to check charge pressure at ‘M3’ port. Watch gauge closely during startup.

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 260 and 450 psi., run engine at IDLE for 20 minutes.

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

4. Reconnect the multi pin connector. Do not start engine.

7. Remove pressure gauge from 'M3' port.

8. Install a 0 - 1000 psi. gauge on pilot manifold quick connect fitting. ("P2" on left side bulkhead )

P2

760-03

3.19

•

Tigercat M760 Mulcher

••

Lubrication and Maintenance STEER CIRCUIT MAIN RELIEF 2500 PSI.

PILOT PRESSURE RELIEF VALVE 675 PSI.

•

•

PILOT PRESSURE REDUCING VALVE 550 PSI.

726D-019

PILOT MANIFOLD

9. Turn pilot pressure reducing valve (far left end, top of pilot manifold) all the way IN until it is lightly seated.

M760-020

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

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

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 VALVE

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

16. Remove pressure gauge from steer relief valve.

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.

1

•

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.

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

760-03

13. Install a 0-5000 psi. gauge (1) on steer circuit main relief (quick connect fitting).

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.

3.20

Tigercat M760 Mulcher

Lubrication and Maintenance

IMPORTANT Without a mulching 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.

SERPENTINE BELT

•

CRANK, LINK AND BOOM ARMS

• CRANK ARM LINK ARM

••

BELT TENSIONER

••

M760-025

COVER PLATE REMOVED

3. Remove the cover plate to expose the belt and belt tensioner.

BOOM ARM

•

SERPENTINE BELT

192-21A

•

REPLACING THE ENGINE SERPENTINE BELT 1. Park the machine on level ground. Parking brake ON, attachment resting on the ground and engine off. Turn battery disconnect switch OFF.

• 1

••

••

BELT TENSIONER

2

M760-021

• ••

REMOVING SERPENTINE BELT

4. Install a Johnson bar with a 3/8" square drive in the square socket hole of the belt tensioner.

••

5. Loosen belt tensioner and remove the serpentine belt.

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

M760-0247

2. Remove the four bolts (1) mounting the cover plate (2) to the engine compartment.

3.21

Tigercat M760 Mulcher

Lubrication and Maintenance

MIDDLE AND REAR DRIVE SHAFT 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.

2

•• •

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

726M-008

1

MIDDLE SLIP SPLINE

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

Set parking brake ON. 2. Stop the engine.

3. Apply grease to grease nipple (1) until new, clean grease exits from the relief fitting (2).

1

• •

2

726M-011

Check to see if grease is exiting from the relief fitting (2). If grease does not exit from the relief fitting, remove the relief fitting and apply grease at the grease nipple. If grease flows out of relief fitting hole replace relief fitting.

If grease does not exit from the relief fitting hole, remove drive shaft and inspect for "hardened" grease build up, rust or other contaminants within the drive shaft. Repair or Replace drive shaft.

3.22

Tigercat M760 Mulcher

Lubrication and Maintenance GREASE GUN

• •

1

• 726M-012

726M-009

REAR SLIP SPLINE

REAR SLIP SPLINE LUBRICATION GREASE APPEARS AT RELIEF HOLE

4. Apply grease to grease nipple (1) until new, clean grease appears at the relief hole at yoke end of slip spline, FIG. 'C'.

720C-01

FIG. 'C' REAR DRIVE SHAFT YOKE END

5. Plug or cover relief hole and continue to apply pressure to grease nipple until new, clean grease appears at slip spline seal.

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.

3.23

Tigercat M760 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 require adjustment, during normal operation, to maintain the set position of the lever, especially at maximum throw.

FRICTION SETTING 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.

4.

Locate the adjustable friction set screw.

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.

M724D02

SPEED CONTROL LEVER

SPEED CONTROL LEVER

• PROTECTIVE RUBBER BOOT

•• ADJUSTABLE FRICTION SET SCREW

••

CONTROL PANEL

••

630B-31

3.24

SPEED CONTROL LEVER FRICTION SET SCREW LOCATION

Tigercat M760 Mulcher

Lubrication and Maintenance

TORQUE CHART LOCATION

Cylinders Pin bolts Piston nut, steer cyl.

Piston nut, boom/tilt cyl.

Gland, steer cyl.

Keeper plate bolts

THREAD DIAMETER

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 620 389-427

Cab securing bolts

3/4" UNC

282-310

393-420

Center joint bearing Bearing retaining bolts Pin retaining bolts

1/2" UNC 3/4" UNC

80-88 282-310

109-119 393-420

Engine mounting Front engine to bracket bolts Front engine bracket to frame Rear engine to bracket bolts Rear engine bracket to frame

M12-1.75 x 65 G 8.8 1" x 8 UNC G8 3/4" x 10 UNC G8 3/4" x 10 UNC G8

682-750 282-310 282-310

925-1016 393-420 393-420

Pump drive gearbox Drive plate to flywheel Bell housing to engine Gearbox to bracket

7/16" x 14 UNC G8 5/8" x 11 UNC G8

52-57 159-175

71-77 216-237

1 1/4" x 12 UNF 3/4" x 10 UNC 3/8" UNF 1/2" UNF

300-350 280-310 37-41 70-80

408-476 380-420 50-55 95-110

Axle mounting bolts Front Rear

7/8" UNC 3/4" UNC

455-501 282-310

617-679 393-420

Wheel bolts

7/8" UNF

500-550

679-745

5/8" x 11 UNC G8 7/8" UNC

159-175 500-550

216-237 679-745

Drive shafts Yoke retaining nut, front shaft Pillow block retaining bolts Universal joint bolts Universal joint bolts

Transmission housing to bracket Transmission bracket to frame

Torque values pertaining to the engine are provided in the appropriate manuals.

3.25

Tigercat M760 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 8 BOLTS

GRADE 5 BOLTS

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

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

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

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

METRIC

METRIC BOLT TORQUE SPECIFICATIONS 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

CLASS 10.9 LUBRICATED DRY Nm lbf-ft Nm lbf-ft

CLASS 12.9 LUBRICATED DRY Nm lbf-ft Nm lbf-ft

M6 M8 M10

4.8 12.0 23.0

3.5 8.5 17.0

6.0 15.0 29.0

4.5 11.0 21.0

9.0 22.0 43.0

6.5 16.0 32.0

11.0 28.0 55.0

8.5 20.0 40.0

13.0 32.0 63.0

9.5 24.0 47.0

17.0 40.0 80.0

12.0 30.0 60.0

15.0 37.0 75.0

11.5 28.0 55.0

19.0 47.0 95.0

14.5 35.0 70.0

M12 M14 M16

40.0 63.0 100.0

29.0 47.0 73.0

50.0 80.0 125.0

37.0 60.0 92.0

75.0 120.0 190.0

55.0 88.0 140.0

95.0 150.0 240.0

70.0 110.0 175.0

110.0 175.0 275.0

80.0 130.0 200.0

140.0 225.0 350.0

105.0 165.0 225.0

130.0 205.0 320.0

95.0 150.0 240.0

165.0 260.0 400.0

120.0 190.0 300.0

M18 M20 M22

135.0 190.0 260.0

100.0 140.0 190.0

175.0 240.0 330.0

125.0 180.0 250.0

260.0 375.0 510.0

195.0 275.0 375.0

330.0 475.0 650.0

250.0 350.0 475.0

375.0 530.0 725.0

275.0 400.0 540.0

475.0 675.0 925.0

350.0 500.0 675.0

440.0 625.0 850.0

325.0 560.0 460.0 800.0 625.0 1,075.0

410.0 580.0 800.0

M24 M27 M30

330.0 490.0 675.0

250.0 360.0 490.0

425.0 625.0 850.0

310.0 650.0 450.0 950.0 625.0 1,300.0

M33 900.0 M36 1,150.0

475.0 825.0 600.0 925.0 675.0 1,150.0 850.0 1,075.0 800.0 1,350.0 1,000.0 700.0 1,200.0 875.0 1,350.0 1,000.0 1,700.0 1,250.0 1,600.0 1,150.0 2,000.0 1,500.0 950.0 1,650.0 1,200.0 1,850.0 1,350.0 2,300.0 1,700.0 2,150.0 1,600.0 2,700.0 2,000.0

675.0 1,150.0 850.0 1,750.0 1,300.0 2,200.0 1,650.0 2,500.0 1,850.0 3,150.0 2,350.0 2,900.0 2,150.0 3,700.0 2,750.0 850.0 1,450.0 1,075.0 2,250.0 1,650.0 2,850.0 2,100.0 3,200.0 2,350.0 4,050.0 3,000.0 3,750.0 2,750.0 4,750.0 3,500.0

TORQUECHARTGENERAL.XLS

3.26

Tigercat M760 Mulcher

Lubrication and Maintenance

ELECTRICAL SCHEMATIC - SHEET 1 OF 6

M760-030.PLT 11834BR6

3.27

Tigercat M760 Mulcher

Lubrication and Maintenance

ELECTRICAL SCHEMATIC - SHEET 2 OF 6

M760-031.PLT 11834BR6

3.28

Tigercat M760 Mulcher

Lubrication and Maintenance

ELECTRICAL SCHEMATIC - SHEET 3 OF 6

M760-032.PLT 11834BR6

3.29

Tigercat M760 Mulcher

Lubrication and Maintenance

ELECTRICAL SCHEMATIC - SHEET 4 OF 6

M760-033.PLT 11834BR6

3.30

Tigercat M760 Mulcher

Lubrication and Maintenance

ELECTRICAL SCHEMATIC - SHEET 5 OF 6

M760-034.PLT 11834BR6

3.31

Tigercat M760 Mulcher

Lubrication and Maintenance

ELECTRICAL SCHEMATIC - SHEET 6 OF 6

M760-035.PLT 11834BR6

3.32

Tigercat M760 Mulcher

Lubrication and Maintenance Rev 2

July 2002

Pressure (PSI)

Engine RPM

Additional Info

675 550

1000 1000

PRESSURE / SPEED SETTINGS - M760 Row Ref. Location 1 2

Pilot Manifold (7875B) Pressure Relief Valve Pressure Reducing Valve

3 4 5 6

Travel Pump (AP116) Charge Pressure Relief Valve High Pressure Relief (B-Side) High Pressure Relief (A-Side) Pump P.O.R.

340(370) 5650(5700) 5650(5700) 5000(5050)

2100 2100 2100 2100

Travel Motor (AQ075) X 2 Pump P.O.R. Motor "X" Port, Reverse Foot Pedal Motor "X" Port, Forward Foot Pedal Motor P.O.R. (/w Forward Foot Pedal at 135 psi)

M1

4000(4025) 125 135 2000(2500)

2100 2100 2100 2100

Hold for 15 sec Hold for 15 sec both motors

Motor P.O.R. (/w Reverse Foot Pedal at 125 psi) Motor P.O.R. (/w Forward Foot Pedal at 135 psi)

M1 M1

800 or less 2000(2500) or less

2100 2100

both motors both motors

340(370) 340(370) 2000(2500) 5000(5050)

2100 2100 2100 2100

Hold for 15 sec Hold for 15 sec both motors

7 8 9 10 11 12 13 14 15 16 17 18

Motor "X" Port, Reverse Foot Pedal Motor "X" Port, Forward Foot Pedal Motor P.O.R. Pump P.O.R.

19 20 21 22

Fan Pump (AP086) Charge Pressure Pressure Relief High Pressure Relief Forward and Reverse Maximum Speed Forward (top displacement limiter) Maximum Speed Reverse (bottom displacement limiter)

295 4700 non-adjustable X=0.31 inches (8mm) X=0.27 inches (7mm)

1000 1000 2100 2100

23 24 25 26

Steer Circuit Steer Valve Main Relief (AU005) Steer Priority Valve (AT079) Steer Right Port Relief (AT078) Steer Left Port Relief (AT078)

2500 2355 3325 non-adjustable 3325 non-adjustable

2100 1000 1000 1000

27 28 29 30 31 32 33

Cutter Pump (AP085) Charge Pressure Relief Valve · P.O.R. Forward · P.O.R. Reverse · High Pressure Relief Forward · High Pressure Relief Reverse Hot Oil Flushing Valve (AU072) Accumulator, Low Pressure Side

350 5000 2500 5500 non-adjustable 3000 non-adjustable 320 225 nitrogen gas

1000 1000 1000 1000 1000 2100

34 35 36 37 38 39 40

Boom Valve (8737B) Main Relief Tilt In Port Relief Tilt Out Port Relief Mulch Deflector Door Open Port Relief Mulch Deflector Door Close Port Relief Boom Up Port Relief Boom Down Port Relief

2500 2900 2900 1000 1000 2900 2200

2100 1000 1000 1000 1000 1000 1000

M3 M2 M1

G

Important Notes: 1) All adjustments to be made with hydraulic oil temperature at 120°F - 140°F 2) Use Boom Lift Lock Support 4128A when working under boom 3) Use Steering Articulation Lock Bar 7067A when working on steering PressureSet.xl

3.33

1250 fan rpm 900 fan rpm

Tigercat M760 Mulcher

Lubrication and Maintenance

Assemb que Assemblly Tor orque

EATON Aeroquip Recommended Parallel Connection Assembly torque

Eaton recommends that a

The values listed are for

Torque wrench be used to

steel connections. Contact

assure proper fitting

Eaton Aeroquip for torques values for

assembly of these

other materials

connections.

Straight Thread O-Ring Boss Low Pressure with 37º (SAEJ514) Thread Size (inches) 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 3/16-12 1 5/16-12 1 5/8-12 1 7/8-12 2 1/2-12

Dash Size -03 -04 -05 -06 -08 -10 -12 -14 -16 -20 -24 -32

Straight Thread O-Ring Boss High Pressure with ORS (J1453)

Jam Nut or Jam Nut or Straight Straight Fitting Torque Fitting Torque lb.-ft.

Newton Meters 8-9 12-13 13-15 18-20 14-15 19-21 23-24 32-33 40-43 55-57 43-48 59-64 68-75 93-101 83-90 113-122 112-123 152-166 146-161 198-218 154-170 209-230 218-240 296-325

Dash Size -03 -04 -05 -06 -08 -10 -12 -14 -16 -20 -24

ORS

Dash Size -04 -06 -08 -10 -12 -16 -20 -24

Thread Size (inches) 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 3/16-12 1 5/16-12 1 5/8-12 1 7/8-12

Jam Nut or Jam Nut or Straight Straight Fitting Torque Fitting Torque lb.-ft.

Newton Meters 8-10 11-16 14-16 20-22 18-20 24-27 24-26 33-35 50-60 68-78 72-80 98-110 125-135 170-183 160-180 215-245 200-220 270-300 210-280 285-380 270-360 370-490

SAE 37º (JIC)

Thread Size (inches) 9/16-18 11/16-20 13/16-16 1-14 1 3/16-12 1 7/16-12 1 11/16-12 2-12

Swivel Nut Torque lb.-ft.

10-12 18-20 32-35 46-50 65-70 92-100 125-140 150-165

Swivel Nut Torque Newton Meters 14-16 24-27 43-47 62-68 88-95 125-136 170-190 204-224

Dash Size -04 -05 -06 -08 -10 -12 -16 -20 -24 -32

Metric Thread Size mm M10x1 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M20x1.5 M22x1.5 M26x1.5 M27x2 M33x2 M42x2 M48x2

Thread Size (inches) 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 5/16-12 1 5/8-12 1 7/8-12 2 1/2-12

Swivel Nut Torque lb.-ft.

11-12 15-16 18-20 38-42 57-62 79-87 108-113 127-133 158-167 245-258

Swivel Nut Torque Newton Meters 15-16 20-22 24-28 52-58 77-85 108-119 148-154 173-182 216-227 334-352

BSPP Straight Adapter or Locknut Torque lb.-ft.

Newton Meters 13-15 18-20 15-19 20-25 19-23 25-30 33-40 45-55 37-44 50-60 52-66 70-90 55-70 75-95 81-96 110-130 96-111 130-150 162-184 220-250 170-192 230-260 258-347 350-470

Nominal Thread Size Straight Adapter or Locknut Torque inches** lb.-ft.

Newton Meters G1/8-28 13-15 18-20 G1/4-19 19-23 25-30 G3/8-19 33-40 45-55 G1/2-14 55-70 75-95 G3/4-14 103-118 140-160 G1-11 162-184 220-250 G1 1/4-11 170-192 230-260 G1 1/2-11 258-347 350-470 ** "G" denotes parallel threads, other than ISO 6149 (Port connection only)

Eaton Aeroquip Fluid Conveyance Products A-HOOV-MC001-E January 2005

3.34

Tigercat M760 Mulcher

Lubrication and Maintenance

Par ker ark

Assemb que Assemblly Tor orque

3.35

Tigercat M760 Mulcher

Lubrication and Maintenance

Par ker ark

Assemb que Assemblly Tor orque

JIC 37 Degree Flare SAE Dash Size -2 -3 -4 -5 -6 -8 -10 -12 -14 -16 -20 -24 -32 -40

Thread Size 5/16-24 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 3/16-12 1 5/16-12 1 5/8-12 1 7/8-12 2 1/2-12 3-12

Tube Connection FFWR

NPTF Swivel or Hose Connection FFWR

NA NA 2 2 1 1/2 1 1/2 1 1/2 1 1/4 1 1 1 1 1 1

SAE Dash Size

NA NA 2 2 1 1/4 1 1 1 1 1 1 1 1 1

F.F.W.R : Flats From Wrench Resistance All values are for Steel, Stainless Steel and Brass

-2 -3 -4 -5 -6 -8 -10 -12 -14 -16 -20 -24 -32 -40

1/8-27 NA 1/4-18 NA 3/8-18 1/2-14 7/8-14 3/4-14 NA 1-11 1/2 1 1/4-11 1/2 1 1/2-11 1/2 2-11 1/2 NA

SAE Dash Size -2 -3 -4 -5 -6 -8 -10 -12 -14 -16 -20 -24 -32 -40

Thread Size NA NA 9/16-18 NA 11/16-16 13/16-16 1-14 1 3/16-12 NA 1 7/16-12 1 11/16-12 2-12 NA NA

NA NA 1/4 TO 1/2 NA 1/4 TO 1/2 1/4 TO 1/2 1/4 TO 1/2 1/4 TO 1/2 NA 1/4 TO 1/2 1/4 TO 1/2 1/4 TO 1/2 NA NA

F.F.W.R : Flats From Wrench Resistance All values are for Steel, Stainless Steel and Brass

2-3 NA 2-3 NA 2-3 2-3 NA 2-3 NA 1.5-2.5 1.5-2.5 1.5-2.5 1.5-2.5 NA

Swivel or Hose Connection TFFT

2-3 NA 2-3 NA 2-3 2-3 NA 2-3 NA 1.5-2.5 1.5-2.5 1.5-2.5 1.5-2.5 NA

T.F.F.T. : Turns from finger tight All pipe values are for Steel, Stainless Steel and Brass

O'ring Face Seal / Seal-Lok Tube Connection FFWR

Tube Connection TFFT

Thread Size

BSPT

Swivel or Hose Connection FFWR

SAE Dash Size

NA NA 1/2 TO 3/4 NA 1/2 TO 3/4 1/2 TO 3/4 1/2 TO 3/4 1/3 TO 1/2 NA 1/3 TO 1/2 1/3 TO 1/2 1/3 TO 1/2 NA NA

-2 -3 -4 -5 -6 -8 -10 -12 -14 -16 -20 -24 -32 -40

Thread Size 1/8-28 NA 1/4-19 NA 3/8-19 1/2-14 NA 3/4-14 NA 1-11 1 1/4-11 1 1/2-11 2-11 NA

Tube Connection TFFT 2-3 NA 2-3 NA 2-3 2-3 NA 2-3 NA 1.5-2.5 1.5-2.5 1.5-2.5 1.5-2.5 NA

T.F.F.T. : Turns from finger tight All pipe values are for Steel, Stainless Steel and Brass

3.36

Swivel or Hose Connection TFFT

2-3 NA 2-3 NA 2-3 2-3 NA 2-3 NA 1.5-2.5 1.5-2.5 1.5-2.5 1.5-2.5 NA

Tigercat M760 Mulcher

Lubrication and Maintenance

3.37

Tigercat M760 Mulcher SECTION 5 - PILOT SYSTEM OCTOBER, 2006

CONTENTS - SECTION 5 ACCUMULATOR CHARGE VALVE ................................................................ 5.2 OPERATING DESCRIPTION ....................................................................... 5.2 REPLACE FILTER ....................................................................................... 5.9 SCHEMATIC ............................................................................................... 5.2 ACCUMULATORS .......................................................................................... 5.3 BRAKE ACCUMULATOR ............................................................................ 5.3 CHARGING ............................................................................................... 5.10 CHECK PRE-CHARGE PRESSURE ......................................................... 5.10 PILOT ACCUMULATOR ............................................................................... 5.3 TESTING DEVICE ..................................................................................... 5.11 COMPONENTS .............................................................................................. 5.2 HYDRAULIC OIL HEATING PROCEDURE .................................................... 5.16 PILOT CIRCUIT DESCRIPTION ............................................................... 5.4, 5.6 PILOT CIRCUIT SCHEMATIC .................................................................. 5.7, 5.8 PILOT MANIFOLD .......................................................................................... 5.4 ASSEMBLY DIAGRAM ............................................................................... 5.5 OPERATING DESCRIPTION ....................................................................... 5.4 PILOT SHUT OFF ........................................................................................ 5.4 PILOT PRESSURE SETTINGS ..................................................................... 5.11 RELEASE PILOT SYSTEM PRESSURE ........................................................ 5.9

Tigercat M760 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 steer/boom 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 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 STEER/BOOM 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 M760 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 M760 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 Boom joystick Hydraulic Push Bar (Opt) Mulch Deflector Open Mulch Deflector Closed Front Differential Lock Rear Differential Lock Spare Spare

(P2) (P2) (P2) (C1) Solenoid valve (C2) Solenoid valve (C3) Solenoid valve (C4) Solenoid valve (C5) Solenoid valve (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 reducing valve reduces and maintains the pilot pressure on the outlet side of the pilot manifold to a pre-set value.

PILOT PRESSURE RELIEF VALVE 675 PSI.

•

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 M760 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

• • • •

C5*

• ORIFICE

•

C4 *

•

ORIFICE C3*

• C2* C1* AW119

IN FROM ACCUMULATOR CHARGE VALVE

C8*

•

PILOT OIL TO STEER JOYSTICK AND CLAMP PEDAL (FRONT OF BLOCK)

760M-075

PILOT MANIFOLD ASSEMBLY 5.5

Tigercat M760 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 M760 Mulcher

M760-037

Pilot System

PILOT CIRCUIT - JOYSTICK STEERING 5.7

Tigercat M760 Mulcher

M760-037

Pilot System

PILOT CIRCUIT - WITH STEERING WHEEL 5.8

Tigercat M760 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 compartment door.

1. The machine should be parked on level ground with felling head 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. Clean the charge valve and 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 5.9

Tigercat M760 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.

5.10

Tigercat M760 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 felling head 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:

PRESSURE REDUCING VALVE

••

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

5.11

PILOT MANIFOLD

Tigercat M760 Mulcher

M760-038

Pilot System

HYDRAULIC GROUP - WITH STEERING WHEEL STEERING 5.12

Tigercat M760 Mulcher

M760-038

HYDRAULIC GROUP - WITH STEERING WHEEL STEERING 5.13

Pilot System

Tigercat M760 Mulcher

M760-039

Pilot System

HYDRAULIC GROUP - WITH JOYSTICK STEERING 5.14

Tigercat M760 Mulcher

M760-039

HYDRAULIC GROUP - WITH JOYSTICK STEERING 5.15

Pilot System

Tigercat M760 Mulcher HYDRAULIC OIL HEATING PROCEDURE

Pilot System 5. Adjust throttle to FULL.

Heat the hydraulic oil in the machine in preparation for hydraulic set-up procedures as follows: 1. Park the machine on level ground, parking brake ON, felling head down and engine off.

Install articulation lock bar, block wheels and stop engine.

2. Connect a 0-5000 psi gauges to the mid inlet test port on the boom valve.

•• MID INLET TEST PORT

MID INLET MAIN RELIEF

6. Operate clamp closed for 15 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.

WARNING

•• 724D-D20

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 mid inlet main relief to 2000 psi using the clamp close function.

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 mid inlet main relief to normal pressure settings using clamp closed function, refer to PRESSURE SETTINGS in SECTION 18 (SAW).

5.16

Tigercat M760 Mulcher SECTION 6 - ELECTRICAL, GAUGES & ALARMS OCTOBER, 2006

CONTENTS - SECTION 6 DISPLAY DIAGNOSTIC – GREEN LIGHT ..................................................... 6.10 DISPLAY SCROLL ....................................................................................... 6.11 DISPLAY WARNING – RED LIGHT .............................................................. 6.10 ELECTRICAL SCHEMATIC SHEET 1 OF 6 ............................................................................................ 6.2 SHEET 2 OF 6 ............................................................................................ 6.3 SHEET 3 OF 6 ............................................................................................ 6.4 SHEET 4 OF 6 ............................................................................................ 6.5 SHEET 5 OF 6 ............................................................................................ 6.6 SHEET 6 OF 6 ............................................................................................ 6.7 EMS ............................................................................................................. 6.11 ENGINE MONITORING SYSTEM (EMS) ...................................................... 6.11 FUSE AND RELAY COMPARTMENT ............................................................ 6.9 HYDRAULIC FILTER BYPASS ..................................................................... 6.10 IGNITION ...................................................................................................... 6.11 INSTRUMENT PANEL .................................................................................. 6.10 LOW HYDRAULIC OIL LEVEL, RED LIGHT ................................................. 6.10 WIRE COLOUR CODE CHART ....................................................................... 6.8

Tigercat M760 Mulcher

Electrical, Gauges and Alarms

ELECTRICAL SCHEMATIC - SHEET 1 OF 6

M760-030.PLT 11834BR6

6.2

Tigercat M760 Mulcher

Electrical, Gauges and Alarms

ELECTRICAL SCHEMATIC - SHEET 2 OF 6

M760-031.PLT 11834BR6

6.3

Tigercat M760 Mulcher

Electrical, Gauges and Alarms

ELECTRICAL SCHEMATIC - SHEET 3 OF 6

M760-032.PLT 11834BR6

6.4

Tigercat M760 Mulcher

Electrical, Gauges and Alarms

ELECTRICAL SCHEMATIC - SHEET 4 OF 6

M760-033.PLT 11834BR6

6.5

Tigercat M760 Mulcher

Electrical, Gauges and Alarms

ELECTRICAL SCHEMATIC - SHEET 5 OF 6

M760-034.PLT 11834BR6

6.6

Tigercat M760 Mulcher

Electrical, Gauges and Alarms

ELECTRICAL SCHEMATIC - SHEET 6 OF 6

M760-035.PLT 11834BR6

6.7

Tigercat M760 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)

6.8

Tigercat M760 Mulcher Electrical, Gauges and Alarms FUSE AND RELAY COMPARTMENT- CAB REAR WALL

6.9

Tigercat M760 Mulcher

Electrical, Gauges and Alarms 1

2

3

4

6

5

7

•• ••

• ••

•• •

••

• • 21

20

7501-7A

INSTRUMENT PANEL

INSTRUMENT PANEL 1. HYDRAULIC FILTER BYPASS - red light

3. DISPLAY WARNING – red light

This light is activated when any of the hydraulic oil filters are bypassed.

Cold weather may cause this light to activate during machine startup, refer to Cold Weather Startup Procedure in this section.

This light is activated by the ECM when any monitored engine parameter exceeds a preset limit. See CAT engine manual for further information.

4. DISPLAY DIAGNOSTIC – green light

Under normal conditions if this light is activated, Do not continue to operate the machine.

This light flashes diagnostic code from the ECM. See CAT engine manual for further information.

2. LOW HYDRAULIC OIL LEVEL – red light This light is activated when the level of oil in the hydraulic oil reservoir reaches an unacceptably low level.

Do not operate the machine with a low hydraulic oil level. Check for sources of oil loss. Correct oil leak and then refill the reservoir to the proper level if this occurs.

6.10

Tigercat M760 Mulcher

7503-1A

Electrical, Gauges and Alarms

ENGINE MONITORING SYSTEM ABBREVIATION

PARAMETER

The EMS displays various engine parameters.

SPD

ENGINE SPEED

The Engine Control Module (ECM) positioned on the side of the diesel engine monitors and processes engine operating parameters and diagnostic information. This information is then transmitted to the EMS.

GA-1

ENGINE OIL PRESSURE

GA-2

COOLANT TEMPERATURE

GA-3

BATTERY VOLTAGE

GA-4

FUEL PRESSURE

BOOST

BOOST PRESSURE

IAIRT

INLET AIR TEMPERATURE

FUELT

FUEL TEMPERATURE

ACCRP

NOT USED

ACCRT

HYDRAULIC OIL TEMPERATURE

FUEL

FUEL RATE

HRS

ENGINE HOURS

LOAD

PERCENT OF ENGINE LOAD

5. ENGINE MONITORING SYSTEM (EMS)

The EMS has ten (two rows of five) indicators to display system related diagnostics. A digital LCD readout displays the engine/ auxiliary parameters monitored. If one of the monitored engine parameters exceeds a preset limit, the indicator light will come ON. See CAT engine manual for further information.

6. DISPLAY SCROLL This is a three position switch. Press and hold until the desired abbreviation is displayed on the LCD Digital Display on EMS monitor and then release to display the desired parameter.

The display can be scrolled either forward or in reverse sequence.

EMSCHART.EPS

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

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

NOTE: The parking brake must be in the ENGAGED position to start the engine.

6.11

Tigercat M760 Mulcher

Electrical, Gauges and Alarms

6.12

Tigercat M760 Mulcher SECTION 7 - ENGINE OCTOBER, 2006

CONTENTS - SECTION 7 COOLING SYSTEM COOLANT FLOW DIAGRAM ........................................ 7.6 COOLANT FLOW DURING OPERATION ..................... 7.6 FILLING THE SYSTEM WITH COOLANT ..................... 7.6 ENGINE RPM .................................................................. 7.3 ENGINE, STARTING ....................................................... 7.2 ENGINE, STOPPING ...................................................... 7.3 PRECLEANER OPERATION ................................................................ 7.7 SERVICE ..................................................................... 7.7 START CIRCUIT DIAGRAMS AT REST ...................................................................... 7.4 RUN AND DRIVE .......................................................... 7.5 RUN, NO DRIVE ........................................................... 7.5 START .......................................................................... 7.4 STARTING ENGINE ........................................................ 7.2 STARTING SYSTEM DESCRIPTION .............................. 7.2 STOPPING ENGINE ....................................................... 7.3

Tigercat M760 Mulcher

Engine

STARTING CIRCUIT

STARTING ENGINE:

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

1. Ensure that PRE START CHECKS have been performed and that the area is clear of personnel prior to starting the engine.

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.

2. Sound horn to warn personnel of machine start-up.

3. Move throttle control to the LOW IDLE position, set parking brake ON, insure that the Direction / Speed lever is in the center locked position.

•

NOTE: The engine will not turn over unless the parking brake is ON. 4. Turn ignition switch to the START position to crank engine.

PROXIMITY SWITCH

5. When engine starts, release ignition key to RUN position.

337-19

NOTE: If the engine does not start after three attempts, check the fuel supply system.

Absence of blue or white exhaust smoke during cranking indicates no fuel is being delivered.

PARKING BRAKE "OFF" POSITION

IMPORTANT • After engine has started, keep engine speed low until engine oil pressure registers on EMS. If it does not register within 10 seconds, stop engine and investigate cause.

• Allow a cold engine to warm up at LOW IDLE for at least five minutes before applying any load. Check all engine parameters on the EMS often during the warm up period.

337-20

CAUTION

PARKING BRAKE "ON" POSITION

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

The parking brake must be in the ON position to allow the engine to start. The engine is started by turning the key to the START position and then releasing it to the RUN position after the engine starts. Refer to START CIRCUIT DIAGRAMS in THIS SECTION.

If engine stalls while operating the machine, turn the ignition key to the OFF position and repeat steps (1) through (5).

IGNITION KEY SWITCH

M760-028

INSTRUMENT PANEL 7.2

Tigercat M760 Mulcher

Engine STOPPING ENGINE IMPORTANT

6

Stopping the engine immediately after it has been working under load can result in overheating and premature wear of the engine components. Follow the stopping procedure outlined below to allow the engine to cool.

•

THROTTLE CONTROL THROTTLE CONTROL

1.

Park machine on level ground and rest cutting head on the ground.

For HIGH IDLE engine RPM push button on end of throttle control and PULL out completely.

2.

NOTE: All machine operations should be performed at HIGH idle.

Reduce engine speed to LOW IDLE and let run for approximately three minutes to allow gradual dissipation of heat and also to reduce turbocharger speed. This will also prevent loss of coolant by after boil and possible hot spot damage to the engine.

3.

Do not race engine before shut-off.

Maintaining Correct Engine RPM.

4.

Engage parking brake.

It is most important that the RPM of the engine be correct at all times:

5.

Stop engine by turning ignition switch to the OFF position.

M760-06

For LOW IDLE engine RPM push button in and PUSH in throttle control completely.

Low Idle 700 +/- 25 RPM (No Load)

WARNING

High Idle 2100 +/- 25 RPM (No Load) • Before leaving the machine, park it in a safe position on level ground.

CAUTION

• Engage parking brake, lower the attachment to the ground.

Under no circumstances allow the high idle engine RPM to vary from the recommended settings; particularly faster, as serious damage to the hydraulic components will result.

• Never work behind, in front of, or below a machine that has been parked on a grade.

• Take additional precautions by placing the wheels against a rock, tree or other secure object.

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

When setting pressures, increase Low Idle to 1200 RPM with throttle control.

The engine RPM should be checked regularly with a calibrated hand tachometer.

7.3

Tigercat M760 Mulcher

Engine START CIRCUIT DIAGRAMS

START CIRCUIT - AT REST

M760-049

START CIRCUIT - START

M760-050

7.4

Tigercat M760 Mulcher

Engine START CIRCUIT DIAGRAMS

START CIRCUIT - RUN, NO DRIVE

M760-051

START CIRCUIT - RUN AND DRIVE

M760-052

7.5

Tigercat M760 Mulcher ENGINE COOLING SYSTEM

Engine 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.

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, coolant flows across the radiator core to the outlet and back to the water pump.

SURGE TANK

RADIATOR

•

An engine vent discharges air directly from the top of the engine to the surge tank.

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

••

VENT TUBE

•

SHUNT HOSE

• M760-044

RADIATOR SURGE TANK

A surge tank is located above the radiator. A small vent tube is connected between the surge tank and the thermostat housing. The anti-freeze/water solution used in the cooling system always contains small amounts of air produced by combustion gas RADIATOR

CHARGE AIR COOLER

TOP RADIATOR HOSE

••

VENT TUBE

••

•• ••

•• •• BOTTOM RADIATOR HOSE M760-055

HYDRAULIC OIL COOLER

ENGINE COOLING SYSTEM 7.6

Tigercat M760 Mulcher

Engine PRECLEANER - ENGINE AIR INTAKE

FILLING THE SYSTEM WITH COOLANT

SURGE TANK

•• 7502-5A

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.

RAD CAP

••

CHECK ENGINE COOLANT LEVEL

The coolant is added through the filler neck in the surge tank. This coolant fills the bottom radiator hose at the water pump and then fills the radiator from the bottom upwards. Air displaced through the vent tube to the surge tank.

SURGE TANK

RADIATOR

••

•

••

VENT TUBE

•

••

SHUNT HOSE

•

•• M760-044

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

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

•

RADIATOR SURGE TANK

As the radiator is filled, coolant flows through the water pump and engine oil cooler to fill the engine.

Coolant will flow out the top radiator hose through the thermostat bypass and into the engine once the radiator has filled. The engine vent discharges air directly from the engine to the surge tank.

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

ONLY THE PURIFIED AIR GOES TO THE AIR FILTER

PRECLEANER OPERATION

SERVICE Under normal conditions, the outer screen and the precleaner should be checked and cleaned every 8 hours of any debris such as leaves, needles, dirt and twigs.

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.

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.

7.7

Tigercat M760 Mulcher

Engine

7.8

Tigercat M760 Mulcher SECTION 8 - DRIVE OCTOBER, 2006

CONTENTS - SECTION 8 AXLES .......................................................................................................................... 8.20 AXLE LUBRICATION ................................................................................................. 8.22 BRAKE BLEEDING ................................................................................................... 8.22 BRAKE LINING INSPECTION (REAR AXLE ONLY) ................................................... 8.21 DIFFERENTIAL AND DIFFERENTIAL LOCKS ........................................................... 8.21 DRAINING THE AXLES ............................................................................................. 8.22 FILLING AXLES, ALTERNATIVE METHOD ................................................................ 8.23 FILLING THE AXLES ................................................................................................. 8.22 REAR AXLE OSCILLATION SHIM ............................................................................. 8.24 SERVICE BRAKES (REAR AXLE ONLY) .................................................................. 8.21 CIRCUIT DESCRIPTION DUAL MOTOR 1-SPEED TRANSMISSION .................................................................. 8.2 CIRCUIT DIAGRAM, DRIVE DUAL MOTOR 1-SPEED TRANSMISSION ................................................................ 8.11 DRIVE PEDAL PILOT VALVE ......................................................................................... 8.8 DRIVE PREVENT VALVE .............................................................................................. 8.9 DRIVE PUMP AND MOTOR PRESSURE SETTINGS AND ADJUST DUAL MOTOR 1-SPEED TRANSMISSION ................................................................ 8.13 DRIVE SHAFT, FRONT, INSTALLATION ...................................................................... 8.18 HYDROSTATIC DRIVE MOTOR ...................................................................................... 8.6 DESCRIPTION ............................................................................................................. 8.6 SCHEMATIC ............................................................................................................... 8.6 HYDROSTATIC DRIVE SYSTEM DUAL MOTOR 1-SPEED TRANSMISSION .................................................................. 8.2 SPEED CONTROL LEVER VALVE .............................................................................. 8.10 TEST DRIVE DUAL MOTOR 1-SPEED TRANSMISSION ................................................................ 8.12 TRANSMISSION 1-SPEED (DUAL MOTOR) ................................................................. 8.17 WHEEL INSTALLATION ............................................................................................... 8.26

Tigercat M760 Mulcher

Drive

HIGH PRESSURE SUPPLY

BENT AXIS PISTON DRIVE MOTOR (LH) TO VEHICLE DRIVE

SWASHPLATE, AXIAL PISTON DRIVE PUMP

FROM DIESEL ENGINE

BENT AXIS PISTON DRIVE MOTOR (RH) TO VEHICLE DRIVE

LOW PRESSURE RETURN

724D-25

TYPICAL CONTINUOUS CLOSED LOOP HYDRAULIC CIRCUIT DUAL MOTOR (1-SPEED TRANSMISSION)

HYDROSTATIC DRIVE SYSTEM DUAL MOTOR 1-SPEED TRANSMISSION 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.

The primary components of the dual motor one speed transmission 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 a 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.

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.

8.2

Tigercat M760 Mulcher

Drive

DRIVE PUMP

DRIVE PUMP PRIMARY SECTION

The hydrostatic drive pump is mounted at the bottom right position of the pump drive gearbox.

The input drive shaft of the pump is connected directly to the output of the gearbox. The gearbox is driven directly by the diesel engine through a steel flex plate.

CHARGE PUMP

SWASH PLATE

• ••

The hydrostatic drive pump is actually two separate hydraulic pumps (a primary variable displacement, axial piston type pump and a secondary fixed displacement, internal gear pump) mounted in a common case and driven by the same input drive shaft.

• ••

ROTARY GROUP AP096A

DRIVE PUMP CROSS SECTION

DIESEL ENGINE

ATTACHMENT PUMP

•

•

••

• DRIVE PUMP

BOOM/STEER PUMP

M760-042B

FAN PUMP

PUMP ORIENTATION ON REAR OF ENGINE 8.3

Tigercat M760 Mulcher

M760-078

Drive

DRIVE PUMP SCHEMATIC

The primary pump is a variable displacement, swashplate, in line axial piston type pump. The volume and direction of oil flow from the piston pump is determined by the angle of the tiltable 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.

When neither of the drive footpedals are depressed, pilot 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 speed control valve limits the maximum speed of the vehicle by reducing the pressure of pilot oil to the motors, allowing the operator to maintain a given speed without the need to feather the footpedals.

The drive footpedal control valve only functions when the parking brake lever is in the OFF position. This prevents driving the machine when the parking brake is applied. A proximity switch is attached to the parking brake lever. When this lever is in the OFF position, the proximity switch contacts are open, de-energizing the drive enable relay and energizing the drive prevent valve. With the drive prevent valve energized, drive footpedal 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 footpedal oil is directed to tank the drive pump displacement control valve does not move and the pump swashplate angle remains at zero (0o).

The secondary pump is a fixed displacement, internal gear type which provides charge oil (make-up oil) for the hydrostatic pump and motors in the closed loop system. The charge pump also provides pilot oil to the drive pedals and speed control.

The drive footpedal 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 connected to the swashplate of the piston pump. The angle and direction that the swashplate moves determines the speed and direction of travel of the vehicle. The angle and direction that the swashplate moves is directly proportional to the position of the drive footpedal and may be limited by the use of the speed control valve.

8.4

Tigercat M760 Mulcher DRIVE SHAFT

CONTROL CYLINDER

Drive

SWASHPLATE CONTROL VALVE

CHARGE PUMP

'B' PORT RELIEF

PORT 'B'

PORT 'B' CHARGE PUMP RELIEF

A

AP024-F AP024-G

'A' PORT RELIEF SWASHPLATE

SPLINED SHAFT

PORT 'A'

VIEW A

PORT 'A'

PRESSURE OVERRIDE VALVE (P.O.R.)

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

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

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

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

8.5

Tigercat M760 Mulcher

Drive

HYDROSTATIC DRIVE MOTOR

to the minimum setting. Removal of the pressure signal from the speed control joystick 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.

Two motors are used to drive the machine. They are mounted to the input side of the transmission.

A splined coupling connects the motor shaft to the transmission input shaft.

Each motor is a variable displacement, bent axis piston type. The two motors form a closed loop circuit with the drive pump.

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 cylinder to move towards max displacement.

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.

FLUSHING VALVE

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.

•

MAX

DISPLACEMENT CONTROL SPOOL

MIN

POR

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

4000 PSI @ 2200 RPM

•

•

FROM SPEED CONTROL JOYSTICK

The displacement control spool is operated by pilot pressure from the forward and reverse foot pedals via the speed control joystick. When sufficient pressure 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

FROM PUMP

FROM PUMP

720C-24

DRIVE MOTOR SCHEMATIC

•

FLUSHING VALVE

•

ROTATING GROUP

PORT 'M1'

AQ010-5Y

'A'

•

PORT 'A'

PORT 'B'

•

BEGIN OF STROKE ADJUSTING SCREW PORT 'G'

•

• VIEW 'A'

POR ADJUSTING SCREW

DRIVE MOTOR ~ (160CC SIZE) 8.6

DRIVE SHAFT

•

•

•

PORT 'X'

M724D-01

CONTROL CYLINDER

MINIMUM DISPLACEMENT ADJUSTING SCREW

Tigercat M760 Mulcher

Drive

The point at which the displacement control spool begins to move is known as "begin of stroke set point" or "pressure override set point".

TRANSMISSION

The MOTOR POR set point must be correctly set for the system to function properly. Refer to DRIVE MOTOR PRESSURE SETTINGS in THIS SECTION .

••

DRIVE MOTORS

•

•

A minimum displacement adjusting screw on the outside of the motor housing limits the maximum speed of the motor.

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.

M760-049

DRIVE MOTORS AND TRANSMISSION

L.H. DRIVE MOTOR

••

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.

'POR' VALVE

•

••

M760-052

MINIMUM DISPLACEMENT ADJUSTMENT

R.H. DRIVE MOTOR

'POR' VALVE

•• BEGIN OF STROKE ADJUSTING SCREW

••

• •

M760-053

L.H. DRIVE MOTOR ADJUSTMENTS M760-050

8.7

Tigercat M760 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.

1

2

P

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

• •

4

•

2

3

•

1

•

• • •

•

8

'P' PORT

AU013-1

WORK PORTS 1, OR 2

SPOOL ARRANGEMENT

AU013-2

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).

8.8

Tigercat M760 Mulcher

Drive

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. UNDERSIDE OF CAB

DRIVE PREVENT VALVE

•

••

DRIVE PREVENT VALVE

724D-D24

SOLENOID AND CONNECTOR

SM-29

• P1

•

P2

SPOOL SECTION VALVE BLOCK

• •

PORT 1

PORT 2 V-04

DRIVE PREVENT VALVE

OPERATING DESCRIPTION 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.

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.

8.9

Tigercat M760 Mulcher

Drive

SPEED CONTROL LEVER VALVE DUAL MOTOR 1-SPEED TRANSMISSION

•

5

• •

4

•

2

3

•

1

•

• • •

•

8

'P' PORT WORK PORTS 1, 2

SPOOL ARRANGEMENT

AU013-1

AU013-2

OPERATING DESCRIPTION When the lever (1) is operated, plunger (5) is pushed against the return spring (4). The friction clutch makes the lever infinitely adjustable.

At the same time, control spool (2) is moved by control spring (3).

AW020

As the spool moves down, the control chamber to tank connection is closed. As the spool continues to move, the connection between input pressure (P) and the control chamber is opened and the pressure is then able to build up in the control chamber.

SPEED CONTROL LEVER VALVE

This pilot valve is a manually operated directional control valve and operates on the same principal as a direct operating pressure reducing valve.

The control lever, the joystick and foot control valves use similar spool arrangements.

Once the pressure equals the value set by control spring (3), the control spool closes the loop and there is a connection to work port 2.

Oil flow is directly proportional to the position of the control lever setting by the operator and the control spring (3) characteristics.

This control valve is used to control the amount of pilot oil supplied to the drive motors, limiting the maximum speed of the vehicle and allowing the operator to maintain a given speed without having to feather the drive pedals. When the lever is pushed fully forward oil is supplied to the drive motors at pilot pressure (450 psi). When pulled all the way back the machine will be in CREEP MODE. The speed control lever has a friction clutch which is infinitely adjustable and can be used while the machine is in motion.

SPEED CONTROL LEVER

•

Refer also to SPEED CONTROL LEVER in SECTION 2 of the OPERATOR'S MANUAL and SPEED CONTROL LEVER ADJUSTMENT in SECTION 3 of THIS MANUAL.

M724D-02

8.10

SPEED CONTROL LEVER

Tigercat M760 Mulcher

M760-079

Drive

DRIVE CIRCUIT - DUAL MOTOR 1-SPEED TRANSMISSION 8.11

Tigercat M760 Mulcher

Drive

TEST DRIVE

3b Turn A/C switch OFF and set FAN speed to FULL ON (OVERRIDE).

DUAL MOTOR 1-SPEED TRANSMISSION

3c. Operate the MULCHER DEFLECTOR DOOR CLOSE function and STEER the machine.

This drive will verify the following: 1. Motor pressure override.

2. Engine horsepower audit.

3. Top speed control.

4. Front and rear differential lock functions.

5. Boom functions.

6. Parking brake operation.

4. While doing the above, carefully drive the machine FORWARD and apply the foot brake to develop a reading of 4050 psi pressure at MA.

Install 5,000 psi gauges on M1 of the RH DRIVE MOTOR, M1 LH DRIVE MOTOR and a 10,000 psi gauge on MA and MB OF THE DRIVE PUMP test connections.

NOTE: Fasten these gauges so that they can be viewed from the operator’s seat in the cab.

5. Observe the engine rpm while doing the above. The engine should lug down into the following rpm range: 1970-2000 RPM Note: This test may have to be done a few times to get a proper reading.

TOP SPEED CONTROL:

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.

1. Turn ON both front and rear differential locks.

Make sure that the creep switch is OFF. Set the throttle control to FULL. 2. Drive the machine forward at top speed and adjust the throttle control so that the tachometer reads 2100 rpm at top speed.

3. With the aid of an assistant drive the machine forward at top speed and record the time to complete 5 tire revolutions. This should take 6.5 seconds maximum.

MOTOR PRESSURE OVERRIDE (POR) 1. Set throttle control to FULL 2100 rpm.

If it takes longer than 6.5 seconds either the MOTOR minimum displacement, MOTOR POR or PUMP charge pressure may be incorrectly set.

2. Push the Speed Control Joystick (left joystick on seat) all the way forward.

3. Drive the machine FORWARD at FULL SPEED. Apply the foot brake to slow the machine to approximately half speed but no slower.

DIFFERENTIAL LOCK FUNCTIONS:

4. Observe the 'MA' and 'M1" gauges, the pressure on all gauges should begin to rise.

The 'MA' gauge on the DRIVE PUMP will rise to 4000 psi. The pressure at the 'M1' gauges on the DRIVE MOTORS should rise then drop to 2000 psi., pause for a moment, then begin to rise over 3000 psi.

Note: This test may have to be done a few times to get a proper reading.

Note: If these results cannot be obtained, refer to DRIVE MOTOR PRESSURE SETTINGS AND ADJUSTMENTS in THIS SECTION. ENGINE HORSEPOWER AUDIT: 1. Install the articulation lock bar to prevent the machine from steering.

2. Set the throttle control to FULL. Verify the tachometer reading at high idle: 2100 RPM 3a. Leave the THROTTLE control set to FULL. 8.12

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.

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.

Tigercat M760 Mulcher

Drive

DRIVE PUMP AND MOTOR PRESSURE SETTINGS AND ADJUSTMENTS

R.H. DRIVE MOTOR

DUAL MOTOR 1-SPEED TRANSMISSION

••

PUMP SET-UP 1. Park machine on level ground, lower attachment to the ground and install articulation lock pin.

M1

2. Ensure that the hydraulic oil temperature is between 120°F-140°F. ADJUST AUXILIARY BRAKE SET-UP CALIPER (ADJUSTING NUT) TO 70 LBF/FT.

••

M1 L.H. DRIVE MOTOR

••

AUXILIARY BRAKE SET-UP CALIPER 3. Set parking brakes, and adjust auxiliary brake set-up caliper to 70 lb.-ft, to lock the rotating brake disk.

336-3AX

4. Push the Speed Control Joystick (left joystick on seat) all the way forward.

Ma

Mb

••

•

••

G

6. Connect 5000 psi. gauges to the “M1” ports on each motor.

M760-046

DRIVE PUMP TEST GAUGE LOCATIONS 5. Lower Boom, engine off, install 10,000 psi gauges at “Ma” & “Mb” on DRIVE PUMP. Install 1,000 psi gauge on charge pressure test port G. 8.13

Tigercat M760 Mulcher

Drive 12. Hold Foot Brake, press FORWARD pedal, adjust DRIVE PUMP (P.O.R) to give the appropriate reading at “Mb” 5000-5050 psi at 2100 rpm.

MOTOR SET-UP 13. Hold Foot Brake, press REVERSE pedal, and adjust the DRIVE PUMP (P.O.R) to give the appropriate reading at “Ma” 4000-4025 psi at 2100 rpm.

NOTE:This setting will be used only to setup the motors and then be readjusted.

L.H. DRIVE MOTOR

• M724D-02

SPEED CONTROL LEVER

'POR' VALVE

7. Tee a 500 psi gauge into motor control line (Port 2) in the bottom of joystick.

••

••

CHARGE PUMP RELIEF FA1 'B' PORT RELIEF

'A' PORT RELIEF

M760-052

14. Adjust the MOTOR “POR” (pressure override) IN until it lightly seats.

PORT 'B'

PORT 'A'

15. Hold Foot Brake, depressing the FORWARD foot pedal adjust the control pressure at the X port of the motors by moving the speed control joystick to give a reading of 135 psi.

MINIMUM DISPLACEMENT ADJUSTMENT 'POR' VALVE

PRESSURE OVERRIDE VALVE (P.O.R.) AP024-F

••

•

REAR VIEW OF DRIVE PUMP

8. Set charge pressure relief to appropriate pressure at Fa1 - port to 400-425 psi at 2100 rpm.

BEGIN OF STROKE ADJUSTING SCREW

••

M760-053

9. Turn PUMP P.O.R. IN very carefully until it just bottoms and then turn out 1/2 turn.

L.H. DRIVE MOTOR ADJUSTMENTS 16. Hold Foot Brake, depressing the FORWARD foot pedal, adjust the begin of stroke control (BOSC). When the “M1” pressure is 2000 2100 psi at 2100 rpm, approximately half of the system pressure (4000 - 4200 psi at 2100 rpm = “Mb” = system pressure), this is the begin of stroke point. Use TWO gauges to set this point for both MOTORS, moving back and forth between the two motors.

10. Hold Foot Brake, press FORWARD pedal, and adjust “B” (high-pressure relief) to give appropriate reading at “Mb” 5650-5700 psi at 2100 rpm.

11. Hold Foot Brake, press REVERSE pedal, and adjust “A” (high-pressure relief) to give appropriate reading at “Ma” 5650-5700 psi at 2100 rpm.

8.14

Tigercat M760 Mulcher

Drive MINIMUM DISPLACEMENT ADJUSTMENT

'POR' VALVE

• BEGIN OF STROKE ADJUSTING SCREW

•• ••

M760-053

L.H. DRIVE MOTOR ADJUSTMENTS 17. If the reading is HIGH; turn the BOSC screw OUT (counter-clockwise) or if the reading is LOW turn the screw IN (clockwise); until a correct reading at “M1” equal to half of “Mb” is obtained.

22. If the reading is HIGH; turn the pressure override (POR) screw OUT (counterclockwise) or if the reading is LOW turn the screw IN (clockwise); until a correct reading at “M1 is obtained. Release the forward foot pedal and re-apply to ensure that both gauges read correct pressures.

23. Repeat Step 12 to re-set final Pump P.O.R. 5000 - 5050 at 2100 rpm.

24. Remove all pressure gauges and reinstall all plugs and caps.

25. Re-adjust the auxiliary set-up caliper to its ORIGINAL POSITION, and remove articulation lock.

18. CHECK: The BOSC setting can fluctuate if not set properly. To check begin of stroke setting, bring the control pressure at the X port down by moving the joystick all the way back. While depressing the FORWARD foot pedal, gradually increase the control pressure (by moving the joystick forward). If set properly, when 135 psi is reached on the X port, the pressure at “M1” should be approximately half of the system pressure (“Mb”), on both motors. If the pressure is fluctuating by more than 200 psi readjust the stroke setting and ensure both motor settings are identical.

19. Perform the check at step 18 a number of times to ensure repeatability.

20. Hold Foot Brake, depressing the FORWARD foot pedal adjust the speed control joystick to give the maximum reading on the “X” port of the motor (by moving the joystick forward).

This should equal the charge pressure relief valve setting on the pump.

21. Hold Foot Brake, depressing the FORWARD foot pedal, adjust the motor pressure override (P.O.R) screw to give a correct reading at “M1” 2000-2500 psi at 2100 rpm. Use TWO gauges and set both MOTORS, moving back and forth between the two motors.

8.15

Tigercat M760 Mulcher

Drive HYDRAULIC OIL HEAT-UP

(POR) ADJUSTING SCREW

1. Block Air Flow through Oil Cooler, intake side of the Heat Exchanger, with Cardboard. DO NOT block Engine Radiator or Charge Air Cooler.

LOOP FLUSHING RELIEF VALVE

•

•

2. Full Throttle - Operate Clamp Close and Steer for 15 sec, then off for 5 sec, Repeat.

Monitor Engine Temperature and Hydraulic Oil Temperature until Hydraulic Oil Temperature reaches 130 °F. This procedure will take 20-30min depending on Ambient Air Temperature.

'X' DIMENSION

• MINIMUM DISPLACEMENT ADJUSTING SCREW

DRIVE MOTOR (SAUER)

AQ064-1

"X"

DIM X

MIN. DISPLACEMENT "X" DIMENSION

DRIVE MOTOR MINIMUM DISPLACEMENT ADJUSTMENT NOTE: This adjustment need only be made after verifying that: (A) The motor POR and the charge pressure are both set correctly. See PREVIOUS PROCEDURE. (B) If the machine failed the DRIVE TEST, Refer to TOP SPEED CONTROL TEST in THIS SECTION. Perform this procedure on BOTH MOTORS. 1. Park machine on level ground, lower attachment and set parking brake ON. Install articulation lock pin and stop engine.

2. Check the 'X' dimension for the minimum displacement adjusting screw on the drive motor housing, the dimension from the top of the locknut to the end of the exposed screw should be 18.4mm (for 90mm screw).

NOTE: Repeat for the other motor.

8.16

Tigercat M760 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

432-3

ONE SPEED TRANSMISSION SHOWN IN NEUTRAL

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

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.

8.17

Tigercat M760 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 8.18

Tigercat M760 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

M724D-31

DRIVE SHAFT INSTALLATION 8.19

GREASE FITTING

Tigercat M760 Mulcher AXLES

Drive

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) 8.20

Tigercat M760 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

depressed, brake pressure oil moves the piston up 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.

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.

When the brake foot control pedal in the cab is 1

ANNULAR BRAKE

AXL-BRK

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.

2 4

6

7

3

5 AXL-3

EARLIER DESIGN - AXLE ASSEMBLY CROSS SECTION (REAR SHOWN) 8.21

Tigercat M760 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 at a time.

SINGLE BRAKE LINE ACTUATES BOTH BRAKES IN REAR AXLE

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.

BLEED SCREWS

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

PROCEDURE

Care should be taken to refill the axle(s) before moving the machine after draining.

1. Place parking brake ON. 2. Place a clear plastic tube over bleed screw with other end in a container.

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.

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

8.22

•

FRONT AXLE

Tigercat M760 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 feft 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.

8.23

Tigercat M760 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

8.24

Tigercat M760 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.

8.25

Tigercat M760 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.

8.26

Tigercat M760 Mulcher SECTION 9 - BRAKES AND DIFFERENTIAL LOCKS OCTOBER, 2006

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 M760 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 1800 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

M760-015

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.

FOOT PEDALS

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.

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

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.

Tigercat M760 Feller Mulcher

M760-056

Brakes and Differential Locks

BRAKE AND DIFFERENTIAL LOCK CIRCUITS 9.3

Tigercat M760 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 (on machines equipped with dual motors 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 setup 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 M760 Feller 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 M760 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 M760 Feller 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.

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.

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.

5. Install new carrier and lining assemblies into each caliper torque plate.

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.

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.

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 M760 Mulcher

Brakes and Differential Locks

9.8

Tigercat M760 Mulcher SECTION 10 - OIL COOLER/RADIATOR/CROSS-FLOW FAN OCTOBER, 2006

CONTENTS - SECTION 10 CHARGE AIR COOLER ..................................................................................................... 10.2 COOLING SYSTEM COOLANT FLOW DIAGRAM ................................................................................ 10.4, 10.5 COOLING SYSTEM, ENGINE. ......................................... SEE SECTION 7 IN THIS MANUAL ENGINE ACCESS PANELS ............................................................................................. 10.11 ENGINE COOLING SYSTEM. .......................................... SEE SECTION 7 IN THIS MANUAL FAN COOLING CIRCUIT DESCRIPTION .......................................................................... 10.6 FAN SPEED CHECKS ..................................................................................................... 10.10 CHECK FOR NO A/C DURING CLEAN MODE ............................................................ 10.10 FAN 'CLEAN' SPEED .................................................................................................... 10.10 FAN FULL ON SPEED .................................................................................................. 10.10 HYDRAULIC HAND FILL PUMP ........................................................................................ 10.9 OIL COOLER ..................................................................................................................... 10.2 OIL COOLER AND RADIATOR INSTALLATION ................................................................ 10.3 OIL COOLER CIRCUIT DESCRIPTION ............................................................................ 10.5

Tigercat M760 Mulcher

Oil Cooler/Radiator and Cross-flow Fan

CHARGE AIR COOLER/OIL COOLER/ RADIATOR The charge air cooler, hydraulic oil cooler and engine radiator are mounted beside each other as an assembly. The assembly is mounted vertically in the rear chassis to provide cross flow ventilation.

RADIATOR OIL COOLER

CHARGE AIR COOLER

•

A/C CONDENSER CORE

••

•

RECEIVER/ DRYER

RIGHT SIDE - CROSS-FLOW FAN M760-054 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.

• M760-026

A/C CONDENSER AND COOLER ASSEMBLY SURGE TANK

The complete CAC/oil cooler/radiator/A-C condensor/fan drive assembly is rubber isolation mounted to reduce the transmission of noise and to isolate the components from vibration.

RADIATOR

••

••

VENT TUBE

Refer to SECTION 7 for information on the ENGINE COOLING SYSTEM.

•

SHUNT HOSE

For detailed cleaning procedures, refer to CLEANING A/C CONDENSER, CHARGE AIR COOLER, OIL COOLER AND RADIATOR in SECTION 2 of the OPERATOR’S MANUAL.

• M760-044 RADIATOR SURGE TANK The A/C condenser core is mounted in front of these three units and on hinges to facilitate cleaning. The cooling fan is mounted behind the charge air cooler(CAC)/oil cooler/radiator assembly and draws air from the right side of the machine. The air passes through the CAC/oil cooler/radiator and A/C condensor core and exhausts on the left side of the machine.

A/C CONDENSER AND COOLER ASSEMBLY 10.2

Tigercat M760 Mulcher

Oil Cooler/Radiator and Cross-flow Fan

FAN MOTOR

••

A/C CONDENSER (NOT SHOWN)

FAN

CHARGE AIR COOLER

••

SURGE TANK

••

••

•• •• RADIATOR

M760-059

OIL COOLER

CHARGE AIR COOLER, OIL COOLER AND RADIATOR INSTALLATION 10.3

Tigercat M760 Mulcher

Oil Cooler/Radiator and Cross-flow Fan RADIATOR

CHARGE AIR COOLER

ARROWS INDICATE FLOW DIRECTION

TOP RADIATOR HOSE

•

•

VENT TUBE

•• •

• • BOTTOM RADIATOR HOSE M760-055

ARROWS INDICATE FLOW DIRECTION

HYDRAULIC OIL COOLER

ENGINE COOLING SYSTEM

CHARGE AIR COOLER (CAC)

CROSS-FLOW COOLING FAN

RADIATOR

•

•• ••

INTAKE MANIFOLD TURBOCHARGER

•• ••

•• HYDRAULIC OIL COOLER M760-060

CHARGE AIR COOLER: AIR FLOW DURING OPERATION 10.4

Tigercat M760 Mulcher

Oil Cooler/Radiator and Cross-flow Fan

OIL COOLER CIRCUIT DESCRIPTION Return oil from the boom valve and return manifold is directed to flow to the oil cooler, through the oil cooler to the return filter and back to the hydraulic tank.

M760-054

RIGHT SIDE - CROSS-FLOW FAN

Cooling of the oil occurs as the cross flow fan draws air over the oil cooler cooling fins. Cooled oil then passes through the dual head return filter and into the hydraulic tank.

ARROWS INDICATE FLOW DIRECTION

OIL COOLER CIRCUIT

M760-064

RADIATOR

CHARGE AIR COOLER

••

••

• TO RETURN FILTERS FROM BOOM VALVE AND RETURN MANIFOLD M760-055

HYDRAULIC OIL COOLER 10.5

HYDRAULIC OIL COOLER

Tigercat M760 Mulcher

Oil Cooler/Radiator and Cross-flow Fan

FAN COOLING CIRCUIT DESCRIPTION

The fan auto reversing function is factory set to cycle every 30 minutes. The cycle interval has a variable adjustment with an operating range between 10 to 60 minutes. An adjustable potentiometer located in the fuse an relay compartment behind the seat, is used to set the auto reversing cycle time interval. Turn the adjustment screw counterclockwise to increase time interval or clockwise to decrease time interval. Refer to FUSE AND RELAY COMPARTMENT in THIS SECTION.

The fan "cooling" circuit is a closed loop hydraulic system consisting of a variable displacement pump, a fixed displacement motor and a pressure filter.

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.

FULL ON (OVERRIDE) POSITION - When the switch is in the FULL ON (OVERRIDE) position, the fan control system is overridden and the fan will run at FULL speed for cooling regardless of coolant, air or oil temperatures. Normally the fan control switch is placed in the AUTO position for optimal cooling. The FULL ON (OVERRIDE) position is intended for use in the event of a temporary failure of the fan control.

FAN - SWITCH

CLEAN FAN - SWITCH

This is a two position switch, labelled AUTO/FULL ON*. This switch along with an electronic fan control module, controls the operation of the hydraulic cross-flow fan.

This is a two position switch, labelled CLEAN. When the switch is depressed, the direction of rotation is reversed. Reverse rotation is used to clean the charge air cooler, radiator, oil cooler, A/ C condenser and air intake door screens. By "reversing" the flow of the fan, air flow is propelled in the opposite direction, thereby forcing dust and debris off of the radiator.

AUTO POSITION - AUTO is the normal operating position for the fan control switch. When the switch is in the AUTO position, the fan will operate completely in an automatic mode. 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. The electronic fan control module automatically adjusts fan speed to the minimum required level to maintain optimal operating conditions, provide auto reversing and default to fan at full speed if an error in the controller exists.

Automatic control of fan speed to match operating conditions can lower fuel consumption and reduce operating costs. In high temperature operating conditions the fan speed is increased to improve cooling ability and efficient operation of the oil cooler, radiator and air conditioning systems. In low temperature operating conditions fan speed is reduced, as less cooling is required.

When the switch is in the AUTO position, the fan will operate at 25% of its maximum speed when engine coolant or hydraulic oil temperatures are low.

10.6

The electronic fan control will also turn the A/C 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.

It is also important to manually clean debris from the machine on a regular basis to maintain low machine operating temperatures. Refer to CLEANING A/C CONDENSER, CHARGE AIR COOLER, OIL COOLER AND RADIATOR in THIS SECTION.

Tigercat M760 Mulcher

Oil Cooler/Radiator and Cross-flow Fan

COOLING FAN DRIVE SYSTEM

SCHEMATIC

M760-063

COOLING FAN DRIVE CIRCUIT 10.7

M760-061

Tigercat M760 Mulcher

Oil Cooler/Radiator and Cross-flow Fan

•

HYDRAULIC TANK AIR BREATHER

RETURN FILTERS BOOM, STEER & PILOT

••

•• •• LOW PRESSURE RETURN FILTER

••

••

••

RETURN FILTERS CASE DRAIN

HYD OIL LEVEL SIGHT GAUGE

•

••

HYDRAULIC TANK

••

M760-013

HYDRAULIC OIL TANK Located at the left rear of the machine, the hydraulic tank has a capacity of 90 gallons (340 liters).

••

A sight gauge, accessible through the rear door indicates the HIGH and LOW levels of the hydraulic oil. Incorporated into this gauge is a low level sending unit which signals a “low hydraulic oil” light in the cab to come ON when the oil level is low. Always keep the hydraulic oil between the ADD and FULL calibrations.

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

Over filling causes the excess oil to discharge from the breather vent.

10.8

CHARGE PRESSURE FILTERS - DRIVE, CUTTER & FAN M760-012

•

Tigercat M760 Mulcher

Oil Cooler/Radiator and Cross-flow Fan BREATHER FILTER

HYDRAULIC TANK

SUCTION TUBE

•

•• •

1

• • •

CLEAN-OUT COVER PLATE

RETURN TUBES

• •

••

FILL HOSE

OUTLET SUCTION TUBES RETURN STRAINER SCREEN IN TANK

OIL FILL SHUT OFF VALVE

•

•

• •

DRAIN PLUG

7501-20A

HYDRAULIC TANK

HAND FILL PUMP

HYDRAULIC HAND FILL PUMP

DRAINING/REFILLING THE HYDRAULIC TANK

The hydraulic hand fill pump(1), located at the rear of the machine is used for adding oil to the hydraulic oil tank.

Replace the oil in the hydraulic tank every 2000 hours of use and Seasonally as recommended in Section 3 of this manual.

Vent the hydraulic tank as outlined in VENTING THE HYDRAULIC TANK. Place a suitable container under the hydraulic tank and remove the drain plug on bottom of tank.

When the tank is drained, reinstall the drain plug and wipe up any spilled oil. Refill the tank using the hand fill pump. Keep the hydraulic oil between the ADD and FULL calibrations.

NOTE: When refilling the hydraulic system, vent pumps, motors and valves of air by opening a plug or hose fitting located near or on top of the pumps, motors and valves until oil free of air is seen flowing out of the plug or hose fitting. Failure to vent air from the hydraulic system could cause serious damage to hydraulic components. Tighten plugs or fittings and clean up any spilled oil when completed.

NOTE: Changing strainers, filters and replacing the hydraulic oil tends to aerate the oil. For maximum pump life, the machine should sit for 1 hour after servicing to allow entrained air to escape from the oil prior to applying working pressures to the pumps.

NOTE: Check all hydraulic system components especially cooling fan for proper operation after hydraulic oil has been replaced.

10.9

To add oil to the tank, vent the tank, clean suction tube and remove cap. Open oil fill shut-off valve, insert end of suction tube into supply drum and operate the pump. The oil is pumped directly into the hydraulic reservoir via a return filter. The pump should always be operated at a medium speed with steady motion. Pumping too fast may cause oil to by-pass oil filter.

IMPORTANT: Close shut-off valve after filling and replace cap on suction tube.

Tigercat M760 Mulcher

Oil Cooler/Radiator and Cross-flow Fan

FAN SPEED CHECKS

AUTO

FAN 'CLEAN' SPEED AND CHECK FOR NO A/C DURING CLEAN MODE

CLEAN (PURGE)

Park machine on level ground, lower the attachment and stop engine.

2.

Place a piece of reflecting tape on the fan hub.

3.

Start the engine.

4.

Set engine speed to 2100 rpm.

M760-022

FAN CONTROL SWITCH

NOTE: A calibrated "electronic photo tachometer" is required for this procedure.

Before placing the fan switch in the CLEAN position make sure that there are no personnel at the rear of the machine in the area where the fan will expel debris With the help of an assistant momentariliy press the fan switch (1) in the CLEAN position.

6.

Use a photo-tachometer to measure the speed of rotation of the fan blade, it should be 800 rpm.

7.

With the help of an assistant momentariliy press the fan switch (1) in the CLEAN position and visually check clutch on A/C compressor.

It should be disengaged and compressor not running.

8.

•

FAN FULL ON SPEED

CAUTION

5.

• ••

NOTE: A calibrated "electronic photo tachometer" is required for this procedure.

1.

FULL ON (OVERRIDE)

When the CLEAN cycle is complete (15 seconds) the fan automatically returns to normal rotation direction and the clutch on the A/C compressor should engage and the compressor should be running.

10.10

1.

Park machine on level ground, lower the attachment and stop engine.

2.

Place a piece of reflecting tape on the fan hub.

3.

Start the engine.

4.

Set engine speed to 2100 rpm.

5.

Place FAN switch in FULL ON position.

6.

Use a photo-tachometer to measure the speed of rotation of the fan blade, it should be 1200 rpm.

FAN SPEED - DEFAULT NOTE: A calibrated "electronic photo tachometer" is required for this procedure.

1.

Park machine on level ground, lower the attachment and stop engine.

2.

Place a piece of reflecting tape on the fan hub.

3. Disconnect the hydraulic oil temperature sensor.

4.

Start the engine.

5.

Set engine speed to 2100 rpm.

6.

Use a photo-tachometer to measure the speed of rotation of the fan blade, it should be 1200 rpm.

Tigercat M760 Mulcher

Oil Cooler/Radiator and Cross-flow Fan

CLEANING PROCEDURE: 1.

CAUTION

Shut down as per instructions in OPERATING MACHINE in SECTION 2.

Use compressed air for cleaning only when the machine is cold to avoid the risk of fire caused by debris being blown into contact with hot surfaces.

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

Always use personal protective equipment (eyewear) to guard against flying debris.

Always follow proper engine shutdown procedures.

The important benefits are: •

Extended life of engine, cooling and exhaust systems.

•

Reduced risk of post shutdown fires.

•

Interior of machine cools significantly reducing risks from touching hot surfaces.

4.

HAND KNOB

R.H. SIDE ACCESS PANELS

When the units have been cleaned return all cooling components to their operating position.

CAUTION

•

••

•

Avoid the risk of fire caused by debris accumulating on surfaces that may become hot during machine operation.

Always use care when cleaning to ensure that debris removed from one area of the machine does not accumulate on other areas of the machine.

•

NOTE: The cooling assembly must be checked daily and may have to be thoroughly cleaned on a daily, weekly or monthly basis, depending on operating conditions. Use personal protective equipment (eyewear) to guard against flying debris. Use compressed air for cleaning only when the machine is cold to avoid the risk of fire caused by debris contacting hot surfaces. Care must be taken not to set the pressure too high otherwise damage to the components could result.

R.H. ENGINE ACCESS PANELS

726-002

HAND KNOB

L.H. SIDE ACCESS PANELS

•

•

•

•

Pay particular attention to cleaning in the corners of the cooler as these areas usually plug deeply.

Reversing the fan at least once per hour will help reduce the dust accumulation in the cooler cores.

726-001

2.

L.H. ENGINE ACCESS PANELS

Open the right and left side access panels.

3. Remove two nuts and carefully swing open the A/C condenser (on hinges) to expose oil cooler/radiator/CAC cooling assembly. Remove any accumulated debris from between A/C / condenser and oil cooler/radiator/CAC cooling assembly.

10.11

Avoid the risk of fire caused by debris accumulating on surfaces that may become hot during machine operation. Always use care when cleaning to ensure that debris removed from one area of the machine does not accumulate on other areas of the machine. For more information on fire prevention refer to FIRE PREVENTION in SECTION 1 of THIS MANUAL. If an oil leak occurs in this area it should be thoroughly power-washed with a mild soap to ensure that all of the oil is removed. The presence of oil causes dust and dirt to cling to surfaces which will impair the reversible fan's ability to remove dust and dirt particles.

Tigercat M760 Mulcher

Oil Cooler/Radiator and Cross-flow Fan

10.12

Tigercat M760 Mulcher SECTION 11- STEERING AND CENTER JOINT OCTOBER, 2006

CONTENTS - SECTION 11 CENTER JOINT ADJUSTMENT ............................................................. 11.17 CHECKING .................................................................. 11.17 DIAGRAM .................................................................... 11.18 GREASE SEALS ......................................................... 11.18 LUBRICATION ............................................................. 11.17 MAINTENANCE ........................................................... 11.17 CIRCUIT DESCRIPTION ................................................ 11.6 CIRCUIT DIAGRAM ........................................................ 11.7 JOYSTICK CONTROL VALVE ........................................................ 11.5 STEER CIRCUIT DESCRIPTION ................................ 11.6 STEER VALVE ............................................................. 11.4 PRESSURE SETTINGS .................................................. 11.8 PRESSURE SETTINGS .................................................. 11.8 PRIORITY VALVE ............................................................ 11.13 PUMP .............................................................................. 11.2 RELIEF VALVE ................................................................ 11.3 STEERING JOYSTICK .................................................... 11.4 STEERING WHEEL HYDRAULIC SCHEMATIC ........................................... 11.14 OPERATING DESCRIPTION ....................................... 11.10 PRIORITY VALVE ........................................................ 11.13 STEER CONTROL VALVE ........................................... 11.10 STEERING WHEEL ........................................................ 11.10 TESTING THE STEERING OPERATION ........................ 11.16

Tigercat M760 Mulcher STEER/BOOM PUMP

Steering and Center Joint Radial movement of the vanes and turning of the rotor causes the chamber volume between the vanes to increase as the vanes pass the inlet sections of the ring. This results in a low pressure condition which allows atmospheric pressure to force fluid into the chambers.

This is a vane type double 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.

BOOM/ STEER PUMP

•• An additional inlet fluid path exists through a drilled hole in the cam ring. This hole connects the inlet port directly to the inlet areas of the cam ring and provides an additional flow path for fluid to get into the cartridge.

M760-042

STEER/BOOM PUMP

Fluid is trapped between the vanes and carried past a sealing land to the outlet section of the ring. As the outlet section is approached, the chamber volume decreases and the fluid is forced out into the system. System pressure is fed under the vanes, assuring their sealing contact against the ring during normal operation.

The shaft end section of the pump supplies hydraulic oil for the steering, brake and differential lock functions and oil to the pilot circuit. The end section of the pump supplies hydraulic oil for the boom functions.

The action of the cartridge is illustrated below.

SHAFT END SECTION (STEER)

•

M760-005.TIFF

The rotor is driven within the ring by the driveshaft, which is coupled to a power source.

As the rotor turns, centrifugal force on the vanes, aided by under-vane pressure fed from the outlet port, causes the vanes to follow the elliptical inner surface of the ring.

11.2

END SECTION (BOOM)

•

STEER/BOOM PUMP CROSS SECTION

AP133

Tigercat M760 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 STEER RELIEF (2500 PSI) - 1/2" WRENCH - 9/16" WRENCH

•• ••

TEST PORT

••

ADJUSTING SCREW

LOCKNUT

• TANK

PRESSURE 726M-065

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

RPGC

Tigercat M760 Mulcher JOYSTICK STEERING 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.

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.

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.

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

A

LOAD CHECK VALVE

RELIEF VALVE PORT 'B'

B

SPOOL SPOOL CENTERING SPRING TANK PASSAGE

90136-3

THRU' NEUTRAL PASSAGE

STEERING VALVE CROSS SECTION

11.4

Tigercat M760 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 valve spool 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 M760 Mulcher JOYSTICK 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 M760 Mulcher

726M-073

Steering and Center Joint

JOYSTICK STEER CIRCUIT DIAGRAM 11.7

Tigercat M760 Mulcher STEERING PRESSURE SETTINGS

Steering and Center Joint NOTE: The following procedure is applicable to joystick steering systems. For Steering wheel systems the steer valve adjustments do not apply, follow steps 1 to 2, steps 5 to 6 then steps 10 to 13.

NOTE: Refer to RELIEF VALVE ADJUSTING PROCEDURE in SECTION 18 of THIS MANUAL. Before starting this procedure, read the following safety precautions:~

1. Park the machine on level ground, lower the felling head to the ground and set the parking brake ON. Install articulation lock bar, block wheels and stop engine.

• 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.

WARNING

• Be aware of machine pinch points that could cause injury. Never place body parts within the range of motion of moving parts.

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.

• Be sure to use lynch pins when installing articulation lock bar. Vibration and the motion of steering could work retaining pins upward.

2. Install a 0-5000 psi pressure gauge to the steer relief valve gauge test port .

REAR CHASSIS

3. Turn the steer relief valve adjusting screw all the way in and then back out two turns.

FRONT CHASSIS

•

•

RETAINING PIN

4. Turn both steer valve port relief adjusting screws on steer valve out until spring pressure is relieved.

• • LYNCH PIN

LOCK BAR

• 726D-039

LOCK BAR IN LOCKED POSITION

11.8

Tigercat M760 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.

STEER RELIEF (2500 PSI) - 1/2" WRENCH - 9/16" WRENCH

• ••

TEST PORT

•

ADJUSTING SCREW

LOCKNUT

•• TANK

PRESSURE 726M-065

STEER RELIEF VALVE

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

RPGC

Tigercat M760 Mulcher STEERING (WITH STEERING WHEEL) STEERING WHEEL - OPTIONAL

Steering and Center Joint The output flow of the steering control unit varies with the speed that the steering wheel is rotated.

When moving the wheel slowly the output of the steering control is low, causing the machine to steer slowly. When the wheel is turned rapidly the output of the steering control is high, causing the machine to steer much faster.

Fast steering (turning the steering wheel rapidly) is necessary when operating in the woods to provide the required maneuverability.

•

2 1

M760-034

Travelling on the road requires a slower steering response (turning the steering wheel slowly), making it easier to make minor corrections when travelling in a straight line.

•

STEERING WHEEL

When the machine is equipped with Optional Steering Wheel (1) the steering function is Variable Ratio Load Sensing Steering. The speed that the machine responds to the steering wheel input will vary, depending on the speed that the steering wheel is moved. When operating on the road, a slow movement of the steering wheel will not overcorrect and will steer a straight normal course. Operating in the woods requires quick steering changes produced by a rapid movement of the steering wheel, which will quickly change the machines direction.

CAUTION The steering system is always LIVE when engine is running. DO NOT use the steering wheel to assist entering or leaving the cab.

TILT STEERING COLUMN Push handle (2) down to release tilt lock, move steering wheel to desired position. Release handle to lock steering column in place.

The cylinder ports 'L' and 'R' contain built-in anticavitation valves to protect against vacuum (cavitation) conditions.

OPERATING DESCRIPTION The steering control valve has a spool that is able to rotate inside a sleeve. When the steering wheel is stationary, the unit is in the neutral position and the spool is aligned in the sleeve so that oil cannot flow through the valve. The steering cylinders are prevented from moving by the oil that is trapped on both sides of the pistons.

When the steering wheel is turned, the spool rotates inside the sleeve and opens passages to allow oil flow through the spool/sleeve assembly.

This oil flows to the Gerotor section of the valve, causing the gerotor to rotate and then continues back into the valve and out the work port to the end of each steer cylinder.

There is a small, variable bypass orifice in the spool/sleeve assembly that allows a small amount of oil into the pressure side of the steering valve.

This will suppress the initial pressure surge when the steering wheel is partially turned. The orifice is closed off when the wheel is fully turned.

STEER CONTROL VALVE This is a manually operated directional control valve. The steering wheel is directly connected to the steer valve through the mounting box in the front of the cab.

The use of load sensing power steering and a priority valve provides smooth pressure compensated steering.

11.10

Tigercat M760 Mulcher

M760-060

Steering and Center Joint

STEER CONTROL VALVE

The return oil from the cylinders enters back in the other work port, through the spool/sleeve assembly and back to tank. A load sense line, between the steering valve and priority valve, drains oil out of the load sense port in the priority valve. The oil drains to tank through an orifice located between the sleeve and gerotor on the steer valve.

When the steering wheel has stopped moving, the gerotor gear continues to move and turns the sleeve until the sleeve moves to its center (neutral) position and stops sending oil to the gerotor. The valve is no longer sending oil to the cylinders.

The speed that the steering wheel is rotated, determines the speed that the machine will turn.

Turning the steering wheel slowly causes the variable orifice to decrease in size and it will take more turns of the wheel from stop to stop. If the wheel is turned quickly the orifice opens and it will take fewer turns of the wheel from stop to stop.

RETURN MANIFOLD

• HYDRAULIC TANK

••

M760-080

11.11

STEERING HYDRAULIC INSTALLATION WITH STEERING WHEEL OPTION

Tigercat M760 Mulcher

Steering and Center Joint 'P' PRESSURE

'R' RIGHT 'L' LEFT 'T' TANK

••

••

'LS' LOAD SENSING PORT ON SIDE OF STEER VALVE (NOT SHOWN)

•• STEERING COLUMN CONNECTION

LEFT

RIGHT

PUMP IN

PUMP RETURN (TANK)

•R

•

•T

L

•P

HOUSING

• BEARING

SPOOL

• •

•

•

•

• • •

•

STEERING COLUMN CONNECTION

• • CENTERING SPRINGS

AT027-1

SLEEVE

PIN

CHECK VALVE

DRIVE

STEER CONTROL VALVE 11.12

WEAR PLATE

GEROTOR RING AND STAR

• SPACER

END CAP

Tigercat M760 Mulcher PRIORITY VALVE

Steering and Center Joint P

The priority valve receives hydraulic oil from the accumulator charge valve.

T

The oil then passes through the priority valve, where it is divided up to go to either the steer valve and on to the steer cylinders, or the mulcher valve functions.

LS

The priority valve is a feature that allows the steer circuit to have first call on oil before the mulcher valve circuits.

This control is accomplished by a load-sensing feedback circuit from the steer valve to the priority valve.

EF

By splitting the system into two independent circuits, pressure transients are isolated in each circuit and only the flow required for steering goes to the steering circuit. The remaining flow is available for the mulcher valve functions. This provides safe, reliable operation because the steering circuit always has flow and pressure priority.

CF

PRIORITY VALVE

AT028-2

When full oil flow is not required for steering the excess supply of oil is directed to the other circuits.

The priority valve contains a built-in relief valve that is turned in fully. The steer circuit is protected by a separate external relief valve that is factory set at 2500 psi. When this relief setting is exceeded, the flow will be directed to the return manifold and back to tank.

OIL 'IN' FROM ACCUMULATOR VALVE RELIEF VALVE CARTRIDGE TURNED IN FULLY

P

•

LS

• AT028-1

LOAD SENSE CONNECTION TO STEER VALVE

EF TO MULCHER VALVE FUNCTIONS

AT028

PRIORITY VALVE 11.13

CF TO STEER VALVE

Tigercat M760 Mulcher

M760-081

Steering and Center Joint

STEER CIRCUIT HYDRAULIC SCHEMATIC - (STEERING WHEEL OPTION) 11.14

Tigercat M760 Mulcher

M760-082

Steering and Center Joint

STEER CIRCUIT - (STEERING WHEEL OPTION) 11.15

Tigercat M760 Mulcher TESTING THE STEERING OPERATION:

Steering and Center Joint

1. Move the machine to a suitable, level and smooth test area, where it can be safely operated at full throttle. Attachment raised off the ground.

2. With the parking brake OFF, differential locks OFF, NO service brakes applied and full throttle, turn the steering completely one way until it hits the stop.

3. Turn the steering wheel the opposite way, as SLOWLY as possible, until it hits the end stop. This should take 7 1/2 to 8 turns of the wheel.

4. Turn the wheel back to the other end stop, very slowly to verify the 7 1/2 - 8 turns.

5. Turn the wheel back to the other end stop, as fast as possible. Resistance to turning the wheel will be felt during this operation. This should take 3 1/2 to 4 turns of the wheel.

6. Turn the wheel back to the other end stop, as fast as possible to verify the 3 1/2 - 4 turns.

7. If these values are not obtained, check the priority valve and/or steering control unit.

11.16

Tigercat M760 Mulcher

Steering and Center Joint 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.

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. 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.

5. Fully loosen only the 6 bottom pin retainer bolts (item 2) that were torqued in step 2.

DIAL INDICATOR PLUNGER

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.

11.17

Tigercat M760 Mulcher

Steering and Center Joint

11. A change of 0.008" to 0.012" should register on the dial indicator.

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 10). 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.

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.

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; •

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.

TORQUE TO 282 - 310 LBF-FT. 1 NO LOCTITE REQUIRED

•

GREASE SEALS WITH SPRINGS FACING UPWARD

REAR CHASSIS • •

FRONT CHASSIS

11

•

9

• • •

• 6

• • • • CENTER JOINT 11.18

3

2

TORQUE TO 282 - 310 LBF-FT. NO LOCTITE REQUIRED

5

•

GREASE SEALS WITH SPRINGS FACING DOWN 726M-074

4

10

8 7 TORQUE TO 80 - 88 LBF-FT. USE LOCTITE (REMOVABLE)

Tigercat M760 Mulcher SECTION 12 - LIFT BOOM OCTOBER, 2006

CONTENTS - SECTION 12 BOOM LIFT LOCK .................................................................................................................... 12.6 BOOM VALVE ASSEMBLY PROCEDURE ................................................................................................... 12.10 CROSS SECTION OF SPOOL SECTION .............................................................................. 12.2 OPERATING DESCRIPTION .................................................................................................. 12.2 RELIEF VALVES .................................................................................................................... 12.8 CIRCUIT DESCRIPTION ........................................................................................................... 12.4 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 RELIEF VALVES ADJUSTING PROCEDURE .................................................................................................... 12.9 OPERATION .......................................................................................................................... 12.8

Tigercat M760 Mulcher BOOM JOYSTICK VALVE

Lift boom OPERATING DESCRIPTION

The boom joystick 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 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

JOYSTICK PILOT VALVE

RR-12

•

5

• •

4

•

'P' PORT

AUO13-2

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).

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 THIS SECTION.

•

WORK PORTS 1, 2, 3 OR 4

SPOOL ARRANGEMENT

12.2

Tigercat M760 Mulcher

Lift boom

TILT

OUT

CLOSE

LIFT 'DOWN' PORT RELIEF (2200 PSI)

IN

MULCH DEFLECTOR DOOR

OPEN

LIFT 'UP' PORT RELIEF (2900 PSI)

THIS SECTION NOT USED

•

DOWN

LIFT BOOM

•

UP

INLET GAUGE TEST PORT

•

•

MAIN RELIEF (2600 PSI)

•

INLET SECTION

BOOM CONTROL VALVE

M760-057

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 M760 Mulcher LIFT BOOM 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.

12.4

Tigercat M760 Mulcher

Lift boom

LIFT BOOM CIRCUIT M724D-24

12.5

Tigercat M760 Mulcher PRESSURE SETTINGS

Lift boom WARNING

NOTE: Refer to RELIEF VALVE ADJUSTING PROCEDURE in this section.

Do not stand above or below the felling head 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 set-up.

4. Turn the boom mid inlet main relief adjusting screw all the way IN.

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

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.

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

1. Park machine on level ground. Completely raise lift boom. Set parking brake ON. Install articulation lock bar, block wheels and stop engine.

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.

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.

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.

2. 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.

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.

WARNING

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

• Always install 'T' handle retainer bolt • Use only to support boom and cutting head • Do not use to set hydraulics pressures 3. Connect a 0 - 5000 psi pressure gauge (with at least 4' of hose) to the boom control valve mid inlet test port.

12.6

Tigercat M760 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 felling head 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 mid 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 felling head to sit on the ground. Stop engine and readjust the mid 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 M760 Mulcher

Lift boom ANTI-CAVITATION RELIEF VALVE

VALVE POPPET

This valve is used as a MAIN and PORT relief valve in the saw, clamp arm, and accumulating arm control valves.

T P

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

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 SEATING POPPET

Step 3.

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.

P

STEP 3

T

Step 4.

VALVE POPPET

T

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.

P

STEP 4

T

Step 5.

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.

T

VALVE POPPET

P

STEP 5

T CHECK POPPET

As an anti-void or check valve.

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’.

T P

ANTI-VOID CHECK OPERATION

T 12.8

Tigercat M760 Mulcher

Lift boom

ANTI-CAVITATION RELIEF VALVE ADJUSTING PROCEDURE For relief valve with adjusting nut ADJUSTING NUT

•

JAMNUT

•

RELIEF VALVE 51055-2

WITH ADJUSTING NUT

1.

Loosen jamnut.

2.

Turn adjusting nut to obtain desired pressure reading on gauge.

3.

Lock jamnut against adjusting nut, making sure the adjusting nut does not turn.

5.

Re-check relief setting.

12.9

Tigercat M760 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.

12.10

Tigercat M760 Mulcher SECTION 13 - TILT OCTOBER, 2006

CONTENTS - SECTION 13 BOOM LIFT LOCK ................................................................................................. 13.5 BOOM VALVE DIAGRAM ....................................................................................... 13.2 CIRCUIT DESCRIPTION ........................................................................................ 13.2 CIRCUIT DIAGRAM ................................................................................................ 13.3 CONTROL VALVES ................................................................................................ 13.2 PRESSURE SETTINGS ......................................................................................... 13.4 RELIEF VALVES ADJUSTING PROCEDURE ................................................................................. 13.5

Tigercat M760 Mulcher

Tilt

TILT 'OUT' PORT RELIEF (2900 psi) TILT 'IN' PORT RELIEF (2900 psi)

•

•

GAUGE TEST PORT

•

•

•

INLET SECTION

MAIN RELIEF (2600 psi)

BOOM VALVE

CONTROL VALVES

TILT CIRCUIT DESCRIPTION

For a complete description of the boom valve, refer to BOOM VALVE in SECTION 12 of THIS MANUAL.

The boom valve is located on the front chassis above the front axle, behind the cover plate.

Two cylinders are used to tilt the attachment forward and back. The cylinders receive oil from the fixed displacement steer/boom 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.

13.2

Tigercat M760 Mulcher

M724D-23

Tilt

TILT CIRCUIT 13.3

Tigercat M760 Mulcher PRESSURE SETTINGS

Tilt 4. Turn the boom mid inlet main relief adjusting screw all the way IN.

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

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.

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

6. Start the engine, and put the throttle control to the IDLE position.

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

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

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

8. While holding the joystick in the TILT OUT position (fully extended), check gauge pressure reading.

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

If less than 2900 psi, lower felling head to the ground, stop engine and readjust TILT OUT port relief. Repeat above procedure until a gauge reading of 2900 psi is obtained.

1. Park machine on level ground. Completely raise lift boom. Set parking brake ON. Install articulation lock bar, block wheels and stop engine.

IMPORTANT WARNING

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

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.

9. While holding the joystick in the TILT IN position (fully retracted), check gauge pressure reading.

If less than 2900 psi, lower felling head to the ground. Stop engine and readjust TILT IN port relief. Repeat above procedure until a gauge reading of 2900 psi is obtained.

2. 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.

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

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

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

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

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

3. Connect a 0 - 5000 psi pressure gauge (with at least 4' of hose) to the mid inlet test port.

12. While holding the joystick in the TILT IN position, check gauge pressure reading.

If less than 2600 psi, lower felling head to the ground. Stop engine and readjust the mid inlet main relief. Repeat above procedure until a gauge reading of 2600 psi is obtained.

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

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

13.4

Tigercat M760 Mulcher

Tilt

ANTI-CAVITATION RELIEF VALVE ADJUSTING PROCEDURE For relief valve with adjusting nut ADJUSTING NUT

•

JAMNUT

•

RELIEF VALVE 51055-2

WITH ADJUSTING NUT

1.

Loosen jamnut.

2.

Turn adjusting nut to obtain desired pressure reading on gauge.

3.

Lock jamnut against adjusting nut, making sure the adjusting nut does not turn.

5.

Re-check relief setting.

13.5

Tigercat M760 Mulcher

Tilt

13.6

Tigercat M760 Mulcher SECTION 17 - ATTACHMENT DRIVE OCTOBER, 2006

CONTENTS - SECTION 17 ACCUMULATOR ......................................................................................................... 17.9 ATTACHMENT MOTOR. ................. SEE ATTACHMENT MANUFACTURER'S MANUAL ATTACHMENT PUMP ................................................................................................. 17.2 CIRCUIT DESCRIPTION ............................................................................................. 17.4 PRESSURE SETTINGS .............................................................................................. 17.6 SAFETY ....................................................................................................................... 17.6

Tigercat M760 Mulcher ATTACHMENT PUMP

Attachment drive The pump operates in a closed loop circuit with twin fixed displacement attachment motors.

The variable displacement pump pistons run against a tilted swashplate that cause the pistons to compress the hydraulic fluid which provides high pressure oil to power the attachment motors.

760-02

The charge pump provides cooling and make-up oil as well as maintain a positive pressure in the main system loop and provide pressure to operate the control,system.

PISTON

SLIPPER

DISPLACEMENT CONTROL

•• M760-056

••

ATTACHMENT PUMP

The attachment pump mounted on the top left output pad of the pump drive gearbox is an axialpiston variable displacement pump. The pump also contains a fixed displacement, gerotor type charge pump that is driven off the pump drive shaft.

•• CHARGE PUMP M760-069

17.2

•• • •• SWASH PLATE

ATTACHMENT PUMP

INPUT SHAFT

Tigercat M760 Mulcher

M760-068

Attachment drive

MULCHER HYDRAULIC CIRCUIT SCHEMATIC 17.3

Tigercat M760 Mulcher

Attachment drive

ATTACHMENT CIRCUIT DESCRIPTION

2

The attachment is driven by two variable displacement hydraulic motors. A variable displacement hydraulic pump mounted on the pump drive gearbox supplies oil flow to the motors in a closed loop circuit. The electric cutter control valve mounted on the pump controls the flow of hydraulic oil from the attachment pump to the attachment motors.

The cutter switch on the control panel in the cab is used to place the pump in the FORWARD, OFF, or REVERSE mode. It is a 3 position switch controlling the flow of electrical current via a relay to the electric cutter control on the pump.

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.

••

1

•

M760-022

CUTTER CONTROL SWITCHES

CUTTER - REVERSE JOG (2) This is a momentary ON switch (2) labelled JOG REVERSE. This switch is used in conjunction with the CUTTER REVERSE switch for turning or indexing the cutter drum slowly for inspection and alignment during drum replacement.

Before using this switch, place the throttle at LOW IDLE. Place the CUTTER switch in the REVERSE position. Press and hold the JOG switch, the cutter drum rotates at slow speed in REVERSE direction. Release the JOG switch to stop the drum rotation.

NOTE: The attachment will not run unless both cab doors are closed and the pilot reset switch is pressed to activate the pilot system.

CUTTER - FORWARD/OFF/REVERSE (1) This is a three position switch (1) labelled FORWARD, OFF, REVERSE. FORWARD - Place throttle at HIGH IDLE before turning the cutter ON for normal operations.

Cutter drum rotates at FULL speed in the FORWARD direction.

OFF - Cutter drum is turned off.

REVERSE - The switch when set in this position dose not activate the cutter in reverse alone.

Requires the pressing and holding down of the JOG switch to allow the drum to turn in reverse direction.

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

17.4

Tigercat M760 Mulcher

M760-066

Attachment drive

MULCHER ELECTRICAL CIRCUIT SCHEMATIC

17.5

Tigercat M760 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.

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

Attachment drive 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 Workers on the ground should stand behind a safe barrier to provide protection from thrown objects.

8. Warm machine so that hydraulic oil temperature is between 120°F and 140°F. 9. With engine off, install on the CUTTER PUMP a 1000 psi gauge on the test fitting in the block attached to “M3” and a 10,000 psi gauge at “M1” & “M2”.

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 M760 Mulcher

Attachment drive

ATTACHMENT FWD FLOW M2 10,000 PSI GAUGE SET TO 5000 PSI @ 1000 RPM

ATTACHMENT REV FLOW M1 10,000 PSI GAUGE SET TO 2500 PSI @ 1000 RPM

1

FLUSHING VALVE 1000 PSI GAUGE SET TO 320 PSI 6 @ 2800 RPM ATTACHMENT PUMP ENGAGED

2

• ATTACHMENT CHARGE PRESSURE 1,000 PSI GAUGE SET TO 350 PSI @ 1000 RPM

•

10

• •

10. Set engine to 1000 rpm.

11. Charge pressure at “M3” 350 psi.

12. Engage cutter FORWARD via cutter switch in cab or by manual switch on pump controller, adjust “B” (pressure limiter) to give the appropriate reading at “M2” 5000 psi (the high pressure limiter for this port is automatically set 500 psi above this setting and is nonadjustable).

13. Turn OFF cutter and allow the drum to come to a complete stop. DO NOT PROCEDE UNTIL DRUM HAS STOPPED ROTATING.

14. Engage cutter REVERSE via cutter switch and REVERSE JOG switch in cab or by manual switch on pump controller, adjust “A” (pressure limiter) to give the appropriate reading at “M1” 2500 psi (the high pressure limiter for this port is automatically set 500 psi above this setting and is non-adjustable).

16. Remove all pressure gauges and reinstall all plugs and caps.

17. Re-adjust the auxiliary set-up caliper to its ORIGINAL POSITION, and remove articulation lock.

17.7

Tigercat M760 Mulcher

Attachment drive

HOT OIL FLUSHING VALVE

FLUSHING VALVE 1000 PSI GAUGE SET TO 320 PSI @ 2800 RPM ATTACHMENT PUMP ENGAGED

VALVE BLOCK

•• •

•

RELIEF VALVE

• 'G' PORT

M760-059

HOT OIL FLUSHING VALVE

Loosen lock nut on relief valve and adjust valve until the gauge reading is 320 psi at 2800 rpm.

Install a 1000 psi gauge at “G” port on the bottom of the flushing valve block. The machine should be running at 2100 rpm with the cutter engaged (free-wheeling). Check the setting on the hot oil flushing valve block .

17.8

Tigercat M760 Mulcher CHECKING ACCUMULATOR CHARGE

Attachment drive CHARGING THE ACCUMULATOR 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

To check nitrogen charge in the return side accumulator, the machine must be off before beginning procedure.

Drain the stored fluid pressure from the accumulator by pulling-out the accumulator bleed down valve for 2 minutes. The nitrogen charge pressure can then be checked at the schrader valve located at the top of the accumulator bottle.

Remove the valve guard and cap from the top of the accumulator. Attach the charging and testing device onto schrader valve located at the top of the accumulator bottle.

ACCUMULATOR

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.

Check pressure, should be 225 psi.

Accumulator pre-charge - 225 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.

17.9

Tigercat M760 Mulcher

M760-070

Attachment drive

MULCHER HYDRAULIC COMPONENTS 17.10

Tigercat M760 Mulcher SECTION 19 - MULCH DEFLECTOR DOOR OCTOBER, 2006

CONTENTS - SECTION 19 BOOM LIFT LOCK ........................................................................................ 19.6 BOOM VALVE .............................................................................................. 19.2 CROSS SECTION OF SPOOL SECTION .................................................. 19.3 OPERATING DESCRIPTION ..................................................................... 19.3 CIRCUIT DESCRIPTION ................................................................................ 19.4 CIRCUIT DIAGRAM ....................................................................................... 19.5 CONTROL VALVES ...................................................................................... 19.2 PILOT LINE PRESSURES ............................ SEE SECTION 5 - PILOT SYSTEM PRESSURE SETTINGS ................................................................................ 19.6 RELIEF VALVES .......................................................................................... 19.8 SAFETY ....................................................................................................... 19.6 SPOOL SECTION DIAGRAM ........................................................................ 19.3

Tigercat M760 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.

For a complete description of the pilot manifold refer to SECTION 5 of THIS MANUAL.

The inlet section receives oil from the fixed displacement boom pump.

For a complete description of the foot operated pilot valve, refer to FOOT CONTROL VALVE in SECTION 8 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.

MULCH DEFLECTOR DOOR 'CLOSE' PORT RELIEF (1000 PSI) CLAMP ARM SECTION NOT USED FOR MULCHER APPLICATION

TILT •

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 M760 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 steer/boom pump enters the inlet section of the boom valve and is allowed to pass through the 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 M760 Mulcher MULCHER DEFLECTOR DOOR 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 M760 Mulcher

Mulch deflector door

MULCH DEFLECTOR DOOR CIRCUIT M760-058

19.5

Tigercat M760 Mulcher PRESSURE SETTINGS MULCH DEFLECTOR DOOR

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 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 BH350 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 M760 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 M760 Mulcher

Mulch deflector door 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

T VALVE POPPET

T

T P

STEP 5

T P

ANTI-VOID CHECK OPERATION

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 CHECK POPPET

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.

Step 5.

T VALVE POPPET

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.

P

STEP 4

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.

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’.

T 19.8

Tigercat M760 Mulcher

Mulch deflector door 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.

19.9

Tigercat M760 Mulcher

Mulch deflector door

19.10