TIGERCAT 822 FELLER BUNCHER SERVICE MANUAL – PDF DOWNLOAD

SERVICE MANUAL TIGERCAT 822 FELLER BUNCHER TABLE OF CONTENTS

ISSUE 1.0, JUNE 2003

SECTION INTRODUCTION ............................................................................................................... ii NON-APPROVED FIELD PRODUCT CHANGES ............................................................ iii SAFETY ............................................................................................................................ 1 USING HIGH SPEED DISC SAWS SAFELY .......................... APPENDIX TO SECTION 1 CONTROLS AND OPERATION ............................. See separate OPERATOR'S MANUAL LUBRICATION AND MAINTENANCE ............................................................................... 3 HYDRAULIC SYSTEM/ LOAD SENSE CONTROL ........................................................... 4 PILOT/CHARGE SYSTEM ................................................................................................ 5 ELECTRICAL, GAUGES AND ALARMS ........................................................................... 6 ENGINE START AND STOP ............................................................................................. 7 ENGINE ANTI-STALL ....................................................................................................... 9 OIL COOLER AND COOLING FAN ................................................................................ 10 TRACK DRIVE ................................................................................................................ 11 BOOM FUNCTIONS ....................................................................................................... 12 SWING ............................................................................................................................ 15 SAW DRIVE .................................................................................................................... 17 CLAMPS .......................................................................................................................... 18 WRIST ............................................................................................................................ 19

822-SM00

Tigercat

822 Feller Buncher Available Literature Operator's Manual ............................... Part No. 18869A Manuel de l'opérateur (Français) ........ Part No. 21431A Service Manual .................................... Part No. 18870A Parts Catalog ....................................... Part No. 18868A Hydraulic Adapters Book ....................... Part No. 1472A Hydraulic Hose Assemblies Book ......... Part No. 3707A

®

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

Fax: (519) 442-1855

ii

Tigercat 822 Feller Buncher

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 822 Feller Buncher serial number 8220114 to 8220189.

The operator's manual will assist the operator with the techniques of proper and safe operation of the 822 Feller Buncher. 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.

822-01

iii

Tigercat 822 Feller Buncher

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.

iv

Tigercat 822 Feller Buncher

SECTION 1 - SAFETY JUNE 2003

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

Read and understand all manuals for any attchment or accessories.

CONTENTS - SECTION 1 CAB EXITS .................................................................................................... 1.6 COOLING SYSTEM ..................................................................................... 1.13 EFFICIENT REACH (ER) BOOM SYSTEM PRECAUTIONS ...................... 1.14 EMERGENCY CAB EXITS ............................................................................ 1.6 ENGINE DOORS ......................................................................................... 1.15 EXHAUST FUMES ....................................................................................... 1.15 FELLING TREES ........................................................................................... 1.9 FIRE PREVENTION ..................................................................................... 1.17 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 FLUID LEAKS .............................................................................................. 1.13 HYDRAULIC PRESSURE HAZARD ............................................................ 1.13 LOOSE CLOTHING HAZARD ..................................................................... 1.13 PARKING THE MACHINE ........................................................................... 1.10 PROTECTIVE CLOTHING ............................................................................. 1.3 SAFETY INTERLOCK SWITCHES ON CAB DOORS ................................... 1.7 SAFETY PRECAUTIONS, GENERAL ........................................................... 1.3 SAFETY PRECAUTIONS, OPERATING ....................................................... 1.6 SAFETY PRECAUTIONS, SERVICING ....................................................... 1.10 SAFETY SYMBOLS ....................................................................................... 1.2 SIGNAL WORDS ........................................................................................... 1.2

Tigercat 822 Feller Buncher

Safety

SAFETY SYMBOLS

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

Understanding Signal Words

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

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

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

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

1.2

Tigercat 822 Feller Buncher

Safety

GENERAL SAFETY PRECAUTIONS

KEEP BACK 500 FEET

Remember that safety is a prime responsibility of all.

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

Study all the safety messages in this manual and on the labels on the machine carefully.

Follow all instructions from safety inspector and supervisors.

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

DANGER ROTATING SAW The safety of persons outside the cab is the responsibility of the machine operator Always avoid the discharge side of a felling sawhead. A sawhead's high-velocity discharge of debris requires a safe separation distance.

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.

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.

Do not let untrained persons operate the machine.

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

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

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

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

Do not use the machine foot controls as steps.

Use recommended protective clothing and safety devices such as gloves, safety boots, safety hat, goggles, and ear protection when necessary. These safety rules highlight both general and specific measures that the operator should be familiar with and adhere to. More specific measures are illustrated with pictograms which may also be attached to the machine in locations pertinent to their respective message. Keep safety labels in good condition. Repair or replace damaged labels.

1.3

Tigercat 822 Feller Buncher GENERAL SAFETY PRECAUTIONS continued

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

Check all fluid levels.

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

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

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

Avoid mounting or dismounting the machine in areas with slippery surfaces. If this is not possible, clean up or cover slippery surfaces with a non-slip material.

Safety Hazards - Viton Seals O-rings and other seals manufactured of Viton material (fluofine rubber) produce a highly corrosive acid (Hydofluoric) 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.

•

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 fluro-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.

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

Machine should be washed completely at every major service.

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

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

Check windows and door guards for damage.

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

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

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

1.4

Tigercat 822 Feller Buncher

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 ft. (3m) between the machine or boom and any power line carrying up to 50,000 volts or less plus 1/2 inch (10mm) for each addition 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.

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 felling head manufacturer.

1.5

Tigercat 822 Feller Buncher

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

OPERATING SAFETY PRECAUTIONS

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

1. Front 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 FRONT DOOR in THIS SECTION.

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

2. Side door, should be used for emergency exits only. Do not use this door to routinely enter or leave the cab. This door is not equipped with a safety interlock switch and therefore when left open will not deactivate the pilot controls in the cab. This could cause the controls to be operated accidentally.

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

Sound the machine horn before starting the machine.

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

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

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

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 front door or the side door and escape hatch retaining mechanisms must not be tampered with or defeated.

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

Start the engine according to the instructions in this manual. Refer to OPERATING MACHINE in SECTION 2 of the OPERATOR'S MANUAL. Never use a liquid staring aid to start an engine.

WARNING

1.6

Tigercat 822 Feller Buncher

Safety Secure loose items in the cab.

OPERATING SAFETY PRECAUTIONS continued

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

SAFETY INTERLOCK SWITCH ON FRONT DOOR: The front door is equipped with a safety interlock switch to prevent the machine from being operated while the front door is open (pilot system is shut off).

SWITCH

ACTUATOR ON DOOR

••

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

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

••

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

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

822-D02

INTERLOCK SWITCH (FRONT DOOR)

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

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

Close the front door and press the PILOT RESET switch.

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.

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

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

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

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

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

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 felling head 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.

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

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

1.7

Tigercat 822 Feller Buncher

Safety

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

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.

NEVER travel across a STEEP slope or side hill: •

As logs are added to the accumulator pocket the handling and the stability of the machine will change.

•

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

•

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

•

Do not overload the machine as this can create an unstable condition and cause a rollover.

1.8

Tigercat 822 Feller Buncher

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

OPERATING SAFETY PRECAUTIONS continued

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

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

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

Always replace saw tooth retaining bolts when replacing saw teeth.

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

24°

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

Shut down machine immediately if vibration occurs during cutting.

Check that the saw discharge area is clear and undamaged.

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

Do not over load felling head.

20°

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

830-05 830-06

FIG. 2 Do not operate on slopes that exceed the levelling angles of the levelling mechanism. See fig. 2.

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

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

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

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

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

1.9

Tigercat 822 Feller Buncher OPERATING SAFETY PRECAUTIONS continued Never use this machine to clear a logging deck on a new tract of timber when the rest of the equipment and operator's are also moving in. Preplan to clear decks in advance before other equipment arrives.

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

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

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

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

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, lower the felling attachment onto the ground.

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

When parking the machine: •

Park on level ground.

•

Do not park on a hillside or incline.

•

Lower felling attachment onto level ground.

•

Stop the engine.

•

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

1.10

Tigercat 822 Feller Buncher

Safety

SERVICING SAFETY PRECAUTIONS

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

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

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

1.11

Tigercat 822 Feller Buncher

Safety DISCONNECT THE TWO MULTI-PIN PLUGS FROM THE ENGINE CPU

SERVICING SAFETY PRECAUTIONS continued 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 current does not pass through bearings, especially the swing bearing.

Disconnect the negative (-) battery cable from all three batteries.

This machine is equipped with sensitive electronic control equipment, prior to welding:Disconnect the multi-pin plug from the engine anti-stall controller located on the rear inside wall of the cab.

QSC AND QSL9 ENGINES ONLY

ENGINE CPU DISCONNECT - LEFT SIDE OF ENGINE from the left side of the engine. (Applicable on QSC or QSL9 engines only).

830-D39

Disconnect the IQAN display 6 pin connector and the control module 42 pin connector. (Applies only to machines with IQAN control system)

DISCONNECT THE MULTI-PIN PLUG FROM THE ENGINE ANTI-STALL CONTROLLER

DISCONNECT THE 6 PIN PLUG FROM THE BACK OF THE DISPLAY MODULE

•

•• APPLIES ONLY TO MACHINES WITH IQAN CONTROL SYSTEM 830-D36

IQAN DISPLAY DISCONNECT

ENGINE ANTI-STALL DISCONNECT PLUG

ENGINE ANT-STALL DISCONNECT Disconnect the engine CPU (Central Processing Unit) by unplugging the two multi-pin connectors 822-D03

• DISCONNECT THE 42 PIN PLUG FROM THE XP MODULE

DISCONNECT THE TWO MULTI-PIN PLUGS FROM THE ENGINE CPU

••

• APPLIES ONLY TO MACHINES WITH IQAN CONTROL SYSTEM 830-D37

QSC AND QSL9 ENGINES ONLY 830-D38

ENGINE CPU DISCONNECT - LEFT SIDE OF ENGINE

1.12

IQAN XP MODULE DISCONNECT

Tigercat 822 Feller Buncher

Safety

SERVICING SAFETY PRECAUTIONS continued WARNING Diesel fuel or hydraulic fluid under pressure can penetrate the skin and cause serious personal injury, blindness, or death. If any fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with treating this type of Never use your bare hand to check for fluid leaks.

Fluid leaks under pressure may not be visible.

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

Wear safety goggles for eye protection.

Pressure can be maintained in a hydraulic system long after the power source and pump have been shut down. Lower the felling head to the ground, stop engine and relieve trapped pressure (from the accumulator on later machines) by operating the joystick several times before performing work on components, or disconnecting any hoses. Also relieve pressure in the hydraulic reservoir by opening hydraulic tank vent valve and waiting until the sound of escaping air stops.

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

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

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 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.

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

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

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.

1.13

Tigercat 822 Feller Buncher

Safety

SERVICING SAFETY PRECAUTIONS continued WARNING This machine may be equipped with an Efficient Reach (ER) boom system. Because of this, it may behave in an unexpected manner compared to a conventional boom system.

MACHINE MODELS EQUIPPED WITH AN EFFICIENT REACH (ER) BOOM SYSTEM Pay attention to the following when servicing the Efficient Reach Boom System (ER Boom): Certain hydraulic circuits on this machine are inter-connected in order to provide level head travel and to recirculate hydraulic oil to reduce heat generation and fuel consumption. As a result, disconnecting hydraulic lines from one cylinder may release pressure in different cylinder at the same time. Before attempting to disconnect hydraulic hoses or perform work on the boom system, ensure that:(a) The machine is parked on level ground with the head sitting flat on the ground. (b) The stick cylinders are fully extended (fig. 1) or the hoist cylinder fully collapsed (fig. 2). (c) The tip of the stick boom supported .

STICK CYLINDERS FULLY EXTENDED

• TIP OF STICK BOOM FULLY SUPPORTED 830-07

ER. BOOM SYSTEM. FIG.1

HOIST CYLINDER FULLY RETRACTED

•

TIP OF STICK BOOM FULLY SUPPORTED 830-08

ER. BOOM SYSTEM. FIG.2

1.14

Tigercat 822 Feller Buncher SERVICING SAFETY PRECAUTIONS continued Before performing work under the boom system ensure it is firmly supported.

WARNING Do not exceed maximum posted weight capacity of power door by using as platform for heavy components or too many people.

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

When performing required hydraulic checks and blade speed adjustments. Install the saw blade guard.

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

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

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

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

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.

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

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

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

Read, understand and follow all operating safety precautions specified by felling head manufacturer.

1.15

Tigercat 822 Feller Buncher

Safety dislodged by vibration this smoldering debris can fall into other areas of the machine and thereby spread a fire.

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.

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

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

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

8. 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.

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

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.

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

3. Remove debris and blow out dust regularly from the air intake doors, engine radiator, hydraulic oil cooler and A/C condenser core to prevent overheating of the engine and hydraulics. Refer to CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR in SECTION 2 of the OPERATOR’S MANUAL.

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

4. Blow off all debris and dust accumulated near hot engine exhaust components (turbocharger and exhaust manifold as well as exhaust pipes and muffler) at the completion of each work shift or more frequently depending on 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

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

13. 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.

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

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

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

1.16

Tigercat 822 Feller Buncher FIRE PREVENTION continued

Safety WHAT TO DO IN CASE OF A MACHINE FIRE •

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

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.

•

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

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 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.

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.

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

•

Use the PASS method with most extinguishers.

•

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

•

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

•

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

•

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

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

•

Prevent the fire from happening by ensuring that the machine is cleaned regularly and all systems are well maintained.

•

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.

Continued on page 18

*NOTE: Dry chemical fire suppression systems are offered by Tigercat as an optional installation on some of the Tigercat product lines. Please disregard any references made to fire suppression systems if not installed on your machine.

1.17

Tigercat 822 Feller Buncher

Safety WHAT TO DO AFTER A FIRE

FIRE PREVENTION continued Continued from page 17

20229A

•

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

•

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

•

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

•

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

TYPICAL FIRE EXTINGUISHER ACCESS HOLE

•

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

•

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

•

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

•

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

1.18

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

PAGE 1 OF 16

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using high speed disc saws safely FORWARD:

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

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

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

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

FIGURE 2: A SUDDEN MACHINE MOVEMENT MAY 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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using high speed disc saws safely

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

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

THROW ANGLE

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

•

•

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

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

THROW ANGLE

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

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

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

THROW ANGLE

NUDGED LOG WILL NOT CONTACT SAW TEETH.

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

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

5

using high speed disc saws safely Housing types cont.

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

A CHIP ESCAPE PORT CAN ALLOW THROW BEHIND THE MACHINE

REAR

FRONT

FIGURE 6a

FIGURE 6b

FIGURE 6c

FIGURE 6: ADDITIONAL OPENING IN THE HOUSING SKIRT.

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

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

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

6

using high speed disc saws safely COMMENTS AND INSTRUCTIONS

Tigercat

®

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.

Tigercat

®

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

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

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

8

using high speed disc saws safely

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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

9

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using high speed disc saws safely Comments and Instructions cont.

Tigercat

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

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

SLAB

•

SLAB

• 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.

Tigercat

®

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

13

using high speed disc saws safely Comments and Instructions cont.

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

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

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

FIGURE 13: SAW BLADE ENTRANCE AND EXIT SPACE

14

using high speed disc saws safely Comments and Instructions cont.

Tigercat

®

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

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

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

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

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

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

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

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

Do not over speed the blade rpm.

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

Do not neglect tooth fastening inspection, maintenance and replacement.

Do not neglect to repair worn or damaged saw housings.

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

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

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

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

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

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

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

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

Do not select and operate heads that throw rearward.

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

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

15

using high speed disc saws safely

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16

®

Tigercat 822 Feller Buncher SECTION 3 - LUBRICATION & MAINTENANCE JUNE 2003

CONTENTS - SECTION 3 AIR INTAKE CLEAN-OUT COVER PLATE .............................................................. 3.17 AIR INTAKE SEAL .................................................................................................... 3.17 APPROVED HYDRAULIC OILS ................................................................................. 3.7 EFFICIENT REACH (ER) BOOM SYSTEM ................................................................ 3.9 EMERGENCY EXITS, CHECK MONTHLY ................................................................. 3.3 ENGINE AIR CLEANER ............................................................................................ 3.16 AIR CLEANER MAINTENANCE ............................................................................ 3.18 FILTER RESTRICTION INDICATOR ..................................................................... 3.17 ENGINE AIR CLEANER UNLOADER VALVE .......................................................... 3.16 FILTER AND LUBRICATION SCHEDULE ................................................................. 3.8 FILTERS CHANGING HYDRAULIC RETURN FILTERS ...................................................... 3.12 ENGINE AIR FILTER ............................................................................................. 3.16 FUEL FILTER/WATER SEPARATOR ................................................................... 3.10 FUEL TANK STRAINER ........................................................................................ 3.11 HYDRAULIC OIL RETURN FILTERS .................................................................... 3.12 HYDRAULIC OIL RETURN STRAINERS/DIFFUSERS ......................................... 3.15 PILOT FILTER ....................................................................................................... 3.14 REMOVE AND REPLACE ..................................................................................... 3.10 SERVICING GUIDELINES FOR OIL FILTERS ..................................................... 3.12 FIRE PREVENTION .................................................................................................... 3.3 FUEL SHUT-OFF VALVE .......................................................................................... 3.10 GENERAL MAINTENANCE ........................................................................................ 3.3 HYDRAULIC OIL FILTERS ....................................................................................... 3.12 HYDRAULIC OILS ....................................................................................................... 3.7 LUBRICATE GEARBOX LOWER BEARINGS ........................................................... 3.9 LUBRICATION SCHEDULE ........................................................................................ 3.8 NEW MACHINE MAINTENANCE ...............................................................................

FIRST 50-100 HOUR INSPECTION AND SERVICE REPORT ...............................

INITIAL PRE-DELIVERY INSPECTION ...................................................................

TIGHTENING POINTS .............................................................................................

3.2 3.2 3.2 3.2

OIL LOST FROM LEAKAGE ....................................................................................... 3.2 PRESSURE SETTING PROCEDURES. SEE SERVICE MANUAL PRESSURE SETTING VALUES. SEE SERVICE MANUAL PREVENTIVE MAINTENANCE SCHEDULE .............................................................. 3.2 RETURN FILTERS ~ HYDRAULIC OIL .................................................................... 3.12 SCHEDULED MAINTENANCE FREQUENTLY .........................................................................................................

8 HOURS .................................................................................................................

24 HOURS ...............................................................................................................

125 HOURS .............................................................................................................

250 HOURS .............................................................................................................

500 HOURS .............................................................................................................

1000 HOURS ...........................................................................................................

2000 HOURS ...........................................................................................................

SWING DRIVE GEARBOX LUBRICATION OF LOWER BEARING ...................................................................

3.4 3.4 3.4 3.4 3.5 3.5 3.6 3.6 3.9

TORQUE CHART, GENERAL ................................................................................... 3.21 TORQUE SETTINGS, RECOMMENDED ................................................................. 3.20

Tigercat 822 Feller Buncher

Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE FOR 822 FELLER BUNCHER NEW MACHINE MAINTENANCE

*INITIAL PRE-DELIVERY INSPECTION:PERFORM THE INITIAL PRE-DELIVERY INSPECTION USING Tigercat FORM NUMBERS 5281 AND 5282; "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 5282; "PDI AND 50-100 HOUR INSPECTION REPORT" THIS MUST BE COMPLETED WITHIN THE FIRST 50-100 HOUR TIME FRAME.

*IMPORTANT: TO QUALIFY FOR CONTINUED WARRANTY, THIS REPORT MUST BE COMPLETED AND RETURNED TO Tigercat Industries Inc. WARRANTY DEPARTMENT.

Tightening points:~

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

All hydraulic connections Hose clamps All cylinder and boom pin retainers

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

Check swing bearing bolt torque Engine mounting bolts Pump mounting bolts

IMPORTANT

Track shoe bolts Track roller retaining bolts

BEFORE DRIVING MACHINE ENSURE THAT THE TRACK TENSION (SAG) IS SET CORRECTLY.

Track sprocket retaining bolts

TRACK SAG MAY BE SET LESS THAN SPECIFIED FOR SHIPPING PURPOSES.

Track drive gearbox mounting bolts Track drive motor mounting bolts

REFER TO SECTION 11 IN THE SERVICE MANUAL FOR THIS PROCEDURE.

Swing gearbox mounting bolts Cab securing bolts

OIL LOST FROM LEAKAGE

Any other loose nut, bolt or fitting LEAKAGE RATE ONE DROP IN 10 SECONDS ONE DROP IN 5 SECONDS ONE DROP PER SECOND THREE DROP PER SECOND DROPS BREAK INTO STREAM

3.2

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

Tigercat 822 Feller Buncher

Lubrication and Maintenance

GENERAL CAUTION

CHECK EMERGENCY EXITS MONTHLY~ Two alternate exit routes are provided on the LH. side and roof of the cab. These are only to be used if the front door cannot be opened.

ALL HANDLES, STEPS AND PLATFORMS MUST BE KEPT FREE OF GREASE, OIL, FUEL, MUD, SNOW, ICE AND FOREST DEBRIS.

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

Clean around filler caps before checking or adding fluids.

Refer to the and SIDE DOOR AND ESCAPE HATCH EMERGENCY EXIT MAINTENANCE GUIDE in SECTION 2 of the OPERATOR'S MANUAL for checking procedure.

Clean around hydraulic fittings before breaking connection. Plug or cap immediately.

Clean up spills as soon as possible.

Always release pressure in hydraulic tank Before breaking a connection.

Always use clean oil and containers.

Drain dirty oil while still warm.

Do not exceed recommended fluid levels.

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

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

Clean up oil spills on walking surfaces in engine enclosure immediately.

Before welding on machine, be sure the negative battery terminal and the speed control 25 pin connector in cab are disconnected.

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

Clean away all branches, bark and chips.

Clean up all traces of oil to avoid fires.

Always have a fire extinguisher at hand.

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

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

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

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

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

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

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

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

Always install door safety struts when working on machine.

Clean fire suppression system sensors.

3.3

Tigercat 822 Feller Buncher

Lubrication and Maintenance

SCHEDULED MAINTENANCE retaining pins and boom joints

FREQUENTLY:~

NOTE: This procedure will allow grease to flow to the normally "loaded side" of the pin/ bearing surfaces.

• Check engine cooling air intake screens for possible restriction.

In broad leaf applications it may be necessary to reverse the cooling fan as frequently as every 10 mins.

Clean:~ • Oil cooler, engine radiator and enclosure screens.

• Check for debris, snow and ice buildup on emergency exits and remove accumulation immediately.

• Remove potentially damaging limbs or sticks.

Check:~ • For leakage around hydraulic components and flexible hoses paying particular attention to cooling fan motor hydraulic connections.

• ER Boom system: Periodically, the main boom must be lifted up as far as it will go and then lowered to operating height in an area free from overhead obstructions in order to circulate hydraulic oil from the cylinders back through the cooler and filters. This oil does not circulate through the cooler or filters during normal horizontal motion and the oil does not get completely changed during normal vertical motion, so it is important that this procedure be followed at least once every hour.

• For loose nuts, bolts and fittings.

• Condition and tension of fan belts.

• Visually check condition of tracks.

• Conduct an overall visual inspection.

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

EVERY 24 HOURS :~ EVERY 8 HOURS:~

• Perform "frequently" maintenance

• Perform "frequently" maintenance

• Perform 8 hour maintenance

And in addition:~

And in addition:~

• Check engine coolant level

• Lubricate swing bearing; 1-fitting - 10 shots while swinging

• Check engine oil level • Drain water from fuel/water separator

EVERY 125 HOURS:~

• Check air intake precleaner operation • Check air cleaner unloader valve

• Perform "frequently" maintenance

• Check air filter resriction indicator

• Perform 8 hour maintenance

• Check hydraulic oil level

• Perform 24 hour maintenance

Lubricate:~ • Swing pinion; 1-fitting - 10 shots

And in addition check:~ • Return filter bypass warning light is NOT ON with engine running at high idle with oil flow and hydraulic oil at operating temperature

• ‡ Boom joints; 6-fittings - purge • ‡ Cylinders; boom, stick & tilt; 15-fittings total with high cap. tilt link system or 12-fittings with ER boom system - purge

• High pressure pilot filter restriction indicator with engine running at high idle and oil flow • Track drive gearbox oil level with one level plug at 6 O'Clock and the other at 9 O'Clock

‡ Lubricating cylinder pins and boom joints:1. Ensure machine is on level ground

• Fluid level in batteries unless maintenance free

2. Completely tilt felling head back

• Engine r.p.m.

3. Fully extend stick boom cylinder

• Hydraulic pump and motor securing bolts

4. Force heel of felling head onto ground

• Torque tightening points as per new machine maintenance

5. While in this position lubricate all cylinder

3.4

Tigercat 822 Feller Buncher

Lubrication and Maintenance

SCHEDULED MAINTENANCE • Replace air intake primary element.

Visually check for damage to:~ • Main and stick booms

• Replace oil in track drive gearboxes with one level plug at 6 O'Clock and the other at 9 O'Clock

• Tracks, track frames and carbody • Swing bearing area • Attachment Make repairs immediately

EVERY 500 HOURS:~ • Perform "frequently" maintenance

Visually inspect for:~ • Frayed electrical wiring and hydraulic hoses

• Perform 8 hour maintenance

NOTE: Neglecting the proper maintenance of these items can result in fire.

• Perform 24 hour maintenance • Perform 125 hour maintenance

• Wear in any other components

• Perform 250 hour maintenance

Clean/replace:~ • Inspect for debris buildup between radiator and oil cooler

And in addition replace:~ • Air intake safety element.

• Hydraulic oil return filters. †

• Air conditioner re-circulation filter

• Hydraulic oil high pressure pilot filter. †

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

Lubricate:~ • Power door hinges; 2 fittings - 1 shot • Door cylinder pins apply oil liberally • Other door hinges; apply oil liberally

EVERY 250 HOURS:~ • Perform "frequently" maintenance

Check:~ • Torque on swing bearing and swing gearbox retaining bolts.

• Perform 8 hour maintenance

• Torque on track drive gearboxes and motor mounting bolts.

• Perform 24 hour maintenance • Perform 125 hour maintenance

• Track rollers and idlers for oil leakage. These components are filled with oil and considered maintenance free. If oil leakage is detected repair of component(s) will be necessary.

And in addition:~ • Check all hydraulic pressures • Lubricate swing drive gearbox lower bearing; 2-fittings - 5 shots each ‡ Do not use a power grease gun.

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

‡ With swing gearbox at operating temperature slowly add 5 shots of lithium based ep2 to each side of the gearbox. Note: During cold weather applications the swing function must be operated for several hours to achieve operating temperature. Caution: Do not force grease, gearbox failure may result. Do not use winter grease. Grease should purge from gearbox pinion seal.

• Replace engine oil and filter.

• Replace engine fuel filter(s).

• Replace filter in fuel filter/water separator. † Use of filters other than genuine Tigercat replacement filters is not recommended.

3.5

Tigercat 822 Feller Buncher

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 1000 HOURS:~ • Perform "frequently" maintenance • Perform 8 hour maintenance • Perform 24 hour maintenance • Perform 125 hour maintenance • Perform 250 hour maintenance • Perform 500 hour maintenance And in addition check:~ • Fuel in-tank strainer • Replace air cleaner unloader valve

EVERY 2000 HOURS:~ • Replace turbocharger rubber inlet elbow and coupling - High temperatures in this area can cause the rubber to harden • Check ALL air intake tubing, rubber couplings and band clamps for signs of wear and leakage • Drain and refill hydraulic oil tank with recommended hydraulic oil. See "approved hydraulic oils" It is strongly recommended that a program of regular oil testing be used. Oil change intervals can be established from oil test results

3.6

Tigercat 822 Feller Buncher

Lubrication and Maintenance

APPROVED HYDRAULIC OILS In addition to providing the vehicle with its normal operational functions, hydraulic oil is also used to fill the swing gearbox and brake.

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

®

Tigercat

HYDRAULIC OIL OPERATING RANGE (Not suitable for axle applications)

OPERATING TEMP. RANGE LOWEST START-UP TEMP.

HYDRAULIC OIL TEMPERATURE -40

OIL TYPE

-40

-30 -20

-20 0

-10

0 20

10 40

20 60

30 80

40

50

60

70

100

120

140

160

80 180

90 200

100

˚C 220˚F

CITGO MYSTICK HVI 32 MYSTICK HVI 46 MYSTICK HVI 68 CHEVRON RYKON PREMIUM 32 RYKON PREMIUM 46 RYKON PREMIUM 68 ESSO / EXXON UNIVIS N22 UNIVIS N32 UNIVIS N46 UNIVIS N68 IRVING OIL HYDRAULIC LP 22 HYDRAULIC LP 32 HYDRAULIC LP 46 HYDRAULIC LP 68 MOBIL MOBIL DTE 12M (ISO 22) MOBIL DTE 13M (ISO 32) MOBIL DTE 15M (ISO 46) MOBIL DTE 16M (ISO 68) PETRO-CANADA HYDREX MV 22 HYDREX MV 36 HYDREX MV 60 SHELL TELLUS T22 TELLUS T32 TELLUS T46 TELLUS T68 TEXACO RANDO HDZ 22 RANDO HDZ 32 RANDO HDZ 46 RANDO HDZ 68

CAUTION

OPERATING MACHINE OUTSIDE LIMITS SHOWN WILL RESULT IN FAILURE OF HYDRAULIC COMPONENTS

5168AR03

3.7

Tigercat 822 Feller Buncher

Lubrication and Maintenance

Tigercat® Model 822 FILTER AND LUBRICATION SCHEDULE

2

ENGINE OIL/FILTER; SISU ENGINE

CHK

3 4 5

FUEL FILTER (ENGINE) FUEL/WATER SEPARATOR IN-TANK FUEL STRAINER

DRN

6

AIR INTAKE PRECLEANER

CHK

7

AIR INTAKE PRIMARY ELEMENT

8

AIR INTAKE SAFETY ELEMENT

9

HYDRAULIC RESERVOIR DRY FILL CAPACITY……………...

10

RETURN FILTERS

CHK

11

PRESSURE FILTER, PILOT*

CHK

12

TRACK DRIVE GEARBOX; ‡ CHECK OIL WITH LEVEL PLUGS AT 6 O'CLOCK AND 9 O'CLOCK POSITIONS

CHK D/R ‡

13

TRACK ROLLERS AND IDLERS CHECK FOR OIL LEAKAGE

14

SWING BEARING ***

15

SWING PINION

16

SWING GEARBOX LOWER BEARING *REFER TO 250 HOURS SCHEDULED MAINTENANCE FOR DETAILS BOOM,STICK AND TILT JOINTS: - STANDARD - STANDARD W/TILT LINK - EFFICIENT REACH SYSTEM

19 20 21

BOOM, STICK AND TILT CYLINDERS:STANDARD W/TILT LINK EFFICIENT REACH SYSTEM

57

15

QTY

2000

1000

USG

CHK

REMARKS/LUBRICANT

LITRE

COOLING SYSTEM

18

CAPACITY

CHANGE COOLANT EVERY 2 YEARS REP

1

17

500

250

DESCRIPTION

125

SERVICE EVERY

8

SERVICE POINT NO.

REFER TO Tigercat OPERATOR'S MANUAL FOR FURTHER INFORMATION

60/40 ANTIFREEZE **

25.5 6.75

REP REP

SEE ENGINE MANUFACTURER’S SERVICE MANUAL 1 1

CHK 1 REP

1 REP

CHK

1

D/R 134 35 ..250 ..66

DRAIN TANK, CLEAN OR REPLACE AS NECESSARY CLEAN INTAKE & DISCHARGE AREAS AS REQUIRED EVERY 8 HOURS:CHECK FILTER RESTRICTION INDICATOR WITH ENGINE RUNNING. CLEAN UNLOADER VALVE, REPLACE UNLOADER VALVE EVERY 1000HOURS.

1

DRAIN AND REFILL AS REQ’D

BY SEASONAL OIL CHANGE SEE APPROVED HYDRAULIC OILS* *Tigercat RECOMMENDS REGULAR USE OF AN OIL TESTING PROGRAM

REP

5 1

REP †

2

5 STANDARD FILTERS 1 WATER ABSORBING FILTER (COLOUR BLUE) *CHECK RESTRICTION INDICATOR ON LATER MACHINES FILL WITH S 75W-90 (SPEC) SYNTHETIC GEAR OIL RECOMMENDED FOR SEVERE DUTY APPLICATIONS IF LEAKING REMOVE AND REPAIR FILL WITH SAE 30 OR 40

CHK LUB 24HR *** LUB LUB*

LUB

6

1.5

1

7.6

2

1

10 SHOTS

1

10 SHOTS

1

5 SHOTS EACH FITTING PURGE

2

GREASE WHILE SWINGING *** EVERY 24 HOURS LITHIUM BASE EP2 GREASE GREASE WHILE SWINGING LITHIUM BASE EP2 GREASE LITHIUM BASE EP2 GREASE

LITHIUM BASE EP2 GREASE u 6 12 12 LITHIUM BASE EP2 GREASE

LUB PURGE PURGE

8 10

1 SHOT POWER DOOR HINGES LUB 2 LITHIUM BASE EP2 GREASE DOOR CYLINDER PINS LUB APPLY OIL LIBERALLY LUB FELLING ATTACHMENT SEE MANUFACTURER'S MAINTENANCE SCHEDULE LEGEND: LITHIUM BASED EP2 GREASE CONTAINING MOLYBDENUM DISULFIDE CHK = CHECK ** ANTIFREEZE MUST MEET GM 6038M SPECIFICATIONS DRN = DRAIN SEE ENGINE MANUFACTURER'S MAINTENANCE MANUAL D/R = DRAIN AND REFILL LUB = LUBRICATE † Use of filters other than genuine Tigercat replacement filters is not recommended.

REP = REPLACE

822LUBCHART.XLS 06/2003

3.8

Tigercat 822 Feller Buncher

Lubrication and Maintenance

LUBRICATION OF SWING DRIVE GEARBOX UPPER GEARING LUBRICATION The swing gearbox upper gearing is lubricated by hydraulic oil which flows from the oil cooler bypass/ return manifold into the 'U' port on the swing drive gearbox. A 1/16 inch orifice/connector installed in the 'U' port regulates the flow of oil through the gearbox at approximately 1 GPM. Oil is returned to tank via flushing port 'T'.

LOWER BEARING LUBRICATION The cavity in the lower portion of the gearbox where the two lower bearings are housed is completely filled with grease.

LUBE FITTINGS

••

•

EFFICIENT REACH (ER) BOOM SYSTEM When performing maintenance procedures or setting up a machine equipped with an Efficient Reach (ER) boom system, the following points must be noted: The main and stick boom cylinder circuits are connected hydraulically. Thus, disconnecting a hydraulic line to a boom cylinder may cause either boom to move unexpectedly. The boom may also move unexpectedly if a port relief adjusting screw is unscrewed (counterclockwise) too far and the pressure drops below that which is required to hold the weight of the boom and head. Ensure that the head is resting squarely on a solid footing and the stick cylinders are fully extended (fig. 830-07), tank pressure is relieved and engine is shut off before disconnecting any hydraulic lines. For additional safety precautions refer to ER BOOM SYSTEM PRECAUTIONS in SECTION 1 OF THIS MANUAL. STICK CYLINDERS FULLY EXTENDED

845B-D33

•

LUBRICATE GEARBOX LOWER BEARINGS To gain access to the lube fitting, remove the cover plate directly below the gearbox. Using a hand grease gun, pump 5 shots of grease into each grease fitting. Follow the lubricating procedure on the label located beside the grease fittings and also refer to SCHEDULED MAINTENANCE - 250 HOURS in THIS SECTION. For additional information refer to SECTION 15 in the SERVICE MANUAL.

TIP OF STICK BOOM FULLY SUPPORTED 830-07

ER. BOOM SYSTEM. FIG.1

Also note that because of the hydraulic connection between the main boom and ER cylinders, the ER cylinder can overpower the stick cylinders under certain conditions, causing the stick boom to move unexpectedly. This most often occurs when setting the MAIN BOOM UP relief valve, causing the stick to extend, but it may also happen at other times if the relief settings are not correct. Ensure that all personnel and equipment are clear of the boom path and that there is sufficient overhead clearance for the head to rise before making any adjustments.

3.9

Tigercat 822 Feller Buncher FILTERS - REMOVE AND REPLACE

Lubrication and Maintenance

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.

6. Wearing face protection (in case of a fuel squirt) turn OFF the fuel shut-off valve and unscrew the old filter. The fuel shut off valve is located beside the main hydraulic control valve at the rear left corner of the machine.

FUEL SHUT-OFF VALVE

•

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.

FUEL FILTER/WATER SEPARATOR

822-D34

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

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

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

••

8. 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. Clean the water sediment bowl.

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

PRIMING PUMP

11. 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.

WATER SEPARATOR BOWL

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

DRAIN TAP

822-D53

FUEL SHUT-OFF VALVE

• • FUEL FILTER/WATER SEPARATOR

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

Changing the filter: 1. Park machine on level ground with felling head resting on the ground and stop engine.

14. 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.

2. Open engine enclosure doors fully.

15. Turn the fuel shut-off valve ON, prime fuel system with push button primer pump located on the fuel filter mounting head, start the engine and check for leaks.

3. Turn battery disconnect switch to the OFF position.

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

5. Place a suitable container below to catch any spilt fuel.

3.10

Tigercat 822 Feller Buncher

Lubrication and Maintenance

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

STRAINER INSIDE FUEL TANK

•

CLEANOUT COVER

•• DRAIN PLUG

•• 822-D56

FUEL TANK STRAINER

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

822-D55

8. Check for a accumulation of foreign materials where the strainer screws onto the pipe and elbow.

FUEL TANK CLEANOUT COVER

9. Reinstall the strainer using the hex on end.

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

10. Reinstall fuel tank cover plate with a NEW “O” ring.

11. Reinstall corner panel and light housing/step door.

12. Fill the fuel tank and check for leaks. Start the engine and check for leaks again.

1. Park machine on level ground with felling head resting on the ground.

2. Stop engine. Turn battery disconnect switch to the OFF position.

REMOVE THE LIGHT HOUSING/STEP DOOR AND ADJACENT CORNER PANEL

••

830-D41

•

ACCESS TO FUEL TANK

3. Remove the light housing/step door and adjacent corner panel to access the fuel tank cleanout cover. Or on machines with high capacity fuel tank remove the two panels.

4. Drain the fuel tank. (plug in bottom) 5. Remove the round fuel tank access cover plate and “O” ring.

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

3.11

Tigercat 822 Feller Buncher

Lubrication and Maintenance

HYDRAULIC FILTER SERVICING GUIDELINES

HYDRAULIC OIL RETURN FILTERS The majority of return oil entering the tank passes through 6 spin on hydraulic oil filters, one of the filters is water absorbing filter (colour blue) which is in place to assist with removing unwanted moisture from the hydraulic oil. The filters are connected in parallel to three separate return filter heads. The oil from the 3 return lines passes through return strainers located inside the hydraulic tank.

IMPORTANT

NEVER PRE-FILL ANY HYDRAULIC FILTERS ON 200, 700, 800 AND 1000 SERIES MACHINES NEVER PRE-FILL CHARGE PRESSURE FILTERS ON 600 SERIES SKIDDERS

HYDRAULIC TANK PRESSURE GAUGE

Tigercat generally does not recommend the pre-filling of spin-on filters due to the risk of damage to the hydraulic system caused by unfiltered oil. Unfiltered oil used to pre-fill filters enters directly into the hydraulic circuit. Contaminants in unfiltered oil can cause significant and costly damage to hydraulic valves, pumps and motors. The cleanliness of hydraulic oil cannot be guaranteed unless it is always prefiltered before use.

••

• •

• • • ••

• 1 - WATER ABSORBING RETURN FILTER (COLOUR BLUE)

HYDRAULIC OIL FILTERS There is a bypass valve built into each of the filter heads which is preset at 25 psi. this bypass valve will open in the event the elements become restricted. However a 15 psi. pressure switch installed in the return manifold will turn on the FILTER BYPASS warning light in the cab before this happens. The pressures stated are for normal operating conditions and temperatures.

422-07

ALWAYS PRE-FILL DUAL HEAD HYDRAULIC FILTERS ON 600 SERIES SKIDDERS Dual head hydraulic filters on 600 series skidders must always be pre-filled with clean oil as noted specifically in the manuals for each of these machines.

All 600 series hydraulic circuits direct oil from the dual head filters to the main and drive pump inlets. Air must not be allowed to enter the inlets of these pumps. Entry of air directly into pump inlets can cause significant and costly damage to pumps. In this particular case the risk of damage to pumps caused by entry of air into the circuit is considered to be greater than the risk of damage caused by unfiltered oil.

Prefiltering of any hydraulic oil used to pre-fill these filters is strongly recommended to eliminate the risk of damage caused by unfiltered oil.

RETURN MANIFOLD

5 - HYDRAULIC RETURN FILTERS

FILTER SERVICE NOTE The filters should be checked/changed when the FILTER BYPASS warning light in the cab comes ON. For service and replacement intervals see SERVICE AND LUBRICATION CHART in THIS SECTION. Changing the filter: 1. Park machine on level ground with felling head resting on the ground. Stop engine.

2. Open rear left enclosure door fully and install safety strut.

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

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 822 Feller Buncher

Lubrication and Maintenance FILTER HEAD

•

AIR VENT VALVE

• GASKET

•

DRIP TRAY DRAIN HOLE/HOSE

SQUARE SECTION GASKET INSTALLATION

•

FILTR_SEALS 2

Tighten filter an additional 3/4 turn.

DO NOT use bottom nut for filter installation or damage/leakage may result. Bottom nut is to assist in filter removal only.

AIR VENT VALVE

822-D35

FILTER ELEMENT

FILTER HEAD

4. Wearing face protection, Release air from the hydraulic reservoir by opening the AIR VENT VALVE. NOTE: Air pressure expelling from vent valve will blow accumulated loose debis in try 5. Wearing face protection (in case of an oil spray), unscrew the old filter. Dispose of old filter and any oil properly.

• • GASKET

• FILTR_SEALS 2

FILTER ELEMENT

'O' RING GASKET INSTALLATION

z 'O' Ring Gasket

•

Remove used gasket and clean gasket seat in head.

HYDRAULIC OIL FILTERS

••

Apply clean oil to new gasket surfaces.

DRIP TRAY

Install new gasket on inside lip of filter.

DRAIN HOSE 822-D69

•

DO NOT prefill the filter*. Screw on new filter until gasket makes contact.

DRIP TRAY DRAIN HOSE

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

6. Drain away any accululation of oil in tray by using the drain hose located on the right side of the tray.

DO NOT use bottom nut for filter installation or damage/leakage may result. Bottom nut is to assist in filter removal only.

7. The new Tigercat filter is supplied with two gaskets enclosed, examine the filter head closely to determine which gasket should be used and follow the instructions to ensure proper installation.

8. Use hand fill pump to raise hydraulic oil level up to FULL line and replace oil lost during filter change.

Square Section Gasket

9. Start the engine and check for leaks.

Remove used gasket and clean groove in head.

10. Run engine at IDLE speed for at least 5 minutes to purge air from the filter system. It is also recommended to then STOP the engine for 15 minutes to allow air bubbles in the hydraulic tank to rise.

Apply clean oil to new gasket surfaces.

Install new gasket into groove in filter head.

DO NOT Prefill the filter*. Screw on new filter until gasket makes contact with filter head.

11. Close air vent ball valve. *Refer to HYDRAULIC FILTER SERVICING GUIDELINES on PREVIOUS PAGE.

3.13

Tigercat 822 Feller Buncher

Lubrication and Maintenance

HYDRAULIC HIGH PRESSURE PILOT FILTER

Changing the filter:

There is a hydraulic high pressure pilot filter placed ahead of the pilot supply valve to filter the oil before it goes into the valve. This filter incorporates a clog indicator.

1. Park machine on level ground with felling head resting on the ground and stop engine.

CLOG INDICATOR SIGHT GLASS

2. Turn BATTERY DISCONNECT SWITCH to ‘OFF’ position.

3. Release air from the hydraulic reservoir by opening the AIR VENT VALVE.

••

4.

822-D47

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

HIGH PRESSURE PILOT FILTER

The clog indicator consists of a clear plastic sight glass mounted on top of the filter housing. Under normal operating conditions (or when the hydraulic system is shut down) the indicator will show GREEN. When a pressure differential of 72 psi builds up inside the filter, the indicator will show RED, indicating a clogged filter.

This condition could happen during cold start-ups, but as the oil warms up the indicator will automatically re-set to GREEN. The indicator will not remain in the “clogged” (RED) position when the pilot system is not being used. “Clogged” condition will result in low pilot pressure. If a loss of controls or slow response occurs, filter element may need to be changed. Refer also to SECTION 5 of the SERVICE MANUAL for more information.

A small pressure accumulator is used in the pilot supply circuit to ensure an adequate supply of pilot control oil under all operating conditions. The accumulator will normally bleed down the pilot supply oil to zero PSI in under 30 seconds after engine shut down, but install a 0 to 1000 PSI gauge on the pilot supply circuit test port to be sure no pressure is present before unscrewing the filter bowl.

6. Place rags below to catch any spilt oil.

7. Wearing face protection (in case of an oil spray), unscrew the filter bowl from the filter head. Remove the filter element and dispose of it properly. Clean out the filter bowl before reusing it.

8. Remove and discard the small o-ring from between the filter element and the filter head.

9. Check the seating area for o-rings and seals on the filter bowl and filter head. Wipe clean.

10. DO NOT pre-fill the filter*. Lubricate any new o-rings and seals with clean hydraulic and install the new filter element.

11. Close air vent ball valve. *Refer to HYDRAULIC FILTER SERVICING GUIDELINES on PREVIOUS PAGE.

For service and replacement intervals see SERVICE AND LUBRICATION CHART in THIS SECTION.

3.14

Tigercat 822 Feller Buncher

Lubrication and Maintenance

HYDRAULIC OIL RETURN STRAINERS/DIFFUSERS There are four reusable strainers/diffusers housed in the hydraulic tank, one on the case drain return port and three on the return tubes. The strainers should be inspected whenever the hydraulic tank is drained. See SCHEDULED MAINTENANCE in THIS SECTION.

6. Disconnect the wires from the two sensors and remove the case drain hose located on the round access cover.

STRAINERS

'O' RING ROUND ACCESS COVER

•

• •

ACCESS COVER

•

•

• 409-04

HYDRAULIC OIL TANK

For service and replacement intervals see SERVICE AND LUBRICATION CHART in THIS SECTION.

DRAIN PLUG

CHANGING OR CLEANING THE STRAINER: This should be performed in the event of a pump failure or hydraulic oil contamination.

822-06

•

DRAIN PLUG (ONLY ACCESSIBLE WITH MAIN CONTROL VALVE REMOVED)

HYDRAULIC OIL TANK

7. Drain the hydraulic tank via a drain plug in the bottom of the tank. Access to this plug is by removing a cover plate on the under side of the upper frame.

1. Park machine on level ground with felling head resting on the ground.

8. Remove the round access cover plate and “O”-ring.

2. Stop engine.

3. Open rear left enclosure door fully and install safety strut.

4. Turn BATTERY DISCONNECT SWITCH to the OFF position.

5. Release the pressure in the hydraulic tank by opening the air vent valve.

9. Before removing the strainers, clean any debris from the bottom of the tank and wipe it clean.

10. Remove the four hydraulic oil return strainers using the hex on the end of strainer. Carefully clean the strainers (they may be damaged by rough handling).

11. Check for a buildup of foreign materials where the strainers screw onto the pipes and cover plate.

•

12. Reinstall the strainers using the hex on end.

•

AIR VENT FILTER

14. Connect sensor wires to sensors on access cover.

AIR VENT VALVE

822-D35

13. Reinstall access cover plate with a NEW “O” ring.

HYDRAULIC OIL TANK

15. Refill and check for leaks.

16. Ensure that the air vent valve is closed.

3.15

Tigercat 822 Feller Buncher

Lubrication and Maintenance

ENGINE AIR INTAKE

EXHAUST SYSTEM

ENGINE AIR PRE-CLEANER The engine air precleaner cleans engine air before it reaches the air cleaner filter elements.

It removes contaminants such as dust, powder, insects, rain and snow. This precleaner is self powered and self cleaning requiring virtually no maintenance. However, it should be checked periodically to make sure that foreign materials have not plugged the intake area or the discharge port area and that the rotor spins freely.

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

PRECLEANER TO TURBO CHARGER

•• •

•

AIR CLEANER

•• AIR CLEANER UNLOADER VALVE

CONT AMINANTS ARE BLOWN CONTAMINANTS OUT OF SPECIAL DISCHARGE POR TS BY HIGH VELOCITY PORTS VELOCITY,, AIR POWERED R OTOR RO

•

354-15

AIR CLEANER

• SAFETY ELEMENT

•

PRIMARY ELEMENT

•

••

•

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

ONLY THE PURIFIED AIR GOES TO THE AIR FILTER

822-D57

AIR CLEANER ELEMENTS

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

Refer to AIR CLEANER MAINTENANCE in THIS MANUAL.

PRECLEANER OPERATION

AIR CLEANER UNLOADER VALVE This rubber valve on the tube of the air cleaner housing should be checked before every shift (8 hrs). If this valve is missing, damaged or has turned hard, it will cause the air cleaner to become ineffective. The valve should be replaced every 1000 Hours.

DISCHARGE PORT AREA

218-21B

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

Reattach the valve to the tube. The valve should suck closed at about 1/3 of full throttle.

When operating in extreme high dust conditions this valve should be checked and squeezed frequently to release dust accummulation.

PRECLEANER

AIR CLEANER The air cleaner on this machine uses 2 filter elements, a primary element and a safety element.

3.16

Tigercat 822 Feller Buncher

Lubrication and Maintenance In extremely cold weather it is possible to run the engine with this cover removed to allow the engine to draw warmer air from inside the engine enclosure.

FILTER RESTRICTION INDICATOR

••

IMPORTANT: If the cover is removed, it MUST BE REINSTALLED when operating in warmer outside temperatures otherwise the engine will run at a higher temperature and less Horsepower.

AIR INTAKE SEAL Periodically check to ensure seal on top of precleaner is making proper contact with the sealing surface of the inside top of the power door. Hot air leakage at this seal will reduce engine power.

FILTER RESTRICTION INDICATOR FILTER RESTRICTION INDICATOR

822-D42

A filter restriction indicator is connected to the outlet side of the air filter. Service to the air filter is required when the indicator shows RED. This indicator provides a continuous reading whether the engine is running or is shut down. After servicing the filter, reset the indicator by pressing down on the reset button.

••

CHECK CONDITION OF SEAL

CLEAN OUT COVER

•• ••

822-D58

PRECLEANER

AIR INTAKE SEAL Continued on page 18

421-15A

AIR INTAKE CLEAN-OUT COVER

AIR INTAKE CLEAN-OUT COVER PLATE The precleaner receives air via an air intake grill on the left side of the power door cover and through a passage way fabricated into the power door. With the door opened, a cover plate can be removed to allow access behind the engine air intake grill to remove any accummulation of debris.

3.17

Tigercat 822 Feller Buncher

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

Continued from page 17

AIR CLEANER MAINTENANCE The most common and most damaging air intake servicing problems are: OVER SERVICING Filter elements increase in dust cleaning efficiency as dust builds up on the media.

Looks can be deceiving. A filter that looks dirty is actually more efficient than one that is clean.

A filter with dust build up on the media reaches nearly 100% dust cleaning efficiency. Only when a filter is so clogged with dirt that air restriction goes beyond engine manufacturer’s guidelines, should a filter be replaced.

NOTE: This does not apply to oil filters.

IMPROPER SERVICING Engine exposure to dust during servicing is the largest single reason for engine damage due to dust.

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

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

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

4. Always clean the inside of the outlet tube.

5. Check your old filter. It can help you detect foreign material on the sealing surface that is causing leakage.

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

6. Inspect the new filter for damage.

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

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

3.18

Tigercat 822 Feller Buncher

Lubrication and Maintenance

3.19

Tigercat 822 Feller Buncher

Lubrication and Maintenance

TORQUE CHART LOCATION

THREAD DIAMETER

Cylinder, Hoist, (9442B) Piston nut Cylinder end cap bolts Cylinder, Stick, (6337B) Piston nut Cylinder end cap bolts Cylinder, Stick, (15733B & 15734B) Piston nut Cylinder end cap bolts Cylinders, Leveller Piston nut Cylinder end cap bolts

TORQUE (LUBRICATED) lbf-ft Nm

M18

6980 270

9460 367

M16

3522 197

4780 267

M16

4159 126

5640 171

M22

3200 480

4340 650

Cylinder pin retaining bolts

M20

380

515

Boom joint pin bolts (Use BLUE Loctite on lower MAIN boom joint)

M20

400

530

1" UNC

475

625

7/8" UNC

450-500

620-680

Swing gearbox mounting bolts

M16

200

275

Engine mounting Sisu Engine Bolts, brk’t/m’nt to chassis rear Bolts, brk’t/m’nt to chassis front Bolts, bracket to engine, front Bolts, bracket to engine, rear

M24 M22 M12 M12

675 540 80 80

925 725 110 110

3/8" UNC M10

33-36 47

45-49 63

3/4 UNF M24 X 12.9 M16 M24 3/4" UNC 7/8" UNC M20 M20 M20

T/T* T/T* 140 475 310 475 380 380 380

T/T* T/T* 190 650 420 646 515 515 515

Cab securing bolts Swing bearing Swing bearing bolts

Pump drive Drive plate to flywheel Bell housing to engine Undercarriage Track shoe bolts (D6) Track shoe bolts (FH400) Idler bolts Idler bolts Roller mounting bolts Roller mounting bolts Sprocket bolts Gearbox mounting bolts Drive motor mounting bolts

*T/T represents Torque-turn, this is a method of torquing the track shoe bolts which is fully described in SECTION 11 of the Tigercat SERVICE MANUAL. Torque values pertaining to the engine and attachment are provided in the appropriate manuals.

3.20

Tigercat 822 Feller Buncher

Lubrication and Maintenance

GENERAL TORQUE SPECIFICATIONS The torque values listed below are for general use only.

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

IMPERIAL

GRADE 5 BOLTS

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

DRY lbf-ft Nm 11 - 12 15 - 16 20 - 28 27 - 38 44 -48 60 - 65 70 - 77 95 - 104 106 - 117 144 - 158 153 - 168 208 - 228 212 - 233 288 - 316 376 - 414 510 - 561 606 - 667 822 - 904 909 - 1000 1233 - 1355 1288 - 1417 1746 - 1921 1817 - 1999 2464 - 2710 DRY lbf-ft Nm 13 - 14 18 - 19 23 - 28 31 - 38 49 - 54 67 - 73 78 - 86 106 - 116 120 - 132 163 - 179 171 - 188 232 - 255 240 - 264 326 - 358 420 - 462 570 - 626 668 - 735 906 - 996 995 - 1096 1359 - 1486 1445 - 1590 1960 - 2155 2012 - 2213 2728 - 2997

LUBRICATED lbf-ft Nm 8 - 10 11 - 13 26 - 30 35 - 40 33 - 36 45 - 49 52 - 57 71 - 77 80 - 88 109 - 119 115 - 127 156 - 172 159 - 175 216 - 237 282 - 310 393 - 420 455 - 501 617 - 679 682 - 750 925 - 1016 966 - 1062 1310 - 1441 1360 - 1496 1844 - 2027 LUBRICATED lbf-ft Nm 10 - 13 14 - 17 18 - 25 25 - 33 37 - 41 50 - 55 58 - 64 79 - 86 90 - 99 122 - 134 128 - 141 174 - 191 180 - 198 244 - 268 315 - 347 427 - 470 501 - 550 679 - 745 746 - 821 1012 - 1113 1083 - 1191 1469 - 1613 1509 - 1660 2046 - 2250

COARSE DRY THREADS lbf-ft Nm 1/4" - 20 7- 8 10 - 11 5/16" - 18 14 - 18 19 - 24 3/8" - 16 31 - 34 42 - 46 7/16" - 14 49 - 54 66 - 73 1/2" - 13 75 - 83 102 - 112 9/16" - 12 109 - 120 148 - 162 5/8" - 11 150 - 165 204 - 223 3/4" - 10 266 - 293 360 - 397 7/8" - 9 394 - 433 535 - 586 1" - 8 591 - 649 802 - 879 1 1/8" - 7 794 - 873 1077 - 1183 1 1/4" - 7 1120 - 1232 1519 - 1670 FINE DRY THREADS lbf-ft Nm 1/4" - 28 9 - 10 12 - 13 5/16" - 24 17 - 22 23 - 29 3/8" - 24 35 - 39 48 - 53 7/16" - 20 55 - 61 75 - 83 1/2" - 20 85 - 94 116 - 127 9/16" - 18 121 - 133 164 - 180 5/8" - 18 170 - 187 231 - 253 3/4" - 16 297 - 327 403 - 443 7/8" - 14 434 - 477 589 - 646 1" - 12 646 - 711 876 - 965 1 1/8" - 12 891 - 980 1208 - 1328 1 1/4" - 12 1240 - 1364 1682 - 1849

LUBRICATED lbf-ft Nm 8 - 10 11 - 13 10 - 15 13 - 20 23 - 25 31 - 34 37 - 41 50 - 55 57 - 63 77 - 85 82 - 90 111 - 122 113 - 124 152 - 168 200 - 220 271 - 298 296 - 326 402 - 441 443 - 489 601 - 663 596 - 656 808 - 889 840 - 924 1139 - 1252 LUBRICATED lbf-ft Nm 9 - 10 12 - 13 16 - 20 21 - 27 26 - 29 35 - 39 41 - 45 56 - 61 64 - 70 87 - 95 91 - 100 124 - 135 128 - 141 174 - 191 223 - 245 303 - 332 326 - 359 442 - 486 484 - 534 657 - 724 668 - 735 906 - 996 931 - 1024 1262 - 1387

METRIC

SIZE

CLASS 4.8 LUBRICATED DRY Nm lbf-ft Nm lbf-ft

CLASS 8.8 OR 9.9 LUBRICATED DRY Nm lbf-ft Nm lbf-ft

M6 M8 M10

4.8 12 23

3.5 8.5 17

6 15 29

4.5 11 21

9 22 43

6.5 16 32

11 28 55

8.5 20 40

13 32 63

9.5 24 47

17 40 80

12 30 60

15 37 75

11.5 28 55

19 47 95

14.5 35 70

M12 M14 M16

40 63 100

29 47 73

50 80 125

37 60 92

75 120 190

55 88 140

95 150 240

70 110 175

110 175 275

80 130 200

140 225 350

105 165 225

130 205 320

95 150 240

165 260 400

120 190 300

M18 M20 M22

135 190 260

100 140 190

175 240 330

125 180 250

260 375 510

195 275 375

330 475 650

250 350 475

375 530 725

275 400 540

475 675 925

350 500 675

440 625 850

325 460 625

560 800 1075

410 580 800

M24 M27 M30

330 490 675

250 360 490

425 625 850

310 450 625

650 950 1300

475 700 950

825 1200 1650

600 875 1200

925 1350 1850

675 100 1350

1150 1700 2300

850 1250 1700

1075 1600 2150

800 1150 1600

1350 2000 2700

1000 1500 2000

M33 M36

900 1150

675 850

1150 1450

850 1075

1750 2250

1300 1650

2200 2850

1650 2100

2500 3200

1850 2350

3150 4050

2350 3000

2900 3750

2150 2750

3700 4750

2750 3500

ISSUE 3 800

3.21

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

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

Tigercat 822 Feller Buncher

Lubrication and Maintenance

3.22

Tigercat 822 Feller Buncher

SECTION 4 - HYDRAULIC SYSTEM CONTENTS - SECTION 4

JUNE0 2003

FILTERS, HYDRAULIC OIL FILTER SERVICE NOTE .......................................................................................................................................

PILOT, HIGH PRESSURE .....................................................................................................................................

RETURN FILTERS .................................................................................................................................................

STRAINER SERVICE NOTE ..................................................................................................................................

VENT/BREATHER ..................................................................................................................................................

4.5 4.5 4.5 4.5 4.4

HAND FILL PUMP, HYDRAULIC OIL ........................................................................................................................ 4.6 HIGH PRESSURE LIMITING CONTROL VALVE SET LOAD SENSE RELIEF VALVE .................................................................................................................... 4.27 HYDRAULIC OIL TANK DESCRIPTION ....................................................................................................................................................... 4.4 OIL LEVEL SIGHT GAUGES ................................................................................................................................. 4.4 VENT/BREATHER .................................................................................................................................................. 4.4 HYDRAULIC PUMPS CLAMPS AND FAN PUMP ..................................................................................................................................... 4.9 FAN PUMP ............................................................................................................................................................. 4.9 MAIN PUMP ............................................................................................................................................................ 4.8 MAIN PUMP CONTROL VALVE ....................................................................................................................... 4.25 MAIN PUMP WEAR TEST ................................................................................................................................. 4.8 SAW PUMP ............................................................................................................................................................ 4.9 HYDRAULIC SYSTEM OPERATION CIRCUIT DESCRIPTION ..................................................................................................................................... 4.15 CLAMPS AND ACCUMULATING ARMS CIRCUIT ............................................................................................... 4.2 FAN DRIVE SYSTEM ............................................................................................................................................. 4.3 FLOW ON DEMAND AND LOAD COMPENSATION .......................................................................................... 4.15 MAIN HYDRAULIC SYSTEM; BOOM, SWING, WRIST, DRIVE .......................................................................... 4.2 MARGIN PRESSURE ............................................................................................................................................. 4.9 MARGIN PRESSURE, SET ................................................................................................................................. 4.25 PILOT CIRCUIT ...................................................................................................................................................... 4.3 PRESSURE GAUGE CONNECTIONS ................................................................................................................ 4.26 SAW CIRCUIT ........................................................................................................................................................ 4.3 SWING SYSTEM .................................................................................................................................................... 4.2 TRACK DRIVE SYSTEM ........................................................................................................................................ 4.2 HYDRAULIC TANK .................................................................................................................................................... 4.4 LOAD SENSING BASIC DESCRIPTION ......................................................................................................................................... 4.11 BASIC PRINCIPLES ............................................................................................................................................ 4.10 OPERATING TIPS ................................................................................................................................................ 4.13 SET LOAD SENSE RELIEF VALVE .................................................................................................................... 4.27 SET MARGIN PRESSURE ................................................................................................................................... 4.25 MAIN CONTROL VALVE/MANIFOLD CONTROL SPOOL SECTIONS ........................................................................................................................... 4.16 CONTROL VALVE SECTIONS ............................................................................................................................ 4.17 CONTROL VALVE SPOOL OPERATION ............................................................................................................ 4.19 HIGH PRESSURE LIMITING CONTROL VALVE ................................................................................................ 4.24 MAIN CONTROL VALVE DESCRIPTION ............................................................................................................ 4.16 PORT RELIEF AND ANTICAVITATION VALVE .................................................................................................. 4.18 ADJUSTING PROCEDURE ............................................................................................................................. 4.18 SWING AND DRIVE MOTOR SPOOL SECTIONS ............................................................................................. 4.16 PILOT FILTER, HIGH PRESSURE ............................................................................................................................ 4.5 PRESSURE SETTINGS .......................................................................................................................................... 4.28 SCHEMATIC DIAGRAMS HIGH PRESS. LIMITING CONTROL ................................................................................................................... 4.24 LOAD SENSING (FLOW ON DEMAND) ............................................................................................................. 4.10 LOAD SENSING SYSTEM CIRCUIT DIAGRAM ................................................................................................. 4.14 MAIN PUMP ............................................................................................................................................................ 4.8 MAIN VALVE WITH HIGH PRESS. LIMITING CONTROL .................................................................................. 4.16

Tigercat 822 Feller Buncher HYDRAULIC SYSTEM OPERATION

Hydraulic system Boom cylinders

The hydraulic system has five basic circuits;

The boom hydraulic circuits are incorporated in the main hydraulic load sensing system. All hoist, stick and tilt cylinders have cushions at both ends. All cylinder rods are ground, heat treated, chrome plated and polished.

1. Variable displacement main hydraulic circuit with load sensing for the boom, swing, wrist and travel functions.

2. Variable displacement circuit for the saw.

Swing system

3. Fixed displacement open centre circuit for the clamps functions.

The swing hydraulic circuit is incorporated in the main hydraulic load sensing system. It utilizes a bent-axis piston motor incorporating two crossover relief valves. The motor is connected to a dual, double reduction planetary gearbox which provides variable swing speeds up to 6 rpm. A rotary manifold facilitates the hydraulic connection to the undercarriage of the vehicle and permits continuous 360 degree swing. The swing drive gearbox incorporates a wet, multi-disc brake installed between the motor and gearbox. The swing brake is controlled by a switch on the instrument panel.

The brake is spring-apply, hydraulic-release and will automatically apply whenever the pilot oil supply is shut off. For detailed description of the SWING system, refer to SECTION 15 of THIS MANUAL.

4. Closed centre pilot circuit to supply oil for the pilot system.

5. Open centre circuit with fixed displacement gear pump and fixed displacement piston motor for the fan drive.

1. THE MAIN HYDRAULIC SYSTEM This a closed centre circuit utilizing a variable displacement axial-piston pump with load sensing and horsepower limiting control. The load sensing system ensures that the pump will deliver only the amount of oil that is required by an individual boom or swing function or combination of functions.

This feature improves fuel economy and reduces heat generation because power is not wasted on excess pump flow that is not being used. Refer to LOAD SENSING in THIS SECTION.

Track drive system The track drive hydraulic circuit is incorporated in the main hydraulic load sensing system and utilizes high-torque, axial-piston hydraulic motors. The motors are mounted to a three stage planetary drive gearbox and each is completely housed within the width of the track shoes. The gearboxes include wet, multipledisc, spring-apply, hydraulic-release brakes which automatically release when driving and apply when stationary. Independent control of each track permits counter rotation. For a detailed description of the TRACK DRIVE SYSTEM, refer to SECTION 11 of THIS MANUAL.

The horsepower limiting control ensures that the engine will not lug down below the full load rpm by reducing the output from the main hydraulic pump. For detailed description of ENGINE ANTI-STALL, refer to SECTION 9 of THIS MANUAL. The main control valves are pressure and flow compensated to provide independent and load independent operation for all functions. The control valves are mounted on a common supply/return base manifold. Two 'P' (pressure) ports on the back of the manifold receive supply oil from the main pump. The return oil from the main control valves exits the base manifold at two 'T' ports and 75 psi internal check valves. From there the oil passes through the oil cooler, through a return manifold which includes a bypass valve for the oil cooler and on to the return filters and then to the hydraulic tank. A 25 psi bypass valve is incorporated into each pair of return filter heads.

4.2

Tigercat 822 Feller Buncher

Hydraulic system whenever the front door to the cab is opened or the pilot off switch located on the cab control panel is pressed.

2. SAW CIRCUIT This open centre circuit uses a variabledisplacement pressure-compensated piston pump which delivers oil to the variabledisplacement bent-axis piston motor to drive the saw. The saw control valve is pilot operated and controls the flow of hydraulic oil from the saw pump to the saw motor. This control valve is bolted to the clamps and accumulator control valve but operates independently except for sharing the tank return ports on a common outlet section. To protect the saw circuit a relief valve is installed in the inlet section of the saw control valve.

For a full description of the pilot manifold and the pilot circuit, refer to in SECTION 5 in THIS MANUAL. 6. COOLING FAN DRIVE SYSTEM This open centre circuit receives oil from one of two cartridges in a double gear pump driven off the PTO of the saw pump.

A solenoid operated saw pilot valve controls the flow of pilot oil to the end of the spool in the main control valve.

The saw switch on the control panel in the cab is used to turn the saw ON or OFF. Refer to SAW DRIVE description in SECTION 17 of this manual.

3. CLAMPS AND ACCUMULATING ARMS CIRCUIT

The fan motor is a fixed displacement piston motor. The fan is coupled directly to the motor output shaft.

The fan direction is controlled by the fan control valve. Two solenoid operated fan pilot valves one for FORWARD and one for REVERSE supply pilot oil (425 psi) to the pilot end caps of the fan control valve. When the fan switch in the cab is in the NORMAL (FORWARD) position there is no current supplied to either of the fan pilot valves.

The FORWARD pilot valve is de-energized and supplies pilot oil to the FORWARD pilot end cap of the fan control valve to hold the valve spool in the FAN FORWARD position.

In this position oil from the fan pump is directed to the fan motor to rotate the fan FORWARD.

This is an open-centre circuit with a fixed displacement gear pump and a two-section spool valve. The spool valve also includes an inlet (mid) section and an outlet section. The gear pump provides a continuous supply of oil to the clamps and accumulating arms control valve which will divert the oil back to tank if neither of the clamps or accumulating arms functions are in use. The return oil from this open centre circuit is returned to tank via the spin-on return filters.

HOLDING the fan switch in the CLEAN position energizes BOTH the REVERSE and FORWARD fan pilot valves to supply pilot oil to the REVERSE pilot end cap and remove pilot oil from the FORWARD pilot end cap of the fan control valve. This will shift the spool to the REVERSE position and reverse the direction of rotation of the fan. RELEASING the fan switch allows the fan to run in the NORMAL (FORWARD) mode.

For a full description of the "TREE CLAMPS" circuit, refer to SECTION 18 of THIS MANUAL. 4. PILOT CIRCUIT The closed centre pilot circuit receives oil from the main hydraulic system (main pump). Oil from the main hydraulic system passes through a "high pressure" filter to the pilot supply valve (pressure reducing/relieving valve) which maintains the pilot pressure at 425 psi. From there, pilot oil (425 psi) is supplied to the 'P1' port on the anti-stall valve mounted on the main pump and also the IN port of the pilot manifold.

The pilot manifold distributes pilot pressure oil to all of the pilot controlled hydraulic circuits thoughout the machine. A pilot shut-off solenoid valve cartridge located at the IN port on the pilot manifold will shut down the pilot system 4.3

For a full description of the COOLING FAN circuit, and adjustment procedures, refer to SECTION 10 of THIS MANUAL.

Tigercat 822 Feller Buncher HYDRAULIC OIL TANK

Hydraulic system AIR VENT FILTER TANK AIR PRESSURE GAUGE

Also refer to SECTION 2 of the OPERATOR'S MANUAL and SECTION 3 for additional information.

•

CHECK VALVE 10 PSI AIR VENT BALL VALVE

•

Located at the rear left corner of the machine beside the fuel tank, the hydraulic tank has a capacity of 35 gal. U.S. (134 L) with a total machine dry fill capacity of 66 gal. U.S. (250L).

• •

All return oil entering the tank is screened prior to entering the tank by passing through reusable suction strainers attached to the ends of the return tubes at the bottom of the tank. The case drain return oil from the pumps is also screened by a reusable strainer attached to the inside of the round access cover.

RETURN LINE CONNECTIONS

• •

•

DRAIN HOSE

REUSABLE STRAINERS/ DIFFUSERS (3 PLACES)

O-RING

•

VENT/BREATHER, HYDRAULIC TANK •

The air space in the top of the hydraulic tank is vented to atmosphere via a check valve and spin-on filter. The check valve will open or "crack" when the pressure in the hydraulic tank reaches 10 psi. The pressure build-up in the tank can be due to thermal expansion as the hydraulic oil heats up.

A pressure gauge to indicate the pressure inside the tank and an air vent valve to relieve the pressure when servicing the hydraulic system are teed into this vent.

•

•

• •• •

ROUND ACCESS COVER

• •

FIRST SIGHT GAUGE

SECOND SIGHT GAUGE TEMP. GAUGE

•

LOW LEVEL SENDING UNIT, FOR WARNING BUZZER

SERVICE NOTE: Before disconnecting any hoses, release the pressure in the hydraulic tank by opening the air vent ball valve.

DRAIN PLUG

OIL LEVEL SIGHT GAUGES 822-06

Two sight gauges are used to indicate the level of the hydraulic oil in the tank with HIGH and LOW level limits. Also incorporated into the sight gauges are level sensors and a temperature gauge. These gauges are accessible through the rear left side door. Refer to SECTION 2 of the OPERATOR'S MANUAL for additional information.

IMPORTANT: Always keep the hydraulic oil level up to within 2" (5 cm) of the HIGH mark. A low hydraulic oil level will result in severe damage to pumps.

4.4

•

LOW LEVEL SENDING UNIT, FOR WARNING LIGHT

DRAIN PLUG (ONLY ACCESSIBLE WITH MAIN CONTROL VALVE REMOVED)

HYDRAULIC TANK

Tigercat 822 Feller Buncher

Hydraulic system 8. HIGH PRESSURE PILOT FILTER

RETURN FILTERS ~ HYDRAULIC OIL The majority of return oil entering the tank first passes through six spin-on hydraulic oil filters mounted onto three double filter heads, one of the filters is a water absorbing filter (colour blue) the purpose of which is to assist with removing moisture from the hydraulic oil. The input side of the filter heads are connected in parallel to a return manifold. The output side of the filter heads direct the oil to tank via three return lines.

5 - HYDRAULIC RETURN FILTERS

RETURN MANIFOLD

TANK AIR PRESSURE GAUGE 422-07

CLOG INDICATOR SIGHT GLASS

••

PRESSURE SWITCH

••

•• •

There is a hydraulic high pressure pilot filter placed ahead of the pilot supply valve (pressure reducing/pressure relieving valve) to filter the oil before it enters the pilot system. This filter incorporates a clog indicator.

••

•

••

••

•• •• HYDRAULIC OIL FILTERS

1 - WATER ABSORBING RETURN FILTER (COLOUR BLUE)

822-D47

There is a bypass valve built into each of the filter heads which is preset at 25 psi. This bypass valve will open in the event the elements become restricted. However a 15 psi. pressure switch installed in the return manifold will turn on the FILTER BYPASS warning light in the cab before this happens. The pressures stated are for normal operating conditions and temperatures.

NOTE: This warning light may come ON during cold weather start ups.

FILTER SERVICE NOTE The filters should be checked/changed when the FILTER BYPASS warning light in the cab is ON with oil at operating temperature.

RETURN STRAINERS/DIFFUSERS Return strainers/diffusers located inside the hydraulic tank act as a final backup for preventing foreign material from entering and contaminating the hydraulic tank.

STRAINER SERVICE NOTE The strainers should be checked/changed at the intervals specified in the LUBRICATION AND MAINTENANCE SCHEDULE in SECTION 3 of THIS MANUAL. For instructions on changing these strainers/diffusers, refer to HYDRAULIC OIL STRAINERS/DIFFUSERS in SECTION 3 of this MANUAL.

4.5

HIGH PRESSURE PILOT FILTER

Under normal operating conditions (or when the hydraulic system is shut down) the indicator will show GREEN. When a pressure differential of 72 psi builds up inside the filter, the indicator will show RED, indicating a clogged filter.

This condition could happen during cold startups, but as the oil warms up the indicator will automatically reset to GREEN. A “Clogged” condition will result in low pilot pressure. If a loss of controls or slow response occurs, filter element may need to be changed.

For filter service and replacement time intervals, refer to SECTION 3 in THIS MANUAL.

Tigercat 822 Feller Buncher

Hydraulic system IMPORTANT: Ensure that all connection points and the suction tube are thoroughly cleaned and dried before use. Small amounts of water can cause serious damage to the hydraulic components. The water absorbing element will remove small amounts of but will not protect the system from careless use. Dust left on the suction tube will significantly reduce the life of the filters.

FEMALE QUICK DISCONNECT

•• •• SUCTION TUBE

822-D46

Re-install the cap and the protective dust boot to the quick disconnect fittings after filling. Failure to keep these connections clean will significantly reduce the life of the filter elements.

HAND FILL PUMP

HYDRAULIC HAND FILL PUMP The hydraulic hand fill pump, on the rear left door, is used for adding oil to the hydraulic tank. A male quick disconnect port is provided on the return RETURN MANIFOLD

••

•• ••

RETURN MANIFOLD PORT

CONNECT THE QUICK DISCONNECT TO THE RETURN MANIFOLD PORT

FILLING HYDRAULIC TANK filter manifold and mates with a female quick disconnect attached to the outlet hose on the hand pump. This ensures that any hydraulic oil added is filtered prior to entering the hydraulic tank.

822-D40

4.6

Tigercat 822 Feller Buncher

Hydraulic system

4.7

Tigercat 822 Feller Buncher SAW PUMP CLAMPS AND (PISTON PUMP) FAN DRIVE PUMP (DOUBLE GEAR PUMP)

Hydraulic system SAW PUMP PRESSURE COMPENSATOR

FAN PILOT FAN PILOT VALVE (FWD) VALVE (REV)

••

•• ••

••

•• ••

••

•• PILOT FILTER

MAIN PUMP MAIN PUMP (PISTON PUMP) CONTROLLER (LS. CONTROL)

•• COOLING FAN CONTROL VALVE 422-08

••

PILOT SUPPLY VALVE

HYDRAULIC PUMPS

HYDRAULIC PUMPS All hydraulic functions are powered by three pumps mounted one behind the other on the flywheel housing of the engine. The first pump (main pump) is a piston pump with load sensing and horsepower limiting controls used for travel, swing and boom and wrist functions.

Mounted and coupled to the main pump is the saw pump. It is a pressure compensated piston pump.

Mounted and coupled to the saw pump is the fixed displacement gear pump used for the clamps, accumulating arm and cooling fan circuits.

MAIN PUMP The main pump is a Linde HPR, axial-piston, variable-displacement pump with load sensing, and horsepower limiting controls.

When all of the control valves on the main linde valve are in the neutral position the pump is destroked and the output is just sufficient to maintain a standby pressure of approx.500 psi in the pump output line. The swashplate control piston is in a condition where the spring force, swashplate forces and the control pressure forces are balanced.

822-10

MAIN PUMP SCHEMATIC DIAGRAM

MAIN PUMP WEAR TEST 1

Plumb a flow measuring device to the line connecting the main pump case drain to tank.

2

Run the machine until the hydraulic oil temperature reaches at least 140°F.

4.8

Tigercat 822 Feller Buncher

Hydraulic system

3

Position the machine so that the upper is perpendicular to the tracks. Tilt the felling head back fully and turn the swing brake ON.

4

With the engine at high idle, simultaneously hold the R.H. joystick in the TILT BACK position (tilt cylinder bottomed out) and hold the SWING CONTROL fully over relief.

5

output remaining constant until the pressure at the LS port changes. This is a dynamic condition with the swashplate angle changing constantly in response to the load fluctuations. The LS pressure is always equal to the highest work port pressure.

NOTE: If the machine controls are not responding as they should, i.e. boom is jerky or sluggish, the margin pressure setting may be out of adjustment.

Record the flow coming out of the main pump case drain.

Normal/acceptable case drain leakage rates for the main pump under the above conditions is 5 GPM to 8 GPM. With case drain leakage rates greater than 9 GPM, the pump will still operate properly but should be considered for replacement.

Also refer to ENGINE ANTI-STALL in SECTION 9 of THIS MANUAL. 'P' GAUGE TEST CONN.

MARGIN PRESSURE

••

When a function control lever is moved, i.e. joystick, to activate a boom or swing function, Load Sense (LS) pressure increases to the point where it is equal to the work port pressure and it shifts the LS control valve spool in the main pump controller.

••

HORSEPOWER CALIBRATION DO NOT ADJUST

••

••

••

••

•• 103-17A

ENGINE ANTI-STALL SOLENOID VALVE

HIGH PRESSURE LIMITING CONTROL

MAIN VALVE MANIFOLD

The pump is protected by a high pressure limiting control which is attached to the main control valve manifold. Refer to HIGH PRESSURE LIMITING CONTROL in THIS SECTION.

GAUGE TEST PORT 'X1' ANTI-STALL SIGNAL PRESSURE GAUGE TEST PORT 'L.S.'

HIGH PRESSURE LIMITING CONTROL

L.S. GAUGE TEST CONN.

••

SAW PUMP For the operation and adjustments of this pump refer to SECTION 17 of THIS MANUAL.

•• •• 822-D65

FAN PUMP

PILOT SUPPLY 'P1'PORT WITH OIL FILTER

••

MAIN PUMP

MARGIN PRESSURE ADJUSTING SCREW

For the operation and adjustments of this pump refer to SECTION 10 of THIS MANUAL.

MAIN PUMP CONTROLLER

CLAMPS AND FAN PUMP

(LS CONTROL)

The clamps and fan pump is a dual gear pump driven off the back of the main pump. For detailed information on this pump, refer to SECTION 18 of THIS MANUAL.

The pump then adjusts its output volume until the pump output pressure exceeds the LS pressure by a small amount. This difference is known as margin pressure (differential pressure or Delta P).

Refer to SET MARGIN PRESSURE in THIS SECTION. At this point the LS control valve spool shifts back to its previous condition and the swashplate control piston will be balanced with the pump 4.9

Tigercat 822 Feller Buncher LOAD SENSING

Hydraulic system

BASIC PRINCIPLES Figs. 1 & 2 Early hydraulic systems used a fixed displacement pump, with valves to control or adjust flow rates or speeds. This throttling or restricting pump flow to achieve control over the functions causes excess oil to flow over the relief valve. This results in wasting power and at the same time creates heat. SEE FIGS. 1 & 2.

FLOW

853SM18

W USED PRESSURE

FIG. 1

FIXED DISPLACEMENT PUMP

853SM16

FIG. 2

HP

Figs. 3 & 4 In an attempt to recover some of the wasted energy, variable volume pumps evolved. These pumps are power regulated or horsepower controlled and since they reduce the pumps output to maintain a constant system hp, oil flow over the relief valve is less, therefore reducing the wasted power losses and heat generation. SEE FIGS. 3 & 4.

WASTED WASTED

=CO NS

The power wasted in the horsepower control system is still considerable and still requires constant "throttling" by the operator if he wants the speeds to remain as selected.

TAN T

This system combines the energy saving benefits of flow on demand with load compensation at each work port. The compensator eliminates the need for operator flow adjustments (throttling).

SEE FIGS. 5 & 6.

FLOW

Figs. 5 & 6 The load control system was developed to address the problems outlined above.

WASTED WASTED

W USED PRESSURE

853SM19 FIG. 3

HP REGULATED PUMP

FIG. 4

853SM16

HP =C ON STA

FLOW

NT

∆p LS W USED PRESSURE

853SM17 FIG.5

LOAD SENSING (FLOW ON DEMAND) 4.10

FIG.6

853SM16

Tigercat 822 Feller Buncher LOAD SENSING BASIC DESCRIPTION

Hydraulic system

OPEN CENTRE VS. CLOSE CENTRE OPEN CENTRE SYSTEM:

853SM21

853SM20

With the control valve in neutral all of the oil from the pump “bypasses” through the open center passage directly to tank. There is no backpressure created by the control valve to force oil into the workport (the workport is actually blocked off when the spool is in neutral, and unblocked when the spool begins to move).

If the oil flowing to the motor or cylinder meets variable loads, this will upset the balance of oil going to the tank and the load. This causes the speed of the function to change with load changes.

853SM21 853SM20

When the control valve lever is moved to actuate a cylinder or motor, the open center passage is blocked off in proportion to the amount the lever is moved. This creates back pressure forcing oil into the valve workport to move the load.

This type of system exhibits the following characteristics; 1. If the load against the cylinder or motor changes, the speed of the function will change.

2. If the load increases on a boom cylinder, the boom will slow or stop. Moving the lever further will increase the pressure against the load, and when high enough, the load will begin to move again.

853SM20

3. The maximum speed of the function is determined by the maximum flow of the pump.

When the control valve lever is fully shifted to the maximum flow position the open center passage is completely blocked, and all of the pump flow is forced against the load.

4.11

Tigercat 822 Feller Buncher CLOSED CENTRE SYSTEM: Load sensing systems use variable flow pumps and only flow oil when required. Unlike the open centre system, the control valve does not have an open centre passage. When in neutral, no oil flows through the control valve to tank and the pump output flow is zero. The pump’s output flow is controlled by a “stroking piston” which is connected to the pump output, and to the valve’s workport or “load”. This sense line to the actual working load defines the system as load sensing.

The key component in the system below is the spring in the stroking piston. The pump’s output pressure must be 250 p.s.i. higher than the load pressure to compress the spring and reduce the flow of the pump. This 250 p.s.i. is the differential or margin pressure.

Hydraulic system point. The stroking piston will change the pump’s flow until pump pressure is 250 p.s.i. higher than load pressure.

In the figures below, note that even though the load pressure may change, (as illustrated by the extra restriction) the flow remains constant. This is because the difference in pressure, or differential pressure, between the pump and load pressures can be maintained by the stroking piston regardless of load. It is important to remember the pump is really responding to the pressure differential resulting from flow through the valve, not the actual load pressure level.

853sm22

853sm22

In the figure above the valve is closed blocking the pump from the load. With the load at zero the pump will maintain 500 p.s.i. of standby pressure and pump flow is zero.

853sm22

The following are key differences from open centre systems;

853sm22

When the control valve lever is moved to actuate a cylinder or motor, the control valve opens the pump to the load. In this case the load is zero and the pump output pressure falls as the oil escapes through the valve. The 250 p.s.i. that was holding the spring in the compressed state is reduced and the spring moves the pump to increase flow. Flow will increase to a level that requires 500 p.s.i. to force the oil through the valve opening. At this point the load pressure combined with the spring force will be high enough to oppose the pump output pressure, and the stroking piston will stop moving.

Changing the control valve lever changes the size of the opening in the valve and upsets the balance of the stroking piston. The stroking piston then adjusts the flow of the pump to find a new balance

1. The load sensing valve’s maximum flow is not equal to the pumps maximum flow as with the open centre system. The valves maximum flow is determined by the maximum size of opening or “orifice” it provides.

2. The speed of the load does not change as the load changes. If the load increases on a boom cylinder the pump pressure will increase automatically to maintain the load’s original speed. If the load stops, it is because the load is too heavy for the boom to lift.

Moving the lever further will not increase the lifting force.

3. A load sensing system provides the speed the operator selects with the lever, and automatically adjusts the pressure to match the load. The open centre system requires the operator to adjust the pressure to match the load and the speed is determined by the load.

4.12

Tigercat 822 Feller Buncher

Hydraulic system

OPERATING TIPS When using the controls on a load sensing system think of what the system is trying to do for you. If you move the lever 20% of its total angle, the system will provide whatever pressure it takes ( up to its maximum capacity if needed) to meet this speed requirement. If you move the lever past the point needed in an attempt to speed up the boom movement, you will only overshoot the speed you wanted. Relax and try to use the least amount of lever action you can.

Load sensing systems respond to rough operation by amplifying these movements. If you find the boom is jerky or always giving “feedback”, you’re probably too active on the controls. If slowing down doesn’t eliminate the roughness, the margin pressure setting may be too high and can be reduced to calm down the machine’s response.

Refer to SET MARGIN PRESSURE in this section.

Another feature of this system is that the maximum flow of each function, in each direction, can be tuned to your requirements. This is easily done by changing the flow adjusting screws on each control valve. Take the time to set up your machine, as this greatly reduces fatigue.

Refer to SET FLOW (FUNCTION SPEED) RATE in appropriate BOOM or SWING sections of THIS MANUAL.

4.13

Tigercat 822 Feller Buncher

822-16

Hydraulic system

LOAD SENSING SYSTEM CIRCUIT DIAGRAM 4.14

Tigercat 822 Feller Buncher MAIN HYDRAULIC (LOAD SENSING) CIRCUIT CIRCUIT DESCRIPTION The main hydraulic circuit includes the components for boom, stick, tilt, swing, wrist and travel operations.

An axial piston, swashplate controlled pump supplies oil for the main hydraulic system. A load sensing signal is sent back from the Linde control valve manifold (LS port) to the main pump regulator (LS port) to control the pump output pressure.

Oil flow for each function is supplied by its own control valve section on the manifold. When the control valves are in neutral, there is no flow through the valves, therefore the system is closed-centre. When all control valves are in neutral, the pump will only supply enough oil to make-up for leakage in the system and the pressure remains at a low level (approx. 500 psi).

The control valve sections trap oil in their circuits when the spools are in neutral.

Oil returning to the tank from the control valve sections must open back pressure check valves in the control valve manifold before flowing to the reservoir via the oil cooler. This creates a small positive pressure in the manifold to prevent cavitation in the cylinders. All oil returning to the reservoir is filtered.

Hydraulic system FLOW ON DEMAND AND LOAD COMPENSATION The combination of control valves and pump used in this system provides flow on demand and load compensation. Flow on demand means that only the required quantity of oil will be delivered to a function by the pump. This will save energy and reduce heat generation in the hydraulic system.

Load compensation means that all functions will continue to receive oil regardless of their pressure and without further movement of the control levers.

Without this system, an operator moving control levers halfway on the boom up and stick out controls would find that the lowest pressure function would move and the other would not move.

To make both functions move the operator would have to move the high load lever much more than the low load lever. In other words, the operator would have to restrict oil flow to one function while opening up the valve fully to the other. This is what the load compensation system does automatically as will be explained further below.

With the load compensation on this unit the operator does not need to continually adjust the control lever to move two or more functions because of pressure differences.

Valves inside of the main control valve spools will automatically adjust flow according to the pilot pressure applied to the spool to move functions independant of load pressure.

4.15

Tigercat 822 Feller Buncher CONTROL VALVE MANIFOLD

DRIVE, LEFT

Hydraulic system

TILT CYLINDER

DRIVE, RIGHT

STICK CYLINDER

HIGH PRESSURE LIMITING CONTROL

WRIST

MAIN BOOM CYLINDERS

SWING

•• •• •

•

••

•

•

•

B

••

••

SIDE

A SIDE

RETURN MANIFOLD

822-D63A

MAIN CONTROL VALVE

MAIN CONTROL VALVE DESCRIPTION

CONTROL VALVE SECTIONS

The main control valve consists of seven individual valve sections, a high pressure limiting relief valve and a non adjustable safety relief.

Each section, including the relief valve is fastened to the control valve manifold which contains five common passages for all valves.

The spools are pilot actuated and returned to neutral by centering springs. An air bleed plug is provided on the top pilot cap. If a hesitation is noticed when actuating a function, air should be bled from the pilot caps. Spool travel stop screws are fitted in the pilot end caps and are used to limit the spool travel so that maximum speed can be adjusted for each individual function. The screws can also be turned in to lower the boom or stick when the engine or pump will not operate.

The five passages are (refer to fig. 853sm24): 1. Centre passage for pump discharge.

2. Two return passages (connected internally).

3. Two for Load Sense (connected internally).

The swing and drive spools have return pilot checks in the end caps which allow pilot oil to enter quickly, but restrict the flow out, thus dampening the movement of the control spool for smoother control of the function.

SWING AND DRIVE "MOTOR" SPOOL SECTIONS The swing and drive valve sections have make-up valves for anti-cavitation. See FIG. 90919.

2

3

BOOM AND WRIST FUNCTIONS SPOOL SECTIONS These functions have relief and anti-cavitation valves. See FIG. 90744 with spool in NO-FLOW position and FIG. 90744-2 with spool in FLOW position.

1

853SM24

MANIFOLD/VALVE SECTION SCHEMATIC WITH RELIEF 4.16

Tigercat 822 Feller Buncher MAKE UP OR ANTICAVITATION VALVE

Hydraulic system MAKE UP OR ANTICAVITATION VALVE

WORK PORTS

•

•

PILOT CHECK

•

PILOT END CAP AIR BLEED PLUG

•

•

SPOOL TRAVEL STOP (ADJUSTABLE)

• •

•

•

•

BALL AND SPRING

LOAD SENSING 'LS'

•

COMPENSATOR VALVE PUMP 'P' RETURN 'T'

RETURN 'T'

LOAD SENSING 'LS'

CONTROL VALVE SECTION TYPICAL FOR "MOTOR" OPERATED SWING AND DRIVE FUNCTIONS

90919

WORK PORTS

ANTICAVITATION RELIEF VALVE MAX. FLOW ADJUSTING SCREW

•

ANTICAVITATION RELIEF VALVE

• •

•

• • • MAIN CONTROL SPOOL COMPENSATOR RETURN 'T'

PUMP 'P'

RETURN 'T'

90744

CONTROL VALVE SECTION - TYPICAL FOR "CYLINDER" OPERATED FUNCTIONS (SHOWN IN NO-FLOW POSITION)

90744-2

CONTROL VALVE SECTION - TYPICAL FOR "CYLINDER" OPERATED FUNCTIONS (SHOWN IN FLOW POSITION) 4.17

Tigercat 822 Feller Buncher PORT RELIEF AND ANTICAVITATION VALVE OPERATION

Hydraulic system MEDIUM SYSTEM PRESSURE

During normal operation, oil pressure in the work circuit is less than the circuit relief valve setting and the circuit relief valve remains closed.

During relief operation, the relief valve will open in three steps.

(Step 1) The pilot poppet 'D' is opened; Flow restriction through the hollow piston 'C' causes the pressure in the cavity behind the main poppet 'B' to decrease.

PILOT POPPET 'D'

• WORK PORT

• •

•

• RETURN

ORIFICE 'A'

NORMAL OPERATION

90744-4A

(Step 2) The piston seats against the poppet.

This further reduces oil flow into the cavity and greatly decreases the pressure against the back side of the main poppet.

MEDIUM SYSTEM PRESSURE

HIGHEST SYSTEM PRESSURE

•

(Step 3) The main poppet 'B' opens.

When the relief valve again closes, the piston and the pilot poppet move together until the pilot poppet is seated. Oil flows into the cavity through the clearance between the piston and the main poppet to move the piston away from the pilot poppet. This permits flow into the cavity through the piston to seat the main poppet.

RELIEF AND HOLLOW ANTICAVITATION PISTON 'C' POPPET 'B'

•

WORK PORT

• RETURN

RELIEF OPERATION

90744-6A

During anticavitation operation the main poppet 'B' will retract to allow oil to flow from the return passage into the work circuit.

LOW WORK PORT PRESSURE

ADJUSTING PROCEDURE 1. Loosen locknut.

•

WORK PORT

2. Turn the adjusting screw to obtain desired pressure reading on gauge.

• RETURN

3. Tighten locknut on adjusting screw making sure adjusting screw does not turn.

90744-5A

ANTICAVITATION OPERATION

4. Re-check pressure gauge reading.

Refer to SET MAIN BOOM, STICK AND PORT RELIEF VALVES in SECTION 12 of THIS MANUAL for more complete details.

PORT RELIEF VALVE

LOCKNUT • 17MM WRENCH

• • • • MAIN VALVE BODY

90744-4

4.18

ADJUSTING SCREW • 5MM ALLEN KEY

MAIN VALVE PORT RELIEF VALVE

Tigercat 822 Feller Buncher

Hydraulic system

CONTROL VALVE SPOOL OPERATION To achieve load sensing compensation, each control spool has two compensator valves and two L.S. check valves. These compensator valves can be either in the form of a shuttle valve or a ball, depending on the function being controlled.

PILOT END CAP

SHUTTLE COMPENSATOR CONTROL VALVE VALVE SPOOL

COMPENSATOR VALVE

SHUTTLE VALVE

PILOT END CAP

•

•

•

• CENTERING SPRING

•

•

• •

•

•

• •

• •

•

•

LOAD SENSING WORK WORK PASSAGE 'LS' PORT 'A' PORT 'B' SUPPLY RETURN RETURN PASSAGE 'P' PASSAGE 'T' PASSAGE 'T'

LOAD SENSING PASSAGE 'LS'

CENTERING SPRING

(A) CONTROL VALVE SECTION ~ IN NEUTRAL

853SM25

(A) Each work port (A & B) has a compensator valve and shuttle valve. Each valve section also has two return passages (T) and two load sensing passages (LS). Each valve section has only one supply passage (P).

With the control valve spool held in neutral by the centering springs in both pilot caps, the pump discharge is blocked. Therefore, the control valves are closed centre. Pump discharge, work port, return, and load sensing passages are all blocked by the spool. Oil in the work ports is trapped.

With all control valve spools in neutral, pump discharge or "standby" oil pressure is approximately 400-600 psi.

PILOT OIL

LS PORT JUST OPENED

SHUTTLE VALVE

CONTROL SPOOL

• •

(B) CONTROL VALVE SECTION ~ • CONTROL SPOOL STARTING TO MOVE TO RIGHT • LS PORT JUST OPENED • ONLY SPOOL ACTUATED 853SM26

(B) Whenever a single function is operated, pilot oil flows to a control valve end cap. Pilot oil will start to move the spool against the centering spring on the opposite end of the spool. The load sensing port (LS) is the first port to open. When the LS port is opened, the shuttle cavity is at LS pressure. Since this is the first function being operated, there is no LS pressure in the manifold and the shuttle does not move.

4.19

Tigercat 822 Feller Buncher PILOT OIL

Hydraulic system SHUTTLE VALVE

•

BALANCE VALVE

•

CONTROL SPOOL

•

WORK PORT 'A' JUST OPENED

(C) CONTROL VALVE SECTION ~ • CONTROL SPOOL CONTINUES TO MOVE TO RIGHT • WORK PORT 'A' JUST OPENED • HIGHEST WORKING PRESSURE

853SM27

(C) The second port to open is work port ‘A’ (port ‘B’ if the control spool moves to the left). The left compensator valve stays to the right as in the neutral condition and the shuttle valve moves to the left directing work port pressure to the area behind the compensator valve to hold it shut until it can be opened by pressure in the ‘P’ port. In this mode, the compensator valve is functioning as a load check valve would in a conventional valve.

PILOT OIL

(5) SHUTTLE (6) COMPENSATOR VALVE VALVE MOVES LEFT

CONTROL SPOOL

TANK PORT 'T' (RETURN)

(1) ANGLED VENT PORT OPENS

• •

•

•

• •

(4) OIL FLOWS TO 'LS' PASSAGE

(3) PRESSURE PORT OPENED SLIGHTLY

(2) WORK PORT 'B' OPENS

(D) CONTROL VALVE SECTION ~ • CONTROL SPOOL CONTINUES TO MOVE TO RIGHT 853SM28

• PRESSURE PORT OPENED SLIGHTLY • HIGHEST WORKING PRESSURE

(D) The next port to open is the angled vent port (1) on the right side of the control spool which connects to the tank port, ‘T’. This connects all passages in the compensator spool to return pressure. There is no movement at this time but as soon as the work port ‘B’ opens (2) and oil flows, the returning oil will push the compensator valve to the right and connect ‘B’ to ‘T’.

The pressure port in the control spool is the last port to open (3). When it opens, pump discharge pressure flows through the passage in the compensator spool and through the shuttle cavity to the load sense passage (4).

The load sensing pressure increases causing the pump to increase its displacement and further increase the pressure. The compensator valve keeps the work port passage closed until the pump discharge pressure is higher than the work port pressure (load check feature).

Once the pump discharge pressure is higher, the shuttle valve moves to the right (5) and connects load sensing pressure to the cavity behind the compensator valve. The compensator valve moves to the left (6) allowing oil to flow to the work port. With the compensator valve open, the cavity to the right of the compensator valve assumes approximate work port pressure and this pressure flows through the passage to the shuttle cavity allowing work port pressure to control load sensing pressure. As the control spool moves further, in response to pilot pressure, the compensator valve and shuttle valve positions remain the same.

4.20

Tigercat 822 Feller Buncher PILOT OIL

(1) COMPENSATOR VALVE

Hydraulic system SHUTTLE VALVE

CONTROL SPOOL FULLY SHIFTED TO RIGHT

•

•• •

•

•

•

•

•

•

LOAD SENSING WORK WORK LOAD SENSING PASSAGE 'LS' PORT 'A' PORT 'B' PASSAGE 'LS' SUPPLY PASSAGE 'P' RETURN RETURN (PUMP DISCHARGE) PASSAGE 'T' PASSAGE 'T'

(E) CONTROL VALVE SECTION ~ • CONTROL SPOOL FULLY SHIFTED TO RIGHT • HIGHEST WORKING PRESSURE

853SM29

(E) In this figure, pump discharge pressure is slightly higher than work port pressure because the compensator valve (1) is open. When using just one function both the compensator valve and the shuttle valve are moved to the end of their bores.

The load sensing pressure is always the same as the highest work port pressure and as a result is always lower than pump discharge pressure. There are two factors that establish this pressure difference between pump discharge and work port pressure, the load sensing valve and the orifice effect of the passages in the control valve between the pump discharge port and the work port. There are three openings the pump discharge oil must flow through to get to the work port. Each time the oil flows through a passage there is a pressure drop, that is, there is an orifice at each passage. The smaller the opening the smaller the oil flow due to the constant load sensing pressure. There is a passage from the work port to the load sensing passage and this is the pressure sensed at the pump regulator; since the flow is very small there is virtually no pressure drop from the work port to the LS port on the pump.

Load sensing pressure is the same at both ends of all the control spools because the two passages in the control valve manifold are joined together in the manifold.

LOAD SENSING ~ TWO OR MORE FUNCTIONS IN USE Load compensation comes into effect whenever two or more functions are actuated at the same time.

The following is an explanation of the function of the valve components whenever a spool with a lower working pressure is activated when a higher working pressure spool is fully shifted.

PILOT OIL

LS PORT JUST OPENED

COMPENSATOR (2) SHUTTLE VALVE MOVES TO RIGHT VALVE

(1) CONTROL SPOOL STARTS TO MOVE

CENTERING SPRING

• ••

•

(F) CONTROL VALVE SECTION ~ • CONTROL SPOOL STARTING TO MOVE TO RIGHT 853SM30

• LS PORT JUST OPENED • LOWER WORKING PRESSURE

(F) Pilot oil will start to move the control spool against the centering spring on the opposite end of the spool. The LS port is the first to open and load sensing pressure is applied to the shuttle valve. The shuttle valve moves to the right to the end of its bore and then LS pressure flows into the cavity at the left end of the compensator valve.

4.21

Tigercat 822 Feller Buncher

Hydraulic system

SHUTTLE VALVE

PILOT OIL

CONTROL SPOOL

COMPENSATOR VALVE

•

•

•

WORK PORT 'A' JUST OPENED

(G) CONTROL VALVE SECTION ~• CONTROL SPOOL CONTINUES TO MOVE TO RIGHT • WORK PORT 'A' JUST OPENED • LOWER WORK PORT PRESSURE

853SM31

(G) As the control spool continues to move, the work port is the next to open. The work port oil pressure passes through compensator valve port and is applied to the end of the shuttle valve but since this work port pressure is lower than LS, the shuttle does not move.

PILOT OIL

SHUTTLE VALVE

(4) COMPENSATOR VALVE MOVES LEFT THEN RIGHT (5)

•

CONTROL SPOOL

•

TANK PORT 'T' (RETURN)

(1) ANGLED VENT PORT OPENS

• •

• •

OIL FLOWS TO 'LS' PASSAGE

(3) PRESSURE PORT OPENED SLIGHTLY

(2) WORK PORT 'B' OPENS

(H) CONTROL VALVE SECTION ~ • CONTROL SPOOL CONTINUES TO MOVE TO RIGHT 853SM32

• PRESSURE PORT OPENED SLIGHTLY • LOWER WORKING PRESSURE

(H) As the control spool continues to move, the angled vent port opens (1), then work port ‘B' opens (2) allowing oil to flow and shift the right side compensator valve connecting port 'B' to 'T'. The pressure port ‘P’ is next to open (3) and supply pressure passes into the cavity to the right of the compensator valve causing it to shift to the left (4) since the supply pressure is somewhat greater than LS pressure. As it shifts to the left (4) oil can travel into work port ‘A’ and in doing so it causes pressure in the cavity to drop which results in LS pressure pushing the compensator valve back to the right (5). The compensator finds a position where the pressures are balanced and some oil flows into work port ‘A’.

4.22

Tigercat 822 Feller Buncher PILOT OIL

Hydraulic system (1) CONTROL SPOOL FULLY SHIFTED TO RIGHT

(2) COMPENSATOR VALVE SETTLES IN A BALANCE POSITION

•

• •

•

•

•

•

•

•

WORK LOAD SENSING WORK LOAD SENSING PORT 'A' PASSAGE 'LS' PORT 'B' PASSAGE 'LS' RETURN RETURN SUPPLY PASSAGE 'P' PASSAGE 'T' PASSAGE 'T' (PUMP DISCHARGE)

(I) CONTROL VALVE SECTION ~ • CONTROL SPOOL FULLY SHIFTED TO RIGHT 853SM33

• LOWER WORKING PRESSURE

(I) As the control spool continues to move (1), the compensator spool continues to move in response to the pressure variations and it settles in a position of balance (2) as shown in the figure with the spool fully shifted. As the loads vary in the work ports, the valve components continue to modulate and compensate for the load variations and maintain movement of the selected functions.

This valve system performs the functions automatically that are performed by an operator using a conventional system as explained in the third paragraph above.

If the second valve being operated had a higher work port pressure than the one already selected, the operation would be the same up to the point where the work port was opened. At this point the LS would change to the new higher work port pressure and the new valve would act in the same way as the first valve selected and described above. The first valve selected would then have the internal spool components take the same positions as the lower work port pressure valve described above.

4.23

Tigercat 822 Feller Buncher HIGH PRESSURE LIMITING CONTROL VALVE The main pump is protected by a High Pressure Limiting control which consists of three relief valve cartridges. The H.P.L. control is attached to the main control valve manifold and contains three relief valves: The first relief valve (P2) limits L.S. pressure to approx. 4000 psi. (Gauge at 'L.S.' test port) which in turn limits the pump output pressure to 4300 psi. (Gauge at 'P' test port) The 300 psi. differential is known as margin pressure. See SET MARGIN PRESSURE in THIS SECTION.

Hydraulic system P2 L.S. PRESSURE LIMIT, SET AT 4300 PSI. WITH GAUGE ON 'P' TEST PORT • 4MM ALLEN KEY • 13MM WRENCH MAIN CONTROL VALVE MANIFOLD

The third relief valve (P1) is screwed fully in and is not used.

•

SYSTEM RELIEF VALVE NON-ADJUSTABLE

• HIGH PRESSURE LIMITING CONTROL

845B-D20

HIGH PRESSURE LIMITING CONTROL VALVE

1. CENTRE PASSAGE FOR PUMP DISCHARGE. 2. TWO RETURN PASSAGES (CONNECTED INTERNALLY).

3. TWO PASSAGES FOR LOAD SENSE (CONNECTED INTERNALLY).

853SM24

• •

•

Margin pressure is the differance between 'P' port pressure and L.S. port pressure, observed while a function is operating.

The second relief is a system relief valve which limits the pump output pressure to 870 psi above L.S. pressure, this relief is non-adjustable.

P1. SCREWED FULLY IN NOT USED

H.P.L. CONTROL, MANIFOLD/ VALVE SECTION SCHEMATIC WITH PORT RELIEFS 4.24

Tigercat 822 Feller Buncher

Hydraulic system

PILOT PRESSURE SUPPLY 'P1' PORT 11.3mm

ENGINE ANTI-STALL PROPORTIONAL SOLENOID VALVE

••

••

•• ANTI-STALL (HORSE POWER) CALIBRATION DO NOT ADJUST REQUIRES TEST BENCH FOR READJUSTMENT

TANK LOAD SENSE PRESSURE

GAUGE TEST PORT 'X1'

••

••

••

8mm

••

•• ••

•• PUMP OUTLET PRESSURE

PUMP SWASH CONTROL PASSAGE

TANK

MARGIN PRESSURE ADJUSTING SCREW • 8MM WRENCH • 19MM WRENCH (Turn OUT to decrease Margin pressure)

CROSS SECTION OF MAIN PUMP CONTROL VALVE

90669

SET MARGIN PRESSURE

••

HORSEPOWER CALIBRATION DO NOT ADJUST

MARGIN PRESSURE is the difference between the LOAD SENSE pressure and the PUMP OUTPUT pressure while a function (boom, swing or travel) is being operated. For the load sensing system to operate correctly the differential pressure between L.S. and 'P' should be 300 psi. 'P' being higher than L.S.

ENGINE ANTI-STALL SOLENOID VALVE

GAUGE TEST PORT 'X1' ANTI-STALL SIGNAL PRESSURE GAUGE TEST PORT 'L.S.'

••

• •

••

**NOTE: If the margin pressure is not set correctly, the machine controls may not respond as they should, i.e. boom is jerky or sluggish.

The margin pressure adjustment is made at the main pump controller attached to the main pump.

PILOT SUPPLY 'P1'PORT WITH OIL FILTER

•• 822-D65

••

••

MAIN PUMP

MARGIN PRESSURE ADJUSTING SCREW

Continued on page 26

MAIN PUMP CONTROLLER (LS CONTROL)

4.25

Tigercat 822 Feller Buncher

Hydraulic system

Continued from page 25

PRESSURE GAUGE CONNECTIONS The pressure gauge connections are the 'P' and 'L.S'.gauge tests port on the Linde main valve manifold and on later machines additional 'P' and "L.S." test ports installed on the main pump. The latter will more accurately and better facilitate the set-up procedure when making adjustments to the main pump.

Therefore when making adjustments at the pump, use the test ports located in that area, when making adjustments to the main Linde valve use the 'P' and 'L.S.' test ports located on the back side of the Linde main valve manifold.

The margin pressure is set at the factory to 300 psi. The margin pressure can be adjusted from 250 - 300 psi., however the flow stops on the valves must be reset in order to maintain the same speed of the functions.

'P' GAUGE TEST CONN.

••

HIGH PRESSURE LIMITING CONTROL

L.S. GAUGE TEST CONN.

••

••

P2 L.S. PRESSURE LIMIT, SET AT 4300 PSI. WITH GAUGE ON 'P' TEST PORT • 4MM ALLEN KEY • 13MM WRENCH

103-17A

GAUGE TEST PORTS ON MAIN VALVE

•• MAIN VALVE MANIFOLD

••

*If a differential pressure gauge is not available, one single 0-5000 psi gauge may be used; First placing it on the L.S. test port and noting the reading, Then on 'P' test port and noting the reading. 'P' should be 300 psi. greater than 'L.S.'.

1. Use a differential pressure gauge* (preferably a differential gauge with ten psi increments).

PUMP OUTLET MANIFOLD

HORSEPOWER CALIBRATION DO NOT ADJUST

••

•• GAUGE TEST PORT 'X1' ANTI-STALL SIGNAL PRESSURE

GAUGE TEST PORT 'P'

PILOT SUPPLY 'P1'PORT WITH OIL FILTER

•

••

MAIN PUMP

SAW PUMP BOLTED TO THIS FACE

•• ••

•• •• ENGINE ANTI-STALL SOLENOID VALVE

GAUGE TEST PORT 'L.S.'

•• •• 822-D66

PRESSURE TEST PORTS ON MAIN PUMP AND CONTROLLER 4.26

MARGIN PRESSURE ADJUSTING SCREW

Tigercat 822 Feller Buncher 2. With hydraulic oil at operating temperature, Connect one side of the differential pressure gauge to the L.S. gauge port and the other side of the gauge to the pressure 'P' gauge test port.

Hydraulic system SET LOAD SENSE RELIEF VALVE NOTE: Constant loosening and tightening of the locknut (sealnut) on the adjusting screws of these relief valves will eventually cause the seal in the nut to break down and leak.

Because of this it is best to keep the adjusting procedure brief.

3. Close and latch the cab front door.

4. Start the engine and place throttle control in FULL position.

5. Press PILOT RESET button to activate pilot system and turn anti-stall switch OFF. 6. Turn swing brake ON and place SWING joystick lever in FULL position (left or right).

7. Loosen locknut on margin pressure adjusting screw on main pump controller and turn adjusting screw until the differential reading on gauge is 300 psi**. (Turn OUT to decrease Margin pressure).

1. With hydraulic oil at operating temperature, Connect a 0 - 5000 psi gauge to 'P' gauge test port on back of main control valve manifold.

2. Close and latch the cab front door.

3. Start engine and set throttle control to FULL position.

4. Press PILOT RESET button to activate pilot system and turn anti-stall switch OFF. 'P' GAUGE TEST CONN.

If only one 0-5000 psi gauge is being used; It should first be connected to the L.S. test port and the reading noted, the same gauge should then be connected to the 'P' test port and the margin pressure adjusting screw adjusted until reading on gauge is 300 psi** greater than the 'L.S.' previously noted reading.

• •

••

••

P2 L.S. PRESSURE LIMIT, SET AT 4300 PSI. WITH GAUGE ON 'P' TEST PORT • 4MM ALLEN KEY • 13MM WRENCH

NOTE: This is a sensitive adjustment, significant changes in pressure will be noticed with only a small movement of the adjusting screw.

8. Allow a short time for pressure reading to stabilize then tighten locknut on adjusting screw. Repeat above procedure to verify the differential pressure setting is still correct.

HIGH PRESSURE LIMITING CONTROL

L.S. GAUGE TEST CONN.

••

SET LOAD SENSE RELIEF VALVE 103-17A

• •

MAIN VALVE MANIFOLD

5. While holding L.H. joystick in the STICK OUT position (fully extended), loosen locknut on P2 relief valve cartridge and turn adjusting screw until pressure gauge reads 4300 psi. Tighten locknut on adjusting screw and re-check pressure reading on gauge.

6. Stop engine and remove pressure gauge.

4.27

Tigercat 822 Feller Buncher PRESSURE SETTINGS

Hydraulic system

WITH Tigercat ST 5700 SAW FELLING HEAD ENGINE RPM (With Sisu 645 DSBIE 253 HP) FULL THROTTLE, NO LOAD, MAX. .................... 2200 RPM IDLE, NO LOAD ................................................... 1000 RPM RATED WORKING .............................................. 2000 RPM L.H. & R.H. FINAL DRIVE CROSSLINE RELIEFS ........................................ 4700 PSI BEGIN OF REGULATION (MOTOR POR) .......... 3600 PSI BRAKE RELEASE ............................................... 500 PSI SPEED (TRACK SPROCKET RPM): ............................... LOW ................................... 10 RPM MAX. ............................... DRIVE ................................. 28 RPM MAX. MAIN PUMP ANTI-STALL SET POINT ..................................... 1950 RPM HIGH PRESSURE LIMITING CONTROL on main Linde valve MAIN RELIEF ....................................................... NON-ADJUSTABLE LOAD SENSE RELIEF P1 ................................... SCREW IN FULLY (LOCKED OUT) LOAD SENSE RELIEF P2 ................................... 4300 PSI (AT 'P' PORT) BOOM PORT RELIEFS ....................................... 4700 PSI (AT 'P' PORT) STICK PORT RELIEFS ........................................ 4700 PSI (AT 'P' PORT) TILT PORT RELIEFS ........................................... 4700 PSI (AT 'P' PORT) WRIST PORT RELIEFS ...................................... 3200 PSI (AT 'LS' PORT) MARGIN PRESSURE .......................................... 300 PSI PILOT SUPPLY MAIN RELIEF ....................................................... 425 PSI ER BOOM VALVE COUNTERBALANCE VALVE .............................. SCREW OUT FULLY (CCW) SWING CROSSLINE RELIEFS ........................................ 3300 PSI (AT 'P' PORT) SPEED ................................................................. 6 RPM SAW PUMP PRESSURE OVERRIDE ...................................... 3600 PSI (AT 'P' PORT) STAND-BY ........................................................... SCREW IN FULLY (LOCKED OUT) SAW CONTROL VALVE MAIN RELIEF ....................................................... 4000 PSI SAW MOTOR BEGIN OF STROKE ............................................ 3200 PSI SPEED ................................................................. 1125 - 1175 RPM MOTOR 'X' DIMENSION ...................................... 22MM (0.88") OF 100MM (3.94") CLAMPS VALVE MAIN RELIEF .......................................................... 2700 PSI (SET AT FULL THROTTLE) CLAMP ARMS PORT RELIEFS .............................. 3200 PSI (SET AT LOW IDLE) ACCUMULATOR ARMS PORT RELIEFS ............... 3200 PSI (SET AT LOW IDLE) FAN VALVE MAIN RELIEF ....................................................... 3000 PSI (SET AT FULL THROTTLE) PORT RELIEFS ................................................... 3300 PSI (SET AT LOW IDLE) MAX. FORWARD SPEED AT FULL THROTTLE 2400-2500 RPM (SPOOL STOP ADJUSTING SCREW FULL OUT) MAX. REVERSE SPEED AT FULL THROTTLE .. 2100 RPM (ADJUST SPOOL STOP) DOOR PUMP MAIN RELIEF ....................................................... 3000 PSI ALL PRESSURES MUST BE SET WITH HYDRAULIC OIL AT OPERATING TEMPERATURE. SEE APPROPRIATE SECTIONS IN THE SERVICE MANUAL FOR SETUP PROCEDURES. NOTE: THIS CHART IS FOR REFERENCE PURPOSES ONLY.

ISSUE 1 0603

4.28

Tigercat 822 Feller Buncher

SECTION 5 - PILOT SYSTEM APRIL 2003

CONTENTS - SECTION 5 ACCUMULATOR CHARGING ............................................................................................... 5.10 CHECK PRE-CHARGE PRESSURE ......................................................... 5.10 GENERAL DESCRIPTION ........................................................................... 5.5 TESTING DEVICE ..................................................................................... 5.10 CIRCUIT DESCRIPTION .................................................................................. 5.8 CIRCUIT DIAGRAM ......................................................................................... 5.7 ELECTRICAL CIRCUIT .................................................................................... 5.6 PILOT MANIFOLD .................................................................................. 5.2, 5.4 PILOT SYSTEM COMPONENTS ACCUMULATOR ............................................................................... 5.5, 5.10 GENERAL DESCRIPTION ........................................................................... 5.2 HIGH PRESSURE FILTER .......................................................................... 5.3 JOYSTICKS AND FOOT PEDALS ............................................................... 5.6 PILOT MANIFOLD ....................................................................................... 5.4 PILOT SHUT OFF VALVE ........................................................................... 5.4 PILOT SUPPLY VALVE .............................................................................. 5.3 PRESSURE SETTINGS .................................................................................. 5.9

Tigercat 822 Feller Buncher PILOT SYSTEM COMPONENTS

Pilot system

GENERAL DESCRIPTION The pilot circuit is supplied with oil from the main pump. Oil is first filtered by an inline high pressure filter before entering the pilot supply valve. The pilot supply valve reduces and maintains the pressure of the oil from the main pump to 425 psi for the pilot system. The pilot oil (425 psi) is then supplied to the pilot manifold, the cooling fan pilot valves and the anti-stall valve mounted on the main pump. Pilot oil is distributed by the pilot manifold to the various pilot actuated functions of the machine. Solenoid operated pilot valves, within the pilot manifold, control the flow of pilot oil to various functions. A saw pilot valve operates in this same manner. Joysticks and foot pedals also distribute oil to shift spools in their corresponding control valves.

PILOT SYSTEM COMPONENTS - PILOT MANIFOLD

822-D68

FAN FORWARD AND REVERSE PILOT VALVES

MAIN PUMP

PILOT FILTER

•• •

•• • •

•

ACCUMULATOR

• •

••

FAN CONTROL VALVE PILOT SUPPLY VALVE

PILOT GAUGE TEST PORT 822-D36

PILOT SYSTEM COMPONENTS 5.2

Tigercat 822 Feller Buncher

Pilot system ADJUSTING SCREW

CLOG INDICATOR

•

PRESSURE REDUCING/RELIEVING VALVE CARTRIDGE

822-D47

•

LOCKNUT

• •

PILOT FILTER - HIGH PRESSURE

HIGH PRESSURE FILTER This filter is placed ahead of the pilot supply valve to filter the pilot oil before it goes into the valve.

This filter incorporates a bypass indicator.

The bypass indicator consists of a clear plastic sight glass mounted on top of the filter housing.

Under normal operating conditions (or when the hydraulic system is shut down) the indicator will show GREEN. When a pressure differential of 72 psi. builds up inside the filter, the indicator will show RED indicating a clogged filter, .

221-14A

PILOT SUPPLY VALVE PILOT SUPPLY VALVE (pressure reducing/relieving valve) The pilot supply valve is a pressure reducing relief valve located below the clamps control valve.

This condition could happen during cold start-ups, but as the oil warms up the indicator will automatically re-set to GREEN. The indicator will not remain in the "clogged" (RED) position when the pilot system is not being used.

This reducing/relieving valve is fully adjustable from 125 psi. to a maximum of 1500 psi. Turning the adjusting screw IN, increases the pressure setting. The correct setting is 425 psi.

"Clogged" conditon will result in low pilot pressure. If a loss of controls or slow response occurs, filter element may need to be changed.

IMPORTANT Contaminated hydraulic fluid can lead to premature failure of hydraulic components and costly repairs. Filters must be replaced at the recommended time intervals, See SECTION 3 in THIS MANUAL. Only Tigercat replacement filters must be used.

Do not substitute with other cheaper inferior brands. Tests have shown that Tigercat filters can have twice the filtering capacity as that of other name brands.

5.3

Tigercat 822 Feller Buncher 'P2' PORT TO ACCUMULATOR

CLAMP CLOSE ACCUM. OPEN CLAMP OPEN ACCUM. CLOSED WRIST CCW WRIST CW TRACK LOW SWING BRAKE PILOT SHUT OFF VALVE 'P2' PORT TO JOYSTICKS, FOOT PEDALS AND SAW PILOT VALVE

••

• • • • •• •

'T' TANK PORT

Pilot system Pilot oil enters the manifold through the inlet port.

The pilot shut off valve controls the flow of oil to the two outlet pressure ports (P2) and to the eight solenoid operated pilot valves. This valve is activated by pressing the pilot reset switch in cab (with the front door closed and latched).

Two outlet pressure ports ('P2') on each end of the manifold, feed the saw pilot valve, both joysticks, both drive foot pedals, and the pilot accumulator. The front facing P2 port is plugged.

Eight solenoid operated pilot valves on the manifold, when energized, supply "on demand" pilot oil to the corresponding functions. These valves are activated by controls in the cab.

••

Two tank ports ('T') drain oil to the reservoir.

•

The pilot shut off valve is mounted in the pilot manifold directly beside the inlet port. All pilot oil must flow through this valve before reaching any other control valve.

PILOT SHUT OFF VALVE

• •

When this solenoid valve is energized (front door closed and latched and pilot reset switch momentarily pressed), pilot oil is supplied to the three outlet 'P2' ports (only two used on this machine) and the eight solenoid valves.

••

'IN' INLET PORT

•

'T' TANK CONNECTION 822-D68

With regard to the swing brake, the brake will be applied if the swing brake switch in the cab has been left in the ON position. The swing brake will be released when the switch is in the OFF position. The accumulator will also be charged when the pilot shut-off valve is energized.

PILOT MANIFOLD

PILOT MANIFOLD The pilot manifold is located in the valve compartment at the rear left corner of the upper frame. Pilot oil enters the manifold at the inlet port 'IN' and is then distributed to the various pilot functions of the machine.

When the pilot shut-off valve is de-energized by either opening the front door or momentarily pressing the pilot OFF switch, pilot oil is blocked to all pilot actuated functions on the joysticks and foot pedals as well as the saw. The swing brake is also applied at this time due to the lack of pilot pressure. The accumulator is drained at this time.

The manifold distributes oil to the following circuits through the ports listed below: • • • • • • • • • • • •

Joysticks (both) Drive pedals (both) Saw pilot valve Pilot Accumulator Clamp arm close Accumulating arm open Clamp arm open Accumulating arm close Wrist CCW Wrist CW LOW/DRIVE range Swing brake

(P2) pressure port (P2) pressure port (1) solenoid valve (2) solenoid valve (3) solenoid valve (4) solenoid valve (5) solenoid valve (6) solenoid valve (7) solenoid valve (8) solenoid valve

5.4

Tigercat 822 Feller Buncher

Pilot system The accumulator in the pilot system ensures that controls remain responsive by maintaining optimum pilot pressure. This also prevents the pilot pressure from dropping when several functions are activated at the same time.

The two accumulators in the cooling fan circuit are installed in each of the pilot lines carrying pilot oil to the pilot end caps of the cooling fan control valve. These are installed to cushion the severity of the control valve spool when shifting from forward to reverse. For additional information on this cooling fan circuit, refer to SECTION 10 in THIS MANUAL.

221-18A

ACCUMULATOR

ACCUMULATOR There are three accumulators used on this machine, one for the pilot system and two for the cooling fan system. They are bladder type and are VALVE GUARD

••• • •

VALVE CAP

•

GAS VALVE

BODY

BLADDER

• HYDRAULIC CONNECTION

••

• POPPET (Seats against oil port after oil evacuation)

ACCU-1 ACCUMULATOR (BLADDER TYPE) installed pre-charged with a nitrogen. The pilot system accumulator is pre-charged to 325 psi and the cooling fan accumulators are pre-charged to 80 psi. The gas pressures in the pilot accumulator should be checked if the pilot system exhibits repeated and frequent charging cycles. Refer to CHECKING PRE-CHARGE PRESSURE in THIS SECTION.

5.5

Tigercat 822 Feller Buncher

Pilot system

JOYSTICKS AND FOOT PEDALS

OPERATING DESCRIPTION

These pilot valves are manually operated, directional control valves and operate on the same principle as a direct operating pressure reducing valve. Both the joystick and foot control

In the neutral position the joystick lever is held centered by return springs (4). When the lever (1) is operated, the plunger (5) is pushed against its 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 ports 1, 2, 3 or 4 in the base of the valve, to the boom valve pilot end caps.

Pilot pressure is directly proportional to the operator position of the joystick or foot pedal and the regulating spring characteristics.

PILOT SYSTEM ELECTRICAL CIRCUIT Refer to circuit diagram; With the engine running, the pilot shut off valve solenoid is not energized until the front door is closed and latched and the pilot reset switch is momentarily pressed.

RR-12

When this switch is pressed, the coil on the function lock-out relay is energized closing the circuit between wires RED 6A and TAN 105B. Wire TAN 105B connects to the front door switch. When this switch is closed (door closed) current flows through wires TAN 107 and GRN 11 to energize the coil on the pilot shut off valve to shift the valve spool and supply oil to the pilot circuit via the pilot manifold. The green pilot on light will also be turned ON. At the same time current flows through wire GRN 11A back to the function lock-out relay coil and latches the function lock out relay in the energized position after the pilot reset switch has been released.

JOYSTICK PILOT VALVE

valves (pedals) use similar spool arrangements.

Operated by hand or foot these valves direct pilot oil to the main control valve pilot end caps. The corresponding spool valve then shifts from its centre position and directs pump flow to operate a function.

•

'P' PORT

AU013-2

5

•

1

•

• •

4 3

• •

•

2

•

Whenever the front door is opened the door limit switch opens interrupting the voltage to the function lockout relay coil, this opens the contacts of the function lockout relay and de-energizes the pilot shut off valve and shuts down the pilot system. This prevents pilot oil from reaching the controls. The amber pilot off light will be turned ON. A second pilot shut off switch is in the same circuit as the front door switch. If an emergency situation should arise, pressing the pilot shut-off switch (Red button) located in the cab will have the same effect as opening the front door.

WORK PORTS 1, 2, 3 OR 4

SPOOL ARRANGEMENT

5.6

Tigercat 822 Feller Buncher

822-25

Pilot system

PILOT SYSTEM CIRCUIT DIAGRAM 5.7

Tigercat 822 Feller Buncher PILOT SYSTEM CIRCUIT DESCRIPTION

Pilot system Two pilot functions are supplied with pilot oil through lines "teed" into the the pilot line leading to the 'IN' port of the pilot manifold: One of these lines distributes pilot oil to the load sense controller on the main pump. The load sense controller is used in conjunction with the anti stall system to de-stroke the main pump when necessary to prevent the engine from stalling.

Oil from the main pump 'P' port manifold flows through the high pressure filter to the pilot supply valve. This pressure reducing/relieving valve controls and provides pilot oil at 425psi. to the 'IN' port of the pilot manifold, the two cooling fan pilot valves and the 'P1' port on the anti-stall valve mounted on the main pump.

The second teed line supplies pilot oil to the cooling fan pilot valves. Holding the fan switch in the PURGE (CLEEN) position energizes these two pilot valves and directs pilot oil the fan control valve pilot end caps to change direction of rotation of the fan. Releasing the fan switch places the fan back in the forward position.

The pilot manifold is a distribution center, directing pilot oil to all of the pilot operated functions on the machine. This distribution is achieved via three outlet pressure ports (only two used on the 822 machines) and eight solenoid operated control valves. A pilot shut-off valve installed in the manifold controls the flow of pilot oil into the manifold.

When this pilot shut-off valve is energized, pilot oil is made available to the three outlet pressure ports and the eight solenoid valves. When the pilot shutoff valve is de-energized, pilot oil from the pilot supply valve is blocked, preventing pilot oil from entering the manifold, thereby rendering all pilot functions inactive. Refer to PILOT SYSTEM RESET in SECTION 2 of the OPERATOR’S MANUAL. One of the outlet pressure ports distributes pilot oil to the ‘P’ ports of both joysticks, both foot pedals and the saw solenoid pilot valve.

Movement of the joystick levers or the foot pedals will direct pilot oil to the pilot end caps of the main control valve to operate the various machine functions such as lifting the boom or driving the machine. Placing the saw switch located in the cab to the ON position will energize the saw pilot valve and divert pilot oil to shift the spool in the saw control valve and run the saw.

The second outlet pressure port is connected to the pilot accumulator which is in place to maintain a constant pressure source (425 psi), ensuring that the controls remain responsive during heavy duty cycles.

The eight solenoid valves in the manifold, when energized by switches in the cab, will distribute pilot oil to; • set the drive motors in either low or drive mode • release the swing brake • shift spools in the clamps control valve which will operate the accumulating arm and clamp arm cylinders.

• shift spools in the main Linde control valve which will operate the wrist cylinders.

5.8

A gauge test port is also teed into this line for use when setting the pilot system pressure.

Tigercat 822 Feller Buncher

Pilot system

SET PILOT PRESSURE

when adjusting screw is being turned. If pilot pressure does not change during this procedure, check the main pump stand-by pressure setting.

1. With hydraulic oil at operating temperature, connect a 0-1000 psi. gauge to the gauge test fitting located beside the pilot supply valve.

7. WITH SWING BRAKE ON, use left joystick to swing upper frame to raise system pressure.

Turn adjusting screw on pilot supply valve until gauge at pilot manifold reads 425 psi.

•

ACCUMULATOR

•

8. Stop engine, and remove pressure gauge.

•• PILOT SUPPLY VALVE GAUGE TEST PORT, 0-1000 PRESSURE GAUGE 822-D36

GAUGE TEST PORT

NOTE: The stand-by pressure of the main pump can vary from 400 psi. to 600 psi. The anti-stall can cause the stand-by pressure to drop to 200 psi. when the engine is running below 2200 rpm. Because the main pump is the original source of the pilot supply (via the main valve manifold), this will in turn affect the pilot supply.

2. Turn anti-stall switch OFF. 3. Loosen locknut and turn adjusting screw all the way OUT on pilot supply valve, tighten locknut on adjusting screw.

ADJUSTING SCREW LOCKNUT

PILOT REDUCING/ RELIEVING VALVE CARTRIDGE

221-14A

• •• ••

PILOT SUPPLY VALVE

4. Start engine and set throttle in IDLE position.

5. Close and latch the front door and have an assistant in the cab momentarily press the pilot reset switch.

6. Loosen locknut on pilot supply valve and turn adjusting screw until pressure gauge at pilot manifold reads 250 psi.

NOTE: Ensure that pilot pressure changes 5.9

Tigercat 822 Feller Buncher

Pilot system

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

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.

Pilot accumulator pre-charge - 325 psi Fan circuit accumulator pre-charge - 80 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

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.

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 ACCUMULATOR above for correct pressure.

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.

Tigercat 822 Feller Buncher

SECTION 6 - ELECTRICAL, GAUGES AND ALARMS MARCH 2003

CONTENTS - SECTION 6 ELECTRICAL INSTALLATION - CAB .............................................................. 6.7 ELECTRICAL SCHEMATIC DIAGRAM ................................... 6.2, 6.3, 6.4, 6.5 GAUGES AND ALARMS ................................................................................ 6.8 CHART ........................................................................................................ 6.8 REAR ELECTRICAL PANEL ........................................................................... 6.6 SOLENOID DRIVERS ..................................................................................... 6.8 SWITCH AND SENSOR LOCATIONS ............................................................ 6.9 WIRE COLOUR CODE CHART ....................................................................... 6.6

Tigercat 822 Feller Buncher

822-26 (16878B R0)

Electrical, gauges and alarms

MACHINE ELECTRICAL SCHEMATIC DIAGRAM PAGE 1 OF 4 6.2

Tigercat 822 Feller Buncher

830-23 (16878B R0)

Electrical, gauges and alarms

MACHINE ELECTRICAL SCHEMATIC DIAGRAM PAGE 2 OF 4 6.3

Tigercat 822 Feller Buncher

830-24 (16878B R0)

Electrical, gauges and alarms

MACHINE ELECTRICAL SCHEMATIC DIAGRAM PAGE 3 OF 4 6.4

Tigercat 822 Feller Buncher

822-23 (16878B R0)

Electrical, gauges and alarms

MACHINE ELECTRICAL SCHEMATIC DIAGRAM PAGE 4 OF 4 6.5

Tigercat 822 Feller Buncher

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 ........................................ (protected and unprotected) 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) ENGINE ANTI-STALL DISCONNECT PLUG (REFER TO SECTION 9)

•

•

• SYSTEM CIRCUIT BREAKERS

••

ENGINE ANTI-STALL MODULE (REFER TO SECTION 9)

••

TERMINAL RAIL 'C' TERMINAL BLOCK 6 GAUGE TERMINAL BLOCK 22 - 8 GAUGE

•• ••• • •

SOLENOID DRIVERS (QUANTITY 7)

TERMINAL BLOCK 26 - 12 GAUGE

• •• •

•• •• PANEL ALARM AND SOCKET

••

TO TERMINAL RAILS 'A' AND 'B'

830-31

REAR ELECTRICAL PANEL 6.6

RELAY PANEL

Tigercat 822 Feller Buncher

Electrical, gauges and alarms REAR PANEL

ENGINE ANTI-STALL MODULE

ENGINE ANTI-STALL DISCONNECT PLUG

TERMINAL RAIL 'C'

SYSTEM CIRCUIT BREAKERS

FIRE SUPPRESSION CONTROL PANEL

RELAY PANEL

••

CONTROL PANEL

••

PILOT SHUT-OFF LIMIT SWITCH ON FRONT DOOR

ANTENNA

• ••

INSTRUMENT PANEL

•

• •

• •

STEREO RADIO

•

CB RADIO

••

•• ••

•• • TERMINAL RAIL 'A'

•

••

SAFETY ALERT HORN TERMINAL RAIL 'B' CIRCUIT BREAKER PANEL •LIGHTS •POWER DOOR •COLD START

830-30

ELECTRICAL INSTALLATION - CAB 6.7

Tigercat 822 Feller Buncher GAUGES AND ALARMS

Electrical, gauges and alarms

The 822 is monitored for proper operation by sensors (senders or switches) located in the hydraulic system and on the engine. These sensors are connected to either gauges, warning lights and alarms. A horn will also sound when the machine is travelling in reverse or when the engine enclosure power operated side door and roof are being operated.

SENSOR FUNCTION

GAUGE RANGE

LIGHT

A safety alert horn located in the engine compartment is activated by a switch on the control panel in the cab. Use this any time it becomes necessary to warn personnel in the area of your presence or when the engine is about to be started.

For a more complete description of the gauges and warning lights listed below, refer to SECTION 2 in the OPERATOR'S MANUAL. HORN

TRIGGER OR RANGE INFO

Engine coolant level ..................... None ............ ON ....... SOUNDS ............ Low coolant level, STOP ENGINE. Engine coolant temp. ............. 100°F - 280°F .... None ...... SOUNDS ..... Operating range 190°F-205°F (87°C-96°C) (38°C) - (138°C) ...................... @ 215°F (102°C)

Engine oil pressure .................. 0 - 100 psi ....... None .......... None ................ Engine shuts down below 15 psi Engine hours .............................. 0-9999 ......... None .......... None ............................. Engine running Hydraulic oil temp. .................. 100°F - 240°F ..... ON ....... SOUNDS .......... Stop machine above operating range (38°C) - (116°C) ....................... @ 205°F (96°C)

See HYDRAULIC OIL OPERATING RANGE CHART in SECTION 3 of THIS MANUAL

Volts .......................................... 8v - 18v ......... None .......... None ............. Normal operating range 12-13.5 volts Fuel level .................................... 'E' - 'F' .......... None .......... None ................... Capacity (US gal/L): 100/378 Hydraulic oil - low ......................... None ............ ON ........... None ....................... 10 Gal. (38L) below Full Hydraulic oil -Very low .................. None ............ ON ....... SOUNDS .................... 18 Gal. (68L) below Full Hydraulic oil filter bypass .............. None ............ ON ........... None ........... Return filter restriction, 15 psi or greater Back-up alarm ...............................N/A ............. N/A ....... SOUNDS ........... One or both drive pedals in reverse Horn, safety alert ............................ N/A ............. N/A ....... SOUNDS ..... Push button on L.H. joystick or control panel

SOLENOID DRIVERS

SOLENOID DRIVERS FOR LH. JOYSTICK SWITCHES

Installed in the WRIST and CLAMPS electrical circuits between the joystick switches and the solenoid valves are six solenoid drivers one per switch. They are mounted on TERMINAL RAIL 'C' located on the rear electrical panel.

• • •• •• • •

These solenoid drivers are in place to protect the joystick switch contacts from the current surge created when energizing the solenoid valves.

The joystick switches are connected to the IN side of the solenoid driver and the OUT side of the driver is connected to the solenoid valves, there is no "hard wire" connection between the IN and OUT connections of the solenoid driver.

SOLENOID DRIVERS FOR RH. JOYSTICK SWITCHES TERMINAL BLOCK 26 - 12 GAUGE

••

TERMINAL BLOCK 6 GAUGE

The signal is instead "induced" to the valve solenoid by the driver when the joystick switch is pressed, thus protecting the switch contacts from the relatively higher current flow had this device not been in place.

• 830-32A

SOLENOID DRIVERS ON TERMINAL RAIL 'C' 6.8

Tigercat 822 Feller Buncher ENGINE COOLANT TEMPERATURE SWITCH (LIGHT AND HORN) ENGINE COOLANT TEMPERATURE SENDER (GAUGE)

BOOST CONNECTION

Electrical, gauges and alarms

ENGINE OIL PRESSURE SWITCH (ENGINE SHUT-DOWN)

POWER DOOR PUMP/ MOTOR

BATTERY DISCONNECT SWITCH

ENGINE OIL PRESSURE SENDER (GAUGE)

ENGINE START SOLENOID RELAY DOOR PUMP RELAY

BATTERIES

ALTERNATOR

••

•

••

•• •

•• •

FUEL SOLENOID MODULE

FAN PILOT VALVES (SOLENOID OPERATED )

• •• • •

ENGINE COOLANT LEVEL SWITCH (LIGHT AND HORN)

• •

•• • • ••

••

• THROTTLE ACTUATOR A/C COMPRESSOR

ENGINE FUEL MODULE CONNECTOR

HYDRAULIC OIL HYDRAULIC OIL TEMPERATURE FILTER BYPASS SWITCH (HORN) SWITCH (LIGHT)

ENGINE SPEED SENSOR (REFER TO SECTION 9)

BACK-UP ALARM HORN (DRIVE PEDAL ACTIVATED) TO BOOM LIGHTS

TO REAR PANEL IN CAB TO REAR PANEL IN CAB

•

•

• HYDRAULIC OIL TEMPERATURE SENDER (GAUGE)

HYDRAULIC OIL TANK

HYDRAULIC OIL LEVEL SIGHT GAUGE AND TEMP. GAUGE LEVEL SWITCH ( LOW ALARM)

OPERATOR'S CAB

••

HYDRAULIC OIL LEVEL SIGHT GAUGE AND LEVEL SWITCH (EXTREME LOW ALARM)

• •

•• •• FUEL TANK

• TO CONNECTOR BLOCK IN CAB

•

BACK-UP ALARM SWITCHES (ALARM HORN)

FUEL LEVEL SENDER (GAUGE)

HORN (SWITCH ON CONTROL PANEL)

822-24

SWITCH AND SENSOR LOCATIONS 6.9

Tigercat 822 Feller Buncher

Electrical, gauges and alarms

6.10

Tigercat 822 Feller Buncher

SECTION 7 - ENGINE START AND STOP MARCH 2003

CONTENTS - SECTION 7 CIRCUIT DESCRIPTION ............................................................................... 7.2 ENGINE START CIRCUIT ............................................................................. 7.2 SCHEMATIC DIAGRAM START CIRCUIT - AT REST ...................................................................... 7.4 START CIRCUIT - BATTERY DISCONNECT SWITCH 'ON' ..................... 7.5 START CIRCUIT - RUN ............................................................................. 7.7 START CIRCUIT - RUN, PILOT RESET SWITCH 'OFF' ............................ 7.9 START CIRCUIT - RUN, PILOT RESET SWITCH 'ON' ............................. 7.8 START CIRCUIT - START ......................................................................... 7.6

Tigercat 822 Feller Buncher

Engine start and stop

ENGINE START CIRCUIT

RED wire (6A) carries the current from the 15 amp. circuit breaker across the function lockout relay, through TAN wires (9A), (9), across the start relay, through TAN wire (16) to energize the coil of the

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

The engine normally installed on these Tigercat 822 machines is a Sisu 645 DSBIE (253 HP).

For engine starting and stopping procedures refer to STARTING ENGINE and STOPPING ENGINE in SECTION 2 of the OPERATOR’S MANUAL. For correct engine speeds, refer to THROTTLE CONTROL in SECTION 2 of the OPERATOR'S MANUAL.

FUEL SOLENOID RELAY AND TIMER MODULE

• START SOLENOID RELAY

DOOR PUMP RELAY

To start engine; Turn battery disconnect switch to the ON position. Turn ignition key to the START position and releasing it to the RUN position after the engine starts.

••

•

CIRCUIT DESCRIPTION With the battery disconnect switch ON, current is supplied to both the start solenoid relay contact and the start solenoid contact. Current is also supplied to the fuel solenoid relay and timer module through wire 106 C. This module energizes the PULL fuel solenoid on the engine for a 1/2 second and then energizes the HOLD fuel solenoid in readiness to start the engine. Current is also supplied to the BATTERY (BAT) contact of the key switch (ignition switch), the power door circuit, cold start switch and some of the cab circuits.

870B12

••

COLD START SOLENOID VALVE

When the key switch is turned to the START (ST) position, the BATTERY (BAT) contact is connected to the START (ST) and RUN contacts of the key switch.

FUEL CONTROL VALVE, 'PULL' AND 'HOLD' SOLENOIDS

•

START RELAY

••

420-04

START AND FUEL SOLENOID RELAYS

323-24

ENGINE FUEL CONTROL

RELAY PANEL

Current (voltage) then flows from the (ST) contact through RED wire (23A), a 5 amp. circuit breaker, RED wire (23B) to energize the coil of the start relay.

Current also flows from the RUN contact through RED wire (2), a 15 amp circuit breaker.

••

RED wire (6B) carries the current to the coil of the alternator excite relay to energize the excite circuit, if

THROTTLE ACTUATOR

the alternator in use has an excite terminal. RED wire (6D) carries the current to the throttle switch.

389-17

7.2

ENGINE FUEL CONTROL

Tigercat 822 Feller Buncher

Engine start and stop

start solenoid relay and the coil on the pilot dump valve. The pilot dump valve will open the hydraulic pilot system to tank during start-up. Current also flows through TAN wire (9) to turn ON the pilot OFF warning light.

To energize the pilot system, momentarily PRESS the pilot reset switch, this will energize the pilot function lockout relay, close the contacts and allow current to flow through wires RED (6A), (6C), TAN (105), (107) and GRN (11) to energize the pilot shut off solenoid valve and turn ON the pilot on warning light.

Energizing the start solenoid relay coil allows current to flow from the battery along RED wire (100) and TAN wire 12 to energize the start solenoid coil on the start motor to close the contacts and operate the start motor to start the engine.

When the pilot reset switch is released current will continue to flow through wire TAN (105B) to latch the pilot function lockout relay in the energized position and allow current to continue to flow to the pilot system.

When the key switch is turned to the RUN position, the (BAT) contact remains connected to the RUN contact allowing current to continue to flow through RED wires (6A) (6B) and (6D) to the post of the function lockout relay, the excite relay coil and the throttle switch.

Pressing the pilot off switch (Red button) located on the cab control panel will de-energize the pilot shut-off valve cartridge and render all pilot functions inoperative. The swing motor brake will also be applied. The pilot on warning light will turn OFF and the pilot off warning light will turn ON.

When engine oil pressure exceeds 15 psi., the contacts of the engine oil pressure switch close and allow current to flow through RED wire (2), across a 5 amp circuit breaker and energize the coil of the engine auto shut down relay and prime the engine shut down system. When this system is activated, either by LOW engine oil pressure opening the engine oil pressure switch or by the fire suppression system sensors, current is removed from TAN wire 106C and the fuel solenoid module. This deactivates the HOLD coil of the fuel solenoid and stops the engine.

For additional information on the PILOT SYSTEM refer to SECTION 5 in THIS SERVICE MANUAL.

In order to operate the machine functions after starting the engine, the front door must be closed and latched to close the contacts of the pilot system limit switch.

7.3

Tigercat 822 Feller Buncher

Engine start and stop

822-27

START CIRCUIT - AT REST 7.4

Tigercat 822 Feller Buncher

Engine start and stop

822-28

START CIRCUIT - AT REST BATTERY DISCONNECT SWITCH - ON

7.5

Tigercat 822 Feller Buncher

Engine start and stop

822-29

START CIRCUIT - START IGNITION KEY - START POSITION

7.6

Tigercat 822 Feller Buncher

Engine start and stop

822-30

START CIRCUIT - RUN IGNITION KEY - RUN POSITION

7.7

Tigercat 822 Feller Buncher

Engine start and stop

822-31

START CIRCUIT - RUN IGNITION KEY - RUN POSITION PILOT RESET SWITCH - HELD ON FRONT DOOR CLOSED/DOOR SWITCH - ON

7.8

Tigercat 822 Feller Buncher

Engine start and stop

822-32

START CIRCUIT - RUN IGNITION KEY - RUN POSITION PILOT RESET SWITCH - RELEASED FRONT DOOR CLOSED/DOOR SWITCH - ON

7.9

Tigercat 822 Feller Buncher

Engine start and stop

7.10

Tigercat 822 Feller Buncher

SECTION 9 - ENGINE ANTI-STALL MARCH 2003

CONTENTS - SECTION 9 CONTROL MODULE IN CAB ........................................................... 9.2 CONTROL MODULE PIN CONNECTIONS ...................................... 9.4 ENGINE ANTI-STALL CURVE.......................................................... 9.4 FAULT FINDING PROCEDURE ~ ANTI-STALL QUICK CHECK ..... 9.5 FAULT FINDING PROCEDURES, ADDITIONAL ............................. 9.6 HORSEPOWER LIMITING CONTROL GENERAL DESCRIPTION ............................................................ 9.2 LOAD SENSE; SET MARGIN PRESSURE ................ SEE SECTION 4 MAIN PUMP CONTROLLER (LS CONTROL) .................................. 9.2 SCHEMATIC DIAGRAMS ENGINE ANTI-STALL CIRCUIT .................................................... 9.5 LOAD SENSING SYSTEM CIRCUIT DIAGRAM ........................... 9.3 SET PILOT PRESSURE ............................................. SEE SECTION 5 SPEED SENSOR, ADJUSTING ........................................................ 9.4 SPEED SENSOR ON ENGINE ......................................................... 9.2 VERIFY ANTI-STALL SETTING ................................. SEE SECTION 4

SEE ALSO SECTION 4

Tigercat 822 Feller Buncher

Engine anti-stall

HORSEPOWER LIMITING CONTROL

ENGINE ANTI-STALL SOLENOID VALVE

• •

HORSEPOWER CALIBRATION DO NOT ADJUST

PILOT SUPPLY 'P1'PORT WITH OIL FILTER

GENERAL DESCRIPTION GAUGE TEST PORT 'X1' ANTI-STALL SIGNAL PRESSURE

In the past it was common to lug an engine down when several functions with high loads were used at the same time and engine stalling was avoided only by the operator. In order to prevent engine over loading, the Tigercat machine is equipped with an electronic system which detects any drop in engine speed and de-strokes the main pump to reduce the load on the engine and at the same time maintain engine speed. This is done without any input from the operator and in most cases he will be unaware of the operation of this system.

GAUGE TEST PORT 'L.S.'

•• ••

A Linde system is used and incorporates the following components: •

A control module on the rear electrical panel.

•

A speed sensor mounted on the back of the engine above the flywheel.

•

A solenoid valve mounted on the main pump.

•

A wiring harness. A disconnect plug is incorporated into the harness. Remove the plug to completely disconnect the control module from the power supply and all sensor connections. This must be done when welding

CONTROL MODULE

•

WIRING HARNESS WITH 25 PIN CONNECTOR

MODULE DISCONNECT PLUG

••

••

••

••

TANK PORT

SOLENOID VALVE LOAD SENSE PRESS. PORT

MARGIN PRESSURE ADJUSTING SCREW

MAIN PUMP CONTROLLER 822-D65 (LS CONTROL) anywhere on the machine to protect the module.

MAIN MAIN PUMP PUMP

A two position anti-stall switch labelled ON/OFF, is located on the control panel and used to turn the anti-stall system ON or OFF. When this switch in is the ON position and the engine is set to FULL throttle, the engine RPM, when under load, is limited to 1950 RPM, to compensate the engine anti-stall valve will signal the main pump to destroke and reduce the flow of oil to the main valve.

During normal operating conditions the engine should be running at FULL throttle and the antistall switch in the ON position.

•

The control module in the cab receives and distributes signals through a 25 pin connector which is attached to the wiring harness.

CONTROL MODULE IN CAB

SPEED SENSOR

••

105-2

••

••

The engine anti-stall system can be turned OFF when required for maintenance work. The engine may then be used at less than full throttle.

• 830-D29

••

••

SPEED SENSOR ON ENGINE 9.2

Tigercat 822 Feller Buncher

822-16

Engine anti-stall

LOAD SENSING SYSTEM CIRCUIT DIAGRAM 9.3

Tigercat 822 Feller Buncher CONTROL MODULE PIN CONNECTIONS

Engine anti-stall ADJUSTING SPEED SENSOR

Refer to Engine anti-stall circuit diagram;

1. Stop engine.

•

Pin 1 is connected to "power" through a 2 amp fuse.

2. Loosen locknut on speed sensor.

•

Pin 13 is connected to ground.

•

Pins 5, 6, 7, and 17 jump wire connected to each other.

•

Pins 12 and 14 are connected to the speed sensor mounted on the flywheel housing.

•

Pin 16 is connected to the solenoid on the anti-stall valve.

•

Pin 11 is connected to the pole terminal '5B' on the anti-stall switch. When this switch is ON pin 11 will be connected to the anti-stall valve solenoid through the switch.

3. Screw speed sensor IN until it touches fly wheel.

4. Turn speed sensor OUT one full turn.

5. Tighten locknut.

NOTE : Before welding anywhere on the machine the 25 pin connector should be disconnected from the control module.

The system control module constantly monitors the engine speed and any drop in RPM from the rated 1950 RPM will result in a signal being sent to the main pump solenoid via wires 91, 92 and 82 from pins 11 and 16. This signal will cause the solenoid valve to shift which directs pressure from the pilot system to shift the displacement control valve causing the pump to destroke, "lightening" the load on the engine without affecting engine speed. This electrical signal is a pulse width modulated signal which provides for precise modulation of the hydraulic valve and the resulting smooth control of the main pump displacement.

X1-XLS

RPM 2260 2212 2198 2182 2168 2155 2152 2133 2112 2098 2064 2062 2041 2018 2014 1961 1785

X1* (psi) 0 6 7 40 78 115 120 175 240 275 310 310 310 310 315 315 315

Machine 845-0101 350

300

This Reading ± 50 psi

250

"X1" (psi)

* This value may vary by as much as ± 20psi from one machine to another.

Do not try to adjust pressure.

This table is for reference purposes only.

200

Horsepower Limiting Controller

150

100

50

These readings 0-15 psi

0 1700

1800

1900 RPM

2000

2100

2200

2300

2400

PRESSURE INCREASES FROM 0 - 310 PSI (APPROX.) WITHIN A RANGE OF APPROX. 100 RPM.

ENGINE ANTI-STALL CURVE ~ ENGINE RPM VS. PSI 9.4

Tigercat 822 Feller Buncher FAULT FINDING ~ ANTI-STALL QUICK CHECK

Engine anti-stall 2. Start engine and place throttle switch in FULL position.

The following is a quick procedure to determine if the anti-stall is functioning properly. If the machine fails any of these tests, then a more detailed diagnosis is necessary. However, there can still be other problems that are not related to the anti-stall system which are being masked.

3. Place anti-stall switch in the OFF position.

4. Activate each "Load Sense" controlled function one at a time (swing, main boom, stick boom, tilt, wrist and track drive).

IMPORTANT: Always ensure that the hydraulic oil is at operating temperature when performing all of the following diagnosis.

A. WHEN DOES THE PROBLEM OCCUR ?

•

X1 pressure should be less than 20 psi.

C. ANTI-STALL 'ON', THROTTLE IDLE 1. Connect a 0-1000 psi gauge to the ‘X1’ gauge test port on the main pump regulator.

Does problem occur with anti-stall ON or OFF? ANSWERS: • Occurs with the system ON or OFF The problem is likely hydraulic related which could include the anti-stall solenoid valve on the main pump.

•

•

Expected Results: All functions should operate normally.

2. Start engine and place throttle switch in IDLE position.

3. Place anti-stall switch in the ON position.

4. Fully activate MAIN BOOM UP function.

Occurs only with the system ON. •

The problem is either related to the hydraulic system, the engine, or the anti-stall system.

•

B. ANTI-STALL 'OFF' 1. Connect a 0-1000 psi gauge to the ‘X1’ gauge test port on the main pump regulator.

822-21

Expected Results: MAIN BOOM UP function should be inactive (boom will not lift) X1 pressure should be greater than 320 psi.

ENGINE ANTI-STALL CIRCUIT 9.5

Tigercat 822 Feller Buncher D. ANTI-STALL ON, THROTTLE FULL 1. Connect a 0-1000 psi gauge to the ‘X1’ gauge test port on the main pump regulator.

2. Start engine and place throttle switch in FULL position.

3. Place anti-stall switch in the ON position.

4. Fully activate MAIN BOOM UP function.

•

Expected Results: Boom up function should operate normally.

•

X1 pressure should be less than 20 psi.

Engine anti-stall ADDITIONAL FAULT FINDING PROCEDURES The following procedures can be used to rule out problem associated with the engine anti-stall system. They are not in any particular order and should be done if additional diagnoses is required.

A. VERIFY ENGINE 'FULL' THROTTLE SETTING 1. Place reflector on engine crank shaft pulley for use with a phototach.

2. Start engine and place throttle switch in FULL position.

E. BEGIN OF MOVEMENT 1. Start engine and place throttle switch in IDLE position.

3. Measure engine no load FULL throttle speed with a phototach.

2. Place anti-stall switch in the ON position.

The engine speed should be verified with a phototach and the measured speed should be compared to the tach. on the instrument panel.

3. Fully activate MAIN BOOM UP function.

(Initially, the boom should not move)

B. VERIFY ENGINE POWER NOTE: Before performing this procedure make sure that all relevant PRESSURES and SPEEDS have been set correctly.

4. Increase the throttle until the boom begins to lift.

5. Measure the engine speed when the boom starts to lift. The transition state of the anti-stall system from fully active to completely inactive is very narrow. It is necessary to approach this point very slowly.

•

Example:

Expected Results: The boom should not move initially.

•

As the engine speed approaches FULL, the boom should begin to move.

•

The point where the boom begins to move should be approximately 1900 RPM.

•

SWING SPEED AND SWING PRESSURE SETTINGS.

•

MAIN SYSTEM (L.S.) PRESSURE SETTINGS.

•

CLAMP VALVE MAIN RELIEF.

Refer to the 822 PRESSURE SETTINGS CHART in SECTION 4 of THIS SERVICE MANUAL for correct values.

1. Perform procedure 'A' above to verify tachometer on instrument panel is accurate.

2. Start engine and place throttle switch in FULL position.

3. Place anti-stall switch in the OFF position.

4. Place swing brake switch in the ON position.

5. Activate the SWING function fully.

• Measure the engine speed.

6. Activate the SWING function fully.

Bottom the TILT cylinder.

• Measure the engine speed.

9.6

Tigercat 822 Feller Buncher

Engine anti-stall H. SPEED SENSOR OUTPUT

7. Activate the SWING function fully.

1. Remove 25 pin connector from anti-stall control module.

Hold a CLAMP function over relief.

• Measure the engine speed.

2. Start engine and place throttle switch in FULL position.

8. Activate the SWING function fully.

Bottom the TILT cylinder.

3. Measure the AC voltage across 13 and 14 on connector.

• The speed sensor output should be greater than 5VAC.

Hold a CLAMP function over relief.

• Measure the engine speed.

• The engine speed should always be above "rated speed" of 2000 RPM. If engine speed falls below rated speed during the above tests, the problem is not likely to be with the engine anti-stall system.

The speed sensor on the engine should be a fixed distance from the flywheel. Do not use the voltage to adjust this distance.

Refer to ADJUST SPEED SENSOR in THIS SECTION.

C. PILOT PRESSURE.

I.

1. Ensure pilot pressure is correct.

1. Remove 25 pin connector from anti-stall control module.

To verify PILOT PRESSURE refer to PILOT SYSTEM in SECTION 5 of THIS MANUAL.

2. Measure resistance between pins 13 and 14 on connector • The resistance should be: 960 ±150ohms

D. MARGIN PRESSURE 1. Ensure margin pressure is correct.

3. Check for shorts from pin 14 to chassis.

(Pin 13 is connected to ground)

To verify MARGIN PRESSURE refer to SET MARGIN PRESSURE in SECTION 4 of THIS MANUAL.

J. SPEED SENSOR COIL

E. ELECTRICAL POWER TO ANTI-STALL CONTROL MODULE.

1. Remove 25 pin connector from anti-stall control module.

1. Remove 25 pin connector from anti-stall control module.

2. Measure resistance of speed sensor coil between pins 13 and 14 on connector • The resistance should be: 960 ±150ohms

2. Start engine and place throttle switch in IDLE position.

3. Measure DC voltage across pins 1 and 13 on connector.

• Voltage should be 13 ± 2 VDC. F.

SPEED SENSOR WIRES

SOLENOID VALVE WIRES. 1. Remove 25 pin connector from anti-stall control module.

2. Measure resistance between pins 11 and 16 on connector.

• The resistance should be 6.6 ±2 ohms 3. Check for wiring and harnesses short circuiting to chassis.

G. SOLENOID VALVE COIL 1. Remove DIN connector from anti-stall solenoid valve.

2. Measure resistance of solenoid coil.

• The resistance should be 6.6 ±2 ohms.

9.7

Tigercat 822 Feller Buncher

Engine anti-stall

9.8

Tigercat 822 Feller Buncher SECTION 10- OIL COOLER AND COOLING FAN JUNE 2003

CONTENTS - SECTION 10 CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR COOLING ASSEMBLY - OVERALL VIEW ............................................... 10.2 COOLING FAN ............................................................................................ 10.6 COOLING FAN CIRCUIT DESCRIPTION ................................................. 10.10 COOLING FAN CIRCUIT DIAGRAM ......................................................... 10.11 FAN DRIVE MOTOR INSTALLATION ......................................................... 10.7 FAN MOTOR ................................................................................................ 10.7 FAN PUMP (CLAMPS/FAN PUMP) ............................................................. 10.6 FAN SPEED ADJUSTMENT ...................................................................... 10.12 HYDRAULIC TANK ...................................................................................... 10.3 MAIN CONTROL VALVE ........................................................ SEE SECTION 4 MAIN PUMP ............................................................................ SEE SECTION 4 OIL COOLER ............................................................................................... 10.2 OIL COOLER BYPASS/ RETURN MANIFOLD............................................ 10.2 OIL COOLER CIRCUIT DESCRIPTION ...................................................... 10.4 OIL COOLER CIRCUIT DIAGRAM .............................................................. 10.5 RETURN MANIFOLD/ RETURN FILTERS .................................................. 10.2

Tigercat 822 Feller Buncher

Oil Cooler and Cooling Fan

OIL COOLER The hydraulic oil cooler is mounted to the rear of the engine radiator. The A/C condenser core is mounted to the rear of the oil cooler. A debris screen is used to protect the cooling assembly.

The hydraulically driven fan draws air through the screen, the A/C condenser, the oil cooler and engine radiator and finally blows the air across the engine. The air is expelled to atmosphere through the perforated panels that make up the engine enclosure.

••

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

DEBRIS SCREEN

422-04

The fan drive system has a CLEAN(PURGE) function which reverses the direction of the fan to clean the cooling assembly by blowing air in the opposite direction through the cooling assembly to remove dust and debris. In addition, the A/C condenser core, the oil cooler and the engine radiator assembly should be checked every 8 hours (every shift) for accumulation of twigs, leaves, pine needles and dust. All of the engine enclosure doors should also be kept clean. Use personal protective equipment to guard against flying debris. Compressed air or water may be used to clean this assembly, but care must be taken not to set the pressure too high otherwise damage to the components could result.

SLIDE DEBRIS SCREEN OUT AND REMOVE

OIL COOLER

RADIATOR

A/C CONDENSER

• •• ••

410-24

HINGED A/C CONDENSER & OIL COOLER

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

5 - HYDRAULIC RETURN FILTERS

RETURN MANIFOLD

•

OIL COOLER BYPASS/ RETURN MANIFOLD The oil cooler bypass return manifold collects oil from the main control valve, saw return and ER boom counterbalance valve (if equipped). The oil cooler bypass return manifold incorporates an oil cooler bypass valve. All oil passing through the oil cooler first passes through the cooler bypass valve. The cooler bypass valve ensures that the differential pressure between the oil cooler inlet and outlet does not exceed set limits. When differential pressure becomes too high oil is returned to tank bypassing the oil cooler, preventing damage to the oil cooler. Pressure increases within the oil cooler can occur in cold weather when the oil temperatures at start-up are very low. Oil from the oil cooler outlets is directed by the oil cooler bypass return manifold to the return manifold and filters before it is returned to tank.

• 422-07

• •• • ••

•• 1 - WATER ABSORBING RETURN FILTER (COLOUR BLUE)

RETURN MANIFOLD/FILTERS

RETURN MANIFOLD/ RETURN FILTERS The return manifold collects return oil from the oil cooler bypass/return manifold and various other tank lines. Before being sent back to the hydraulic tank oil first passes through six spin on hydraulic oil filters mounted onto three double filter heads, one of the filters is a water absorbing filter (colour blue) the purpose of which is to assist with removing moisture from the hydraulic oil. The input side of the filter heads are connected in parallel to the return manifold. The output side of 10.2

Tigercat 822 Feller Buncher

Oil Cooler and Cooling Fan A/C CONDENSER OIL COOLER

RADIATOR COOLING FAN

••

SHROUD

••

••

FINGER GUARD SURGE TANK FAN DRIVE MOTOR

••

••

••

•

•

DEBRIS SCREEN

••

822-04

COOLING ASSEMBLY - OVERALL VIEW

the filter heads direct the oil to tank via three return lines.

For complete description and operation refer to HYDRAULIC OIL TANK in SECTION 4 of this MANUAL. Refer also to SECTION 2 and SECTION 3 of the OPERATOR'S MANUAL. HYDRAULIC TANK

NOTE: REGULARLY CHECK FOR DEBRIS BETWEEN A/C CONDENSER, OIL COOLER AND RADIATOR

MAIN PUMP For operation and adjustment of this pump refer to SECTION 4 of THIS MANUAL. MAIN CONTROL VALVE For operation and description of this valve refer to SECTION 4 of THIS MANUAL.

Located at the rear left corner of the machine beside the fuel tank. All return oil entering the tank is screened prior to entering the tank by passing through three reusable suction strainers attached to the ends of the return tubes at the bottom of the tank. Case drain return oil from the pumps is also screened by a fourth reusable strainer attached to the inside of the round access cover. The air space in the top of the hydraulic tank is vented to atmosphere via a check valve and spin-on filter.

For complete description and operation refer to HYDRAULIC OIL TANK in SECTION 4 of this MANUAL. Refer also to SECTION 2 and SECTION 3 of the OPERATOR'S MANUAL. 10.3

Tigercat 822 Feller Buncher

Oil Cooler and Cooling Fan

OIL COOLER CIRCUIT DESCRIPTION The oil cooler circuit operates as a part of the main hydraulic circuit.

The main pump draws oil from the hydraulic tank and sends it to the main control valve. Return oil from the main control valve sections exits the base manifold at two 'T' ports and 75 psi internal check valves. From there the oil passes through the oil cooler via the oil cooler bypass return manifold, which includes a bypass valve for the oil cooler.

The cooler bypass ensures that the differential pressure between the oil cooler inlet and outlet does not exceed set limits. Pressure increases within the oil cooler can occur in cold weather when oil temperatures at start-up are very low.

Cooling of the oil occurs as air is drawn over the oil cooler cooling fins by the cooling fan. Cooled oil then passes back through the cooler bypass valve and on to the return manifold and return filters and then to the hydraulic tank. A 25 psi bypass valve is incorporated into each pair of return filter heads.

Oil entering the hydraulic tank from the return manifold and filters passes through 3 strainers situated inside the tank below the oil surface.

Refer to HYDRAULIC OIL TANK in SECTION 4 of this MANUAL. Refer also to SECTION 2 and SECTION 3 of the OPERATOR'S MANUAL. Refer to HYDRAULIC SYSTEM OPERATION MAIN HYDRAULIC SYSTEM in SECTION 4 of this MANUAL.

10.4

Tigercat 822 Feller Buncher

822-14

Oil Cooler and Cooling Fan

OIL COOLER CIRCUIT 10.5

Tigercat 822 Feller Buncher

Oil Cooler and Cooling Fan

COOLING FAN The cooling fan is mounted in front of the cooling assembly and draws air through debris screen and cooling assembly. The air is expelled to atmosphere through the perforated panels that make up the engine enclosure.

The operation of a typical external gear pump (so called because the gear teeth are on the external surface of the hub) is shown in Figure gear1.

OUTLET DRIVEN (IDLER) GEAR

The CLEAN (PURGE) fan function, operated by a switch in the cab, reverses the direction of air flow, thus dust and debris is forced out of the radiator, oil cooler, A/C condenser core debris screen and perforated panels that make up the engine enclosure.

DRIVE GEAR

•

•

NOTE: The air flow in the CLEAN (PURGE) mode is substantially less than in the NORMAL (FORWARD) mode. Reduce load on engine whenever placing fan in CLEAN mode.

For additional information regarding operation of the cooling fan refer to COOLING FAN -SWITCH and CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR in SECTION 2 of THE OPERATOR'S MANUAL. THRUST PLATES DRIVE GEAR ON INPUT SHAFT

•

THRUST PLATES DRIVE GEAR ON INPUT SHAFT

CONNECTING SHAFT

• • •

•

INLET GEAR1

TYPICAL GEAR PUMP

A gear pump carries oil from the inlet to the outlet in the spaces between gear teeth. The pumping chamber is formed by the gears, the pump housing, and thrust plates. One of the two gears, called the drive gear, will be connected to the drive shaft. The other idler gear is driven by the drive gear.

• • •

CLAMPS/FAN PUMP

•

AP140

SAW PUMP

•

• GEAR HOUSINGS

PORT PLATE, REAR

••

CLAMPS/FAN PUMP

CLAMPS/FAN PUMP This is a two cartridge dual gear pump driven off the power take-off of the saw pump . The input drive shaft is connected to the saw pump drive shaft by a drive coupling.

One of the two cartridges in the clamps/fan pump provides hydraulic oil flow to the cooling fan circuit. The second cartridge provides hydraulic oil flow to the clamp and accumulating arm functions.

422-08

10.6

PUMP ASSEMBLY

•

INPUT DRIVE SHAFT (CONNECTED TO SAW PUMP)

Tigercat 822 Feller Buncher

Oil Cooler and Cooling Fan The fan motor is equipped with an integral loop flushing valve which provides additional cooling to the cooling fan circuit.

TANK LINE PRESSURE PORT 'B'

•• ••

DANGER ASSEMBLY NOTE: Before re-installing a fan motor, pack spline area of fan hub and motor shaft with EP Moly-Graph grease. See Fig. 630B-10

PRESSURE PORT 'A'

FAN MOTOR

830-D30

FAN MOTOR The fan motor is a fixed displacement inline swashplate axial piston motor. The fan motor is driven by hydraulic pressure from one of the two cartridges in the double gear clamps/fan pump and in turn it directly drives the fan.

CAUTION Ensure that ALL hydraulic connections at fan motor are tight and leak free. leaking oil will be blown into engine area

FILL HATCHED AREA WITH AN EP MOLY-GRAPH GREASE AS SHOWN PRIOR TO INSTALLING MOTOR DO NOT FILL THIS AREA WITH GREASE

• •

• •

•

• ••

• • MOTOR

BOLT

WASHER

RETAINING RING

•

FAN

•

FAN SHAFT BEARINGS

FAN SUPPORT

630B-10

•

FAN DRIVE MOTOR INSTALLATION 10.7

Tigercat 822 Feller Buncher

Oil Cooler and Cooling Fan

FAN CONTROL VALVES

The FORWARD pilot valve is de-energized and supplies pilot oil to the FORWARD pilot end cap of the fan control valve to hold the valve spool in the FAN FORWARD position. In this position oil from the fan pump is directed to the fan motor to rotate the fan FORWARD.

The fan direction is controlled by two solenoid operated fan pilot valves and a pilot operated fan control valve.

FAN PILOT VALVES The two solenoid operated fan pilot valves are mounted above the fan control valve. Each consists of an aluminium body which houses a solenoid operated control valve cartridge.

HOLDING the fan switch in the CLEAN position energizes BOTH the REVERSE and FORWARD fan pilot valves to supply pilot oil to the REVERSE pilot end cap and remove pilot oil from the FORWARD pilot end cap of the fan control valve. This will shift the spool to the REVERSE position and reverse the direction of rotation of the fan. RELEASING the fan switch allows the fan to run in the NORMAL (FORWARD) mode.

One fan pilot valve is used for FORWARD and one for REVERSE pilot oil supply (425 psi) to the pilot end caps of the fan control valve. When the fan switch in the cab is in the NORMAL (FORWARD) position there is no current supplied to either of the fan pilot valves.

DIN CONNECTOR

VALVE BODY

FAN CONTROL VALVE

•

The fan control valve consists of one open center spool section, an inlet section and an outlet section.

1

•

Oil enters the inlet section and is allowed to pass through the spool section and back to tank via the outlet section. The spool section 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.

3

• 1

•

CONTROL VALVE CARTRIDGE

The spool is shifted by pilot pressure applied to either end of the spool. Shifting the spool directs oil to operate the fan motor in the forward (normal) direction or the reverse (purge) direction.

SOLENOID

FAN PILOT VALVE

AT022

ACCUMULATORS (FAN CONTROL) ONE SHOWN, ONE HIDDEN BEHIND PUMPS

MAIN PUMP

••

FAN PILOT VALVE 'FWD'

• •• •• ••

••

ACCUMULATOR (PILOT MANIFOLD) FAN PILOT VALVE 'REV'

CLAMPS/FAN PUMP

SAW PUMP

GAUGE TEST PORT

• •• FAN CONTROL VALVE

422-09

COOLING FAN CONTROL VALVES 10.8

••

Tigercat 822 Feller Buncher

Oil Cooler and Cooling Fan

To protect components and hoses when the valve is closed, each work port in the valve section has a PORT RELIEF VALVE with an anti-cavitation function.

ACCUMULATORS Two accumulators are installed in the fan circuit to cushion the severity of the control valve spool shift from forward (normal) to reverse (purge) when the fan purge (clean) function is used. The accumulators in effect increase the volume of the pilot end caps and slow down the shift in fan direction in order to protect the components of the fan circuit from excess stress caused by the sudden change in fan direction.

A main relief valve is installed in the inlet section of the valve. It controls the pressure to the spool section and is set lower than the PORT RELIEF VALVES.

The accumulators are bladder type and are installed with a nitrogen pre-charge pressure. The gas pressures should be checked if the pilot system exhibits repeated and frequent charging cycles. For a more detailed description of the accumulators refer to ACCUMULATORS in SECTION 5 of THIS MANUAL. Refer also to CHECKING PRE-CHARGE PRESSURE in SECTION 5 of THIS MANUAL.

FAN CONTROL VALVE SCHEMATIC

822-19

SPOOL STOP ADJUSTING SCREW 'REVERSE (PURGE)'

OUTLET SECTION 'FORWARD' PORT RELIEF VALVE

REVERSE PORT RELIEF VALVE

•

•

•

•

••

•

•• •

INLET SECTION

SPOOL STOP ADJUSTING SCREW 'FORWARD'

MAIN RELIEF VALVE

GAUGE TEST PORT

FAN CONTROL VALVE

AT138

SEAL GROOVES RELIEF VALVE PORT 'A'

A

RELIEF VALVE PORT 'B'

B

•

•

SPOOL STOP ADJUSTING SCREW

•• •

•

•

SPOOL STOP ADJUSTING SCREW

• •

• •

• •

•

AT138

••

•

•

PILOT END CAP SPOOL

SPOOL CENTERING SPRINGS

TANK PASSAGE TANK PASSAGE

THRU' NEUTRAL PASSAGE

PARALLEL PASSAGE

WORK PORT BRIDGE

CROSS SECTION OF SPOOL SECTIONS 10.9

PILOT END CAP

Tigercat 822 Feller Buncher

Oil Cooler and Cooling Fan

COOLING FAN CIRCUIT DESCRIPTION This open centre circuit receives oil from one of two cartridges in the double gear clamps/fan pump driven off the PTO of the saw pump.

The fan motor is a fixed displacement piston motor. The fan is coupled directly to the motor output shaft.

The fan direction is controlled by the fan control valve and two solenoid operated fan pilot valves one for FORWARD and one for REVERSE pilot oil supply (425 psi) to the pilot end caps of the fan control valve. When the fan switch in the cab is in the NORMAL (FORWARD) position there is no current supplied to either of the fan pilot valves.

The FORWARD pilot valve is de-energized and supplies pilot oil to the FORWARD pilot end cap of the fan control valve to hold the valve spool in the FAN FORWARD position. In this position oil from the fan pump is directed to the fan motor to rotate the fan FORWARD. HOLDING the fan switch in the CLEAN position energizes BOTH the REVERSE and FORWARD fan pilot valves to supply pilot oil to the REVERSE pilot end cap and remove pilot oil from the FORWARD pilot end cap of the fan control valve.

This will shift the spool to the REVERSE position and reverse the direction of rotation of the fan.

The cooling fan switch will also turn the air conditioning system OFF for as long as the fan switch is in the CLEAN position.

RELEASING the fan switch allows the fan to run in the NORMAL (FORWARD) mode.

An accumulator is teed into each of the pilot lines from the fan pilot valves to the fan control valve.

These two accumulators cushion the severity of the control valve spool shift from FORWARD to REVERSE when the fan PURGE (CLEAN) function is used. The accumulators in effect increase the volume of the pilot end caps and slow down the shift in fan direction in order to protect the components of the fan circuit from excess stress caused by the sudden change in fan direction.

10.10

Tigercat 822 Feller Buncher

Oil Cooler and Cooling Fan

COOLING FAN CIRCUIT 822-15

10.11

Tigercat 822 Feller Buncher

Oil Cooler and Cooling Fan

FAN SPEED ADJUSTMENT

PRESSURE SETTINGS

FAN CONTROL VALVE SPOOL STOP ADJUSTMENT

Perform this procedure only if normal (forward) fan speed is low and cannot be adjusted to at least 2400 rpm. Before proceeding refer to FAN SPEED ADJUSTMENT in THIS SECTION to adjust fan speed. (Note: The fan control valve reliefs are factory set and generally do not require adjustment in the field. )

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

1. Park machine on level ground, lower the felling head to the ground, engage the swing brake and stop engine 2. Place a piece of reflecting tape on the fan hub. Note tape must be placed on the hub since blades flex when the fan is in motion which may give a false reading.

3. Start the engine.

4. Adjust the throttle control to FULL. 5. Measure the forward fan speed with the electronic photo tachometer, it should be 2400-2500 rpm.

CAUTION

CHECK FAN CONTROL PRESSURE 1. Park machine on level ground, lower the felling head to the ground, engage the swing brake and stop engine.

2. Ensure that hydraulic oil is at operating temperature.

3. Connect a 0-5000 psi pressure gauge to the fan control valve test port.

4. Start engine and set throttle to FULL. 5. Gauge should read 2400-3000 psi with the fan operating in the normal (forward) direction. If gauge reading is correct no adjustments is required.

Before placing the fan switch in the CLEAN (PURGE) position make sure that there are no personnel on the right side of the machine where the fan will expel debris.

6. Press and hold the cooling fan purge switch in the cab to shift the pump to reverse and measure the reverse fan speed, it should be 2050-2150 rpm.

7. If adjustment is required due to incorrect readings: a. Adjust the forward spool stop adjusting screw. Turning the adjusting screw IN will lower the speed. Set to 2400-2500 rpm (usually turned all the way OUT). b. Adjust the reverse maximum displacement adjusting screw. Turning the adjusting screw IN will lower the speed. Set to 2100 rpm. The reverse fan speed should always be lower than the forward fan speed. The lower speed is adequate for the fan purge (clean) function and reduces unnecessary stress on cooling fan components.

8. Repeat steps 5 to 7 until correct forward and reverse fan speeds are obtained.

NOTE: The fan control valve reliefs are factory set and generally do not require adjustment in the field. In the event that adjustment is required refer to FAN CONTROL RELIEF ADJUSTMENT in THIS SECTION. FAN CONTROL RELIEF ADJUSTMENT Perform this procedure only if relief adjustment is necessary. Before proceeding refer to CHECK FAN CONTROL PRESSURE in THIS SECTION to determine if adjustment is required.

The fan control valve reliefs are factory set and generally do not require adjustment in the field.

This procedure requires disconnection of hoses which may introduce contamination into the hydraulic system. Care should be taken to avoid contamination, all disconnected hoses should be kept clean and plugged during the procedure.

1. Park machine on level ground, lower the felling head to the ground, engage the swing brake and stop engine.

2. Ensure that hydraulic oil is at operating temperature.

3. Connect a 0-5000 psi pressure gauge to the fan control valve test port.

4. Disconnect the main hoses to the fan motor at the fan control valve and cap fittings with two 12 ORS caps. Plug hose ends and 10.12

Tigercat 822 Feller Buncher

Oil Cooler and Cooling Fan

ensure that hose ends are kept clean during this procedure to avoid contamination of the hydraulic system.

RESET MAIN RELIEF VALVE 13. With throttle control in the FULL position; Loosen the locknut on the main relief valve and unscrew adjusting screw 3 full turns.

5. Loosen locknut on the main relief valve and turn the main relief all the way in, tighten locknut.

14. With fan operating in the normal (forward) direction, check gauge pressure reading.

6. Turn both port relief adjusting screws on the spool section out until spring pressure is relieved and then turn adjusting screws one full turn in.

If less than 3000 psi turn forward port relief adjusting screw in until 3000 psi is obtained on the gauge.

7. Start the engine and set throttle to IDLE.

15. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

8. With fan operating in the normal (forward) direction, check gauge pressure reading.

16. Repeat step 14 to verify setting.

17. Stop engine and remove pressure gauge.

If less than 3300 psi turn forward port relief adjusting screw in until 3300 psi is obtained on the gauge.

18. Reconnect hoses to the fan control valve.

Care should be taken to ensure all connections are kept clean to avoid contamination of the hydraulic system.

9. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

CAUTION Before placing the fan switch in the CLEAN (PURGE) position make sure that there are no personnel on the right side of the machine where the fan will expel debris.

10. With the aid of an assistant. Press and hold the cooling fan purge switch to operate the fan in reverse, check gauge reading.

If less than 3300 psi turn reverse port relief adjusting screw in until 3300 psi is obtained on the gauge.

11. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

12. Repeat steps 8 and 10 to verify settings.

SPOOL STOP ADJUSTING SCREW 'REVERSE (PURGE)'

OUTLET SECTION 'FORWARD' PORT RELIEF VALVE

•

•

••

•

•

•

INLET SECTION AT138

10.13

SPOOL STOP ADJUSTING SCREW 'FORWARD'

• •

GAUGE TEST PORT

FAN CONTROL VALVE

REVERSE PORT RELIEF VALVE

MAIN RELIEF VALVE

Tigercat 822 Feller Buncher

Oil Cooler and Cooling Fan

10.14

Tigercat 822 Feller Buncher

SECTION 11 - TRACK DRIVE CONTENTS - SECTION 11 BRAKE CIRCUIT DESCRIPTION .................................................................. 11.5 CIRCUIT DIAGRAM, DRIVE SYSTEM .......................................................... 11.8 DRIVE MOTOR DESCRIPTION ........................................................................................... 11.4 START-UP PROCEDURE .......................................................................... 11.7 DRIVE MOTOR AND GEARBOX ASSEMBLY .............................................. 11.3 GEARBOX AND DRIVE MOTOR ASSEMBLY .............................................. 11.3 HYDROSTATIC DRIVE SYSTEM ................................................................. 11.3 IMPORTANT TRACK DRIVE NOTES NEW MACHINE ........................................................................................ 11.2 STRAIGHT TRAVEL .................................................................................. 11.2 TRACK SAG ............................................................................................. 11.2 LEFT TRACK SPEED ADJUSTMENT ......................................................... 11.12 PRESSURE SETTINGS, DRIVE SYSTEM BEGIN OF REGULATION, SET, FOR DRIVE MOTOR ............................. 11.10 BRAKE RELEASE PRESSURE ADJUSTMENT ON DRIVE MOT ............ 11.10 CROSSOVER RELIEF VALVES, FOR DRIVE MOTOR ............................. 11.9 RIGHT TRACK SPEED ADJUSTMENT ....................................................... 11.15 SCHEMATIC DIAGRAMS DRIVE CIRCUIT ......................................................................................... 11.8 DRIVE MOTOR ...................................................................... 11.3, 11.5, 11.6 SET BRAKE RELEASE PRESSURE ON DRIVE MOT .............................. 11.10 SET STRAIGHT TRAVEL ............................................................................ 11.15 TRACK COMPONENTS BOTTOM ROLLER RETAINING BOLTS ................................................... 11.18 MEASURING TRACK SAG ...................................................................... 11.16 TRACK SAG ADJUSTMENT ................................................................ 11.17 OPERATING THE MACHINE ................................................................... 11.16 TORQUING UNDERCARRIAGE BOLTS .................................................. 11.17 TRACK SHOE RETAINING BOLTS ......................................................... 11.17 WEAR LIMITS BOTTOM ROLLER WEAR ................................................................... 11.19 BUSHING WEAR, OUTSIDE DIAMETER ............................................ 11.19 IDLER WEAR ...................................................................................... 11.20 PIN AND BUSHING WEAR .................................................................. 11.19 TRACK LINK WEAR ............................................................................ 11.18 TRACK SHOE GROUSER HEIGHT WEAR ......................................... 11.18 TRACK SLIDE WEAR ......................................................................... 11.20 TRACK DRIVE ASSEMBLY ......................................................................... 11.2 TRACK SPEED SET-UP PROCEDURE HIGH FORWARD (MOTOR MINIMUM DISPLACEMENT ......................... 11.14 HIGH REVERSE (VALVE FLOW SETTING) ............................................ 11.15 LOW FORWARD (VALVE FLOW SETTING) ........................................... 11.13 SET MOTOR MAXIMUM DISPLACEMENT .............................................. 11.12 SET STRAIGHT TRAVEL ........................................................................ 11.15 SUMMERY OF PROCEDURE ................................................................. 11.15

JUNE 2003

Tigercat 822 Feller Buncher IMPORTANT TRACK DRIVE NOTES

Track drive STRAIGHT TRAVEL

NEW MACHINE

If the machine does not travel straight, the right and left track speeds are not set the same. Refer to TRACK SPEED SET-UP PROCEDURE in THIS SECTION.

Before driving a new machine ensure that track sag is set correctly. Track sag may be set less than specified for shipping purposes. The correct track sag must be adjusted once a machine has been delivered to the job sight and operating in the accumulated soil buildup in the undercarriage.

Check speeds of each track and follow the set-up procedures closely to obtain straight travel.

TRACK SAG The track sag dimension is very important and should be checked regularly. A 50% increase in the life of the track assembly can be realized, particularly in bushing O/D wear and 'track pitch' by maintaining the correct amount of track sag. A track that is too tight will wear out significantly faster due to increased tension in the chain. Refer to MEASURING TRACK SAG in THIS SECTION.

TOP ROLLERS OR SLIDES

ROTARY MANIFOLD

••

IDLER ASSEMBLY

•• UNDERCARRIAGE LOWER HINGED ACCESS COVER

•• UNDERCARRIAGE

••

•• ••

•

•

•

INSPECTION COVERS

•

•

DRIVE MOTOR

•

TRACK DRIVE GEARBOX DRIVE SPROCKET

822-18

•

LOWER ROLLERS

•

TRACK DRIVE ASSEMBLY 11.2

• TRACK ASSEMBLY

TRACK ACCESS COVER

Tigercat 822 Feller Buncher

Track drive

HYDROSTATIC DRIVE SYSTEM The hydrostatic drive system is part of the main hydraulic system utilizing a variable piston pump (main pump) with load sensing and Horse Power (anti-stall) limiting control along with two pressure and flow compensated valve sections on the main Linde valve manifold. Refer to SECTION 4 in THIS MANUAL for a description of the MAIN HYDRAULIC SYSTEM. A variable displacement swash plate piston motor transmits power to the tracks through a triple reduction planetary gearbox on each track frame.

The gearbox has an integral spring apply, hydraulic-release, multi-disc brake which is automatically released whenever the drive system is pressurized.

The valve will remain in the closed position as long as there is no oil pressure in the line from the main control valve. When the main control valve spool is shifted and oil flows to the motor, a check valve in the counterbalance valve (G) (Refer to motor schematic) opens and oil pressure builds up behind the motor pistons.

The motor cannot move until the oil pressure shifts the counterbalance spool to permit the oil on the low pressure side of the motor to flow back through the counterbalance valve to the main control valve and then to tank.

In order to control the vehicle movement in situations where the vehicle may roll down a grade, each motor is equipped with a counterbalance valve. These valves have a spool valve which controls the flow of oil out of the motor, See motor schematic diagram, it is shown in the centre, closed position.

845B-24

TRACK SPROCKET

PLANETARY TRACK DRIVE GEARBOX

•

MOTOR SCHEMATIC DIAGRAM (AQ019)

•

LOWER FRAME

•

TRACK DRIVE MOTOR (AQ019 SHOWN)

• ••

BRAKE ASSEMBLY

BK004-822

TRACK DRIVE MOTOR AND GEARBOX ASSEMBLY 11.3

Tigercat 822 Feller Buncher

Track drive (1) with nine pistons (2) and an output shaft (3) that is splined to the cylinder block.

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

The motor rotating group consists of a cylinder block SLIPPER

RETAINER

Supply oil from the drive control valve enters the motor through the cover (4) to the pistons. During operation, high pressure supply oil enters the PISTON 2

BALL GUIDE

CYLINDER BLOCK

6

1

SWASHPLATE

PIN

5 SEAL

MAXIMUM DISPLACEMENT PISTON

8

•• ••

SPACER RETAINING RING

••••• ••

••

•• •• • •• ••

9 MINIMUM

•

•

SHIMS

••

••

4 COVER

•

•• •

SHAFT 3

DISPLACEMENT ADJUSTMENT STOP

••

•

10 MAXIMUM

DISPLACEMENT ADJUSTMENT STOP

WEAR SLEEVE

CROSS SECTION OF DRIVE MOTOR

AQ019-2

BEARING SHELL MINIMUM

7 DISPLACEMENT

SPRING

MINIMUM DISPLACEMENT ADJUSTMENT STOP

BRAKE RELEASE PRESSURE REDUCING VALVE ADJUSTMENT

BEGIN OF REGULATION ADJUSTMENT

9

PISTON CROSSOVER

11 RELIEF VALVES 4 COVER

•

• •

•• ••

•• 'B' PORT

PRESSURE PORTS

•

'A' PORT

• PRESSURE REGULATOR VALVE BLOCK MAXIMUM 10 DISPLACEMENT ADJUSTMENT STOP

•

AQ019-1

COUNTERBALANCE VALVE

11.4

DRIVE MOTOR FRONT COVER

Tigercat 822 Feller Buncher piston bores in the cylinder block (1). This forces the pistons against an angled swashplate (5).

Piston sliding action causes the rotating group to turn. The cylinder block is splined to the output shaft (3) which causes the output shaft to turn.

During the second half of the motor rotation, low pressure is discharged as the pistons ride up to a higher position on the swashplate. To reverse rotation, oil flow is reversed. During operation a small amount of supply oil flows through the centre of each piston. This oil lubricates the piston to slipper (6) joint and the slipper to swashplate area.

High pressure supply oil also flows through a tube to lubricate the swashplate to bearing shell area.

Normal leakage and lubrication oil aid in flushing and cooling the motor during drive operation.

Track drive BRAKE CIRCUIT DESCRIPTION Refer to motor schematic diagram Oil pressure entering ports 'A' or 'B' of the motor passes through supply shuttle valve 'F' and enters brake release pressure reducing valve 'D'.

The pressure reducing valve output is adjustable.

In this particular application it is limited to 500 psi., whenever 'A' or 'B' line pressure is above 500 psi., or 'A' or 'B' line pressure below 500 psi.

The brake is fully released by 250 psi. and the maximum pressure the brake can stand without failure is 725 psi. The time required for the brake to release is approximately 1 to 3 seconds to apply.

The swashplate (5) angle is changed by the minimum displacement piston (7) and maximum displacement piston (8). When supply oil acts on the minimum displacement piston (7), the motor runs at its highest speed. When supply oil acts on the maximum displacement piston (8), the motor runs at its slowest speed. The maximum displacement piston is larger than the minimum piston and will hold the motor in maximum displacement when equal pressure acts on both pistons.

NOTE: Swashplate angle (motor displacement) is limited by the minimum and maximum displacement pistons contacting the minimum (9) and maximum (10) displacement adjustment stops. For minimum displacement, the maximum displacement piston contacts the minimum displacement adjustment stop. For maximum displacement, the minimum displacement piston contacts the maximum displacement adjustment stop.

Refer to front cover illustration; The drive motor cover (4) consists of several components to operate the drive functions and regulate the release of drive brakes.

The minimum displacement adjustment stop (9) limits the minimum angle the swashplate can move. The maximum displacement adjustment stop (10) limits the maximum angle the swashplate can move. The crossover relief valve(s) (11) protects the motor circuit from pressure spikes.

845B-24 MOTOR SCHEMATIC DIAGRAM (AQ019) The drive brake release pressure reducing valve (D) reduces the higher supply pressure to the lower pressure used to release the drive brake. The supply pressure comes from the supply shuttle valve (F) when a drive function is actuated.

The edge filter and pressure reducing valve orifice (J) are located in the pressure regulator housing in the passage from the supply shuttle valve (F) to the drive brake release pressure reducing valve (D).

The edge filter and orifice are accessible by removing the pressure regulator. The edge filter is used to break up small particles in the oil so they flow through the orifice. The orifice causes a pressure drop in supply oil flow to the reducing valve and dampens pressure oil fluctuation.

The drive speed change valve (H) routes supply oil to the maximum displacement piston to keep the drive motor in the lowest speed. A servo pressure reducing valve controls the pressure of the supply oil entering the drive speed change valve at 2000 psi. maximum.

Continued on page 6

11.5

Tigercat 822 Feller Buncher

Track drive

Continued from page 5

The flushing orifice (I) is located in the brake circuit to motor case passage. The orifice provides a passage for oil flow from the brake circuit to the motor case for cooling and flushing during drive operation. When the oil is cold the flow of oil is restricted by the orifice to prevent an excessive build up of pressure in the drive motor case. The orifice also provides a passage to release any residual pressure from the brake circuit to the motor case when not driving.

The drive motor may be operated in two ranges; MAXIMUM DISPLACEMENT = 105 cc/rev.

MINIMUM DISPLACEMENT = app. 50cc/rev.

These two ranges are controlled by a solenoid pilot valve on the pilot manifold which is operated by the TRACK (LOW/DRIVE) switch in the cab.

In the LOW position the solenoid on the pilot valve is energized and the motor is in its maximum displacement mode which will give the slowest speed and maximum tractive effort.

845B-24

For faster travelling modes the TRACK (LOW/ DRIVE) switch can be put in the DRIVE position and the motor will be in its minimum displacement position which will give the fastest speed. When in this high speed mode the motor will automatically de-stroke in the event that a high load is encountered, e.g. a short grade or obstacle. This de-stroking is controlled by the drive speed change valve. This valve controls the hydraulic pressure signal to the maximum displacement piston. The piston shifts the motor to maximum displacement when the supply oil pressure in the motor is above the drive speed change valve pressure setting.

11.6

MOTOR SCHEMATIC DIAGRAM (AQ019)

Tigercat 822 Feller Buncher DRIVE MOTOR START-UP PROCEDURE

Track drive

IMPORTANT: The drive motor will be damaged if is not filled with oil before operating the drive function. This procedure must be performed whenever a new drive motor or drive pump is installed or whenever oil has been drained from the motor.

1. Disconnect drive motor drain line on top of motor.

2. Install plug in line to minimize loss of oil.

3. Remove port adapter from motor drain port.

4. Fill motor with oil through the drain port. Add oil slowly until level is to the top of drain port.

5. Re-connect drain line.

6. Run each drive motor slowly with track off the ground for three track revolutions to remove air from the drive circuit.

DRAIN LINE

••

'U' PORT DRAIN CONNECTION

7. Check that the brake release pressure has not changed.

GAUGE TEST PORT 'Y1'

••

•

DRIVE MOTOR TOP VIEW

822-D61

PRESSURE REGULATOR VALVE BLOCK

GAUGE TEST PORT Y1 SYSTEM PRESSURE PORT 'A'

BRAKE LINE TO GEARBOX

•• MAXIMUM DISPLACEMENT ADJUSTMENT STOP

•

6mm ALLEN KEY 19mm WRENCH

••

SYSTEM PRESSURE PORT 'B'

MINIMUM DISPLACEMENT ADJUSTMENT STOP 6mm ALLEN KEY 19mm WRENCH

••

••

COUNTERBALANCE VALVE

••

'B' SIDE

• CROSSOVER RELIEF VALVES

'A' SIDE

6mm WRENCH 13mm WRENCH

•• 'L' PORT DRAIN CONNECTION (FOR L.H. SIDE)

5mm ALLEN KEY 17mm WRENCH 822-D62

BEGIN OF REGULATION ADJUSTING SCREW

DRIVE MOTOR (AQ019) - R.H. SIDE SHOWN 11.7

•

•• • BRAKE RELEASE PRESSURE ADJUSTING SCREW 5mm ALLEN KEY 17mm WRENCH

Tigercat 822 Feller Buncher

822-20

Track drive

TRACK DRIVE CIRCUIT DIAGRAM WITH AQ019 MOTOR 11.8

Tigercat 822 Feller Buncher DRIVE SYSTEM PRESSURE SETTINGS FOR DRIVE MOTOR DRIVE MOTOR CROSSOVER RELIEF VALVES Pressure Setting: 4600 - 4800 psi (cracking pressure) TEST PROCEDURE: Place felling head securely on the ground before performing any service work.

Track drive 12. Set throttle switch to FULL

13. Activate LEFT drive foot pedal in FORWARD or REVERSE and temporarily set LS. relief valve to 4700 psi. on gauge at 'P' test port.

14. With the aid of an assistant; While holding the LEFT drive foot pedal in the FORWARD position

1. Ensure hydraulic oil is at operating temperature.

'B' SIDE REVERSE CROSSOVER RELIEF VALVE

'A' SIDE FORWARD CROSSOVER RELIEF VALVE

2. Remove both LEFT and RIGHT drive motor inspection covers.

••

3. Install a 0 to 10,000 psi gauge on 'P' test port on Linde main valve manifold.

'P' GAUGE TEST CONN.

• •

••

••

822-D60

DRIVE MOTOR - LEFT SIDE SHOWN

P2 L.S. PRESSURE LIMIT, SET AT 4300 PSI. WITH GAUGE ON 'P' TEST PORT • 4MM ALLEN KEY • 13MM WRENCH

103-17A

••

HIGH PRESSURE LIMITING CONTROL

L.S. GAUGE TEST CONN.

GAUGE TEST PORTS ON MAIN VALVE

...

'B' SIDE REVERSE CROSSOVER RELIEF VALVE

'A' SIDE FORWARD CROSSOVER RELIEF VALVE

5mm ALLEN KEY 17mm WRENCH

5mm ALLEN KEY 17mm WRENCH

•• ••

MAIN VALVE MANIFOLD

•

•

4. Disconnect LEFT brake line at port on final drive gearbox. Plug hose with size 04 JIC plug and cap port adapter on gearbox.

5.

Start engine and set throttle speed to above 1500 RPM.

822-D62

DRIVE MOTOR - RIGHT SIDE SHOWN loosen locknut on FORWARD crossover relief valve adjusting screw and unscrew slowly until engine begins to lug. Turn adjusting screw 1/8 of a turn in and tighten locknut.

6. From inside the cab close and latch the front door and press the PILOT RESET switch to activate the pilot system.

7. Place ANTI-STALL switch OFF position.

8. Place DRIVE/LOW switch to LOW.

15. Repeat step (14) for the LEFT REVERSE crossover relief valve.

9. Activate LEFT track drive foot pedal in both FORWARD and REVERSE directions to ensure that the track does not move.

16. Repeat steps (4) through (15) for RIGHT track drive motor.

10. With the aid of an assistant, activate LEFT track drive foot pedal in either FORWARD or REVERSE and check pressure reading on gauge at 'P' port. the gauge should show 4300 psi (Main system LS. relief pressure) 11. Loosen locknut on both crossover relief valve adjusting screws and turn both adjusting screws all the way in. Tighten locknuts.

17. Reset the LS. relief valve to 4300 psi. on gauge at 'P' test port. Refer to SET LOAD SENSE RELIEF VALVE in SECTION 4 of THIS MANUAL. 18. Re-connect brake line(s) to both gearboxes.

19. Remove pressure gauge and wipe up any spills.

20. Replace both LEFT and RIGHT drive motor inspection covers.

11.9

Tigercat 822 Feller Buncher

Track drive

SET BRAKE RELEASE PRESSURE ADJUSTMENT ON DRIVE MOTOR

BRAKE RELEASE PRESSURE ADJUSTING SCREW

Pressure setting: 500 psi. (cracking pressure)

•• ••

Place felling head securely on the ground before performing any service work.

5mm ALLEN KEY 17mm WRENCH

1. Ensure hydraulic oil is at operating temperature.

2. Remove both LEFT and RIGHT drive motor inspection covers.

•

3. Disconnect LEFT brake line at port on final drive gearbox.

••

DISCONNECT BRAKE LINE AT PORT ON FINAL DRIVE GEARBOX.

PRESSURE REGULATOR VALVE BLOCK

BEGIN OF REGULATION ADJUSTING SCREW 6mm WRENCH 13mm WRENCH

822-D62 DRIVE MOTOR - LEFT SIDE SHOWN 10. Remove pressure gauge from brake line and re-connect brake line to gearbox.

11. Repeat steps (3) through (10) for RIGHT track drive motor.

12. Replace both LEFT and RIGHT drive motor inspection covers.

•• GAUGE TEST PORT 'Y1'

•

SET BEGIN OF REGULATION (DRIVE SPEED CHANGE VALVE)

BRAKE LINE 822-D61

DRIVE MOTOR - R.H. SIDE SHOWN

4. Install a 0 to 1,000 psi gauge onto hose end (size 04 JIC).

5.

Start engine and set throttle to FULL

...

1. Ensure hydraulic oil is at operating temperature.

2. Remove both LEFT and RIGHT drive motor inspection covers.

3. Install a 0 to 10,000 psi gauge on 'P' test port on Linde main valve manifold.

'P' GAUGE TEST CONN.

6. From inside the cab close and latch the front door and press the PILOT RESET switch to activate the pilot system.

••

7. Place ANTI-STALL switch to OFF position.

HIGH PRESSURE LIMITING CONTROL

L.S. GAUGE TEST CONN.

••

••

8. Place DRIVE/LOW switch to DRIVE position.

9. With the aid of an assistant; activate LEFT track drive foot pedal in either FORWARD or REVERSE direction and check pressure reading on gauge connected to brake line, the gauge should show 500 psi.

If adjustment is required, loosen locknut on brake release pressure adjusting screw and turn screw in to increase pressure or out to decrease pressure. Tighten locknut.

P2 L.S. PRESSURE LIMIT, SET AT 4300 PSI. WITH GAUGE ON 'P' TEST PORT • 4MM ALLEN KEY • 13MM WRENCH

103-17A

GAUGE TEST PORTS ON MAIN VALVE

•• ••

MAIN VALVE MANIFOLD

4. Disconnect LEFT brake line at port on final drive gearbox. Plug hose with size 04JIC plug and cap port adapter on gearbox.

5. Install a 0 to 5,000 psi gauge on drive motor gauge test port 'Y1', size 04JIC quick connect.

11.10

Tigercat 822 Feller Buncher 6.

Start engine and set throttle to FULL

Track drive ...

7. From inside the cab close and latch the front door and press the PILOT RESET switch to activate the pilot system.

8. Place ANTI-STALL switch to OFF position.

9. Place DRIVE/LOW switch to DRIVE position.

10. Activate LEFT track drive foot pedal in both FORWARD and REVERSE directions to ensure that the track does not move.

11. With the aid of an assistant, activate LEFT drive foot pedal in FORWARD or REVERSE and temporarily set LS. relief valve to 3600 psi.** on gauge at 'P' test port on Linde main valve manifold.

12. With the aid of an assistant, activate LEFT track drive foot pedal in the FORWARD direction and check pressure reading on gauge at motor gauge test port 'Y1' it should show between 800 and 1,000 psi.

If adjustment is required, loosen locknut on begin of regulation adjusting screw and turn screw in to increase pressure or out to decrease pressure. Tighten locknut.

13. Stop engine.

14. Repeat steps (4) through (12) for the right drive motor.

15. Reset the LS. relief valve to 4300 psi. Refer to SET LOAD SENSE RELIEF VALVE in SECTION 4 of THIS MANUAL. 16. Re-connect brake line(s) to both gearboxes.

17. Remove pressure gauge and wipe up any spills.

18. Replace both LEFT and RIGHT drive motor inspection covers. **NOTE For begin of regulation; this pressure setting can be adjusted between 3100 psi and 3600 psi depending on the operator's requirements. The lower the begin of regulation setting the sooner the drive motors will automatically shift to LOW when encountering difficult terrain conditions.

11.11

Tigercat 822 Feller Buncher TRACK SPEED SET-UP PROCEDURE IMPORTANT: EACH motor maximum displacement setting must be correctly set before making adjustments to the valve spool stops described here in. Refer to the following SET MOTOR MAX. DISPL. (SLOW SPEED) procedure.

Also note that changes in margin pressure will also affect track speeds.

NOTE: Both left and right 822 track drives have 4 (speed) settings which are dealt with in the following procedures, they are: 1, Forward-Drive 2, Forward-Low 3, Reverse-Drive 4, Reverse-Low. However, there are only 3 adjustments required to accomplish this; 1, Forward flow stop adjusting screw 2, Reverse flow stop adjusting screw 3, Motor minimum displacement adjustment stop

Track drive WARNING DO NOT place arms, legs or body under track while in the raised position.

5. Use blocks to firmly support track frame in raised position.

SET MOTOR MAX. DISPL. (SLOW SPEED) NOTE: The motor maximum displacement setting is the SLOW speed setting and is factory set to: MAXIMUM DISP. = 105CC/REV. NOTE: Turn the screw either IN (clockwise) to speed up or OUT (counterclockwise) to slow down the final drive.

6. On LEFT track drive motor, unscrew the maximum displacement adjusting screw all the way OUT. 7. From inside the cab close and latch the front door and press the PILOT RESET switch to activate the pilot system.

8. Place ANTI-STALL switch to OFF position.

9. Set TRACK (LOW/DRIVE) switch to LOW.

SET TRACK SPEED Low speed 10 rpm**. High speed 28 rpm. **NOTE: This value is dependant on engine HIGH IDLE speed or FULL throttle. 10 rpm is based on 2150 - 2200 rpm.

10. Set throttle switch to FULL

...

MINIMUM DISPLACEMENT ADJUSTING SCREW 6mm ALLEN KEY 19mm WRENCH

1. Ensure hydraulic oil is at operating temperature.

2. Remove both left and right final drive inspection covers to access track motors.

••

LEFT TRACK ADJUSTMENT POSITION MACHINE

•

3. Position felling head in vertical position and swing boom to LEFT side of machine.

MAXIMUM DISPLACEMENT ADJUSTING SCREW 6mm ALLEN KEY 19mm WRENCH

822-D60

MAXIMUM DISPLACEMENT ADJUSTING SCREW

ANGLE TO BE BETWEEN 90° & 110°

845-12

LEFT TRACK DRIVE MOTOR

6mm ALLEN KEY 19mm WRENCH

•

LIFT LEFT TRACK MINIMUM DISPLACEMENT ADJUSTING SCREW

4. Place felling head on ground and by forcing down with boom controls, lift track clear of ground. (Hoist down and stick out)

6mm ALLEN KEY 19mm WRENCH 822-D61

11.12

••

RIGHT TRACK DRIVE MOTOR

Tigercat 822 Feller Buncher

Track drive

11. With an assistant depressing LEFT TRACK drive pedal FORWARD, turn maximum displacement screw IN until the end of adjusting screw just makes contact with piston inside the motor.

CONTROL FORWARD SPOOL VALVE STOP SCREW FOR MANIFOLD LEFT TRACK

FORWARD SPOOL STOP SCREW FOR RIGHT TRACK

••

••

••

12. Release drive pedal and turn screw IN an additional 1/4 turn = 105cc.

Tighten locknut while holding adjusting screw from turning.

B SIDE

•

13. LEFT drive motor maximum displacement (slow track speed) is now set to 105cc per revolution.

A

RIGHT DRIVE VALVE

LEFT DRIVE VALVE

SIDE

LOW FORWARD (VALVE FLOW SETTING) 14. Turn ‘DRIVE/LOW’ switch to ‘LOW’ 15. Set throttle switch to FULL

RETURN MANIFOLD

...

16. With an assistant depressing ‘LEFT’ TRACK drive pedal ‘FORWARD’, record track drive sprocket speed.

A TIMING MARK, VISIBLE FROM THE CAB CAN ALSO BE PLACED ON THE TRACK

•

••

••

REVERSE SPOOL STOP SCREW FOR RIGHT TRACK

REVERSE SPOOL STOP SCREW FOR LEFT TRACK

MAIN CONTROL VALVE 17. To obtain the 10 or 11 RPM value adjust FORWARD spool stop adjusting screw for the LEFT track drive control valve.

822-D63A

••

SPOOL STOP ADJUSTING SCREW • 19mm WRENCH • 6mm ALLEN KEY

••

• ROTATION

TO RECORD TRACK SPEED, PLACE TIMING MARKS ON TRACK FRAME AND GEARBOX HOUSING

84-18

SET TRACK SPEED Track containing 45 links*: A reading of 10RPM is desired which equals 1 complete revolution of the track every 23.5 seconds.

853MV-2

VALVE FLOW SETTING TRACK DRIVE MAIN CONTROL VALVE

Track containing 47 links*: A reading of 11 RPM is desired which equals 1 complete revolution of the track every 22.3 seconds.

Turn the screw either IN (clockwise) to slow down or OUT (counterclockwise) to speed up the final drive. Tighten locknut on adjusting screw and re-check sprocket speed.

*NOTE: Refer to TRACK TIMING CHART.

11.13

Tigercat 822 Feller Buncher

Track drive

HIGH FORWARD (motor minimum displacement)

TRACK TIMING CHART GEARBOX RPM

18. Turn ‘DRIVE/LOW’ switch to ‘DRIVE’ 19. Set throttle switch to FULL

...

DESIRED LOW

20. With an assistant depressing ‘LEFT’ TRACK drive pedal ‘FORWARD’, record track drive sprocket speed.

Track containing 45 links*: A reading of 28 RPM is desired which equals 1 complete revolution of the track every 8.4 seconds.

Track containing 47 links*: A reading of 29 RPM is desired which equals 1 complete revolution of the track every 8.5 seconds. *NOTE: Refer to TRACK TIMING CHART. 21. To obtain the 28 or 29 RPM adjust the minimum displacement adjusting screw for the LEFT track drive motor. Turn the screw either IN (clockwise) to slow down or OUT (counterclockwise) to speed up the final drive. Tighten locknut on adjusting screw and re-check sprocket speed.

DESIRED HIGH DO NOT EXCEED

MINIMUM DISPLACEMENT ADJUSTMENT STOP

••

822 TRACKCHART.XLS

• MAXIMUM DISPLACEMENT ADJUSTMENT STOP 822-D60

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

LEFT TRACK DRIVE MOTOR IMPORTANT: DO NOT exceed the recommended track speed specified above, over speeding will damage the drive motor.

11.14

NUMBER OF TRACK LINKS 45 47 51 TRACK REVOLUTION TIME (SECONDS) 23.48 21.34 19.57 18.06 16.77 15.65 14.67 13.81 13.04 12.36 11.74 11.18 10.67 10.21 9.78 9.39 9.03 8.70 8.39 8.10 7.83 7.57 7.34 7.11 6.91 6.71 6.52 6.35 6.18 6.02 5.87

24.52 22.29 20.43 18.86 17.52 16.35 15.33 14.42 13.62 12.91 12.26 11.68 11.15 10.66 10.22 9.81 9.43 9.08 8.76 8.46 8.17 7.91 7.66 7.43 7.21 7.01 6.81 6.63 6.45 6.29 6.13

26.61 24.19 22.17 20.47 19.01 17.74 16.63 15.65 14.78 14.00 13.30 12.67 12.09 11.57 11.09 10.64 10.23 9.86 9.50 9.18 8.87 8.58 8.32 8.06 7.83 7.60 7.39 7.19 7.00 6.82 6.65

Tigercat 822 Feller Buncher HIGH REVERSE (valve flow setting)

Track drive SUMMERY OF PROCEDURE • REMOVE INSPECTION COVERS

22. Repeat steps 18 to 20 to set ‘LEFT’ HIGH REVERSE.

LEFT TRACK ADJUSTMENT • POSITION MACHINE, LEFT track off ground • LOW FORWARD (valve flow setting) • HIGH FORWARD (motor minimum displacement) • HIGH REVERSE (valve flow setting)

23. To obtain 28 or 29 RPM value adjust REVERSE spool stop adjusting screw for the LEFT track drive control valve. Turn the screw either IN (clockwise) to slow down or OUT (counterclockwise) to speed up the final drive. Tighten locknut on adjusting screw and re-check sprocket speed.

RIGHT TRACK ADJUSTMENT • POSITION MACHINE, RIGHT track off ground • LOW FORWARD (valve flow setting) • HIGH FORWARD (motor minimum displacement) • HIGH REVERSE (valve flow setting) • REPLACE INSPECTION COVERS

TRACK SPEED SET-UP PROCEDURE continued; RIGHT TRACK ADJUSTMENT

SET STRAIGHT TRAVEL Following completion of TRACK SPEED SETUP PROCEDURE, drive the machine in both forward and reverse directions with the ‘DRIVE/ LOW’ switch in ‘DRIVE’ and again with the switch in ‘LOW’ position. Ensure that both DRIVE pedals are equally and fully depressed.

ANGLE TO BE BETWEEN 90° & 110°

845-12

LIFTING RIGHT TRACK

If the machine continuously drifts to the left or to the right, the above set-up procedure should be reviewed. It is important that the LEFT and RIGHT track speeds are synchronized with each other to prevent unnecessary wear from occurring to the track components.

24. Re-position machine to raise RIGHT track.

25. Repeat steps 3 through 13 to set RIGHT drive motor maximum displacement.

LOW FORWARD (valve flow setting) 26. Repeat steps 14 to 17 to set RIGHT TRACK valve flow setting.

HIGH FORWARD (motor minimum displ.)

27. Repeat steps 18 to 21 to set RIGHT drive motor minimum displacement.

HIGH REVERSE (valve flow setting) 28. Repeat steps 22 and 23 to set RIGHT TRACK valve flow setting.

29. Replace final drive inspection covers for both right and left track drives.

11.15

Tigercat 822 Feller Buncher TRACK COMPONENTS

Track drive

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

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

TRACK SAG NOTE: The track sag dimension is very important and should be checked regularly, 50% increase in the life of the track assembly can be realized, particularly bushing O/D wear and track pitch by maintaining the correct amount of track sag. A track that is too tight will wear out significantly faster due to increased tension in the chain.

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

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

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

ANGLE TO BE BETWEEN 90° & 110°

845-12

MEASURING TRACK SAG 1. Position felling head in vertical position and swing boom to side of machine.

2. Place felling head on ground and by forcing down with boom controls, lift track clear of ground.

3. Rotate track in forward and reverse several times. Stop the track while in reverse. Do not clean the track.

4. Stop engine.

5. Measure distance between top surface of track shoe at centre of lower surface of track frame.

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

UNDERSIDE OF TRACK GUARD

SAG DIMENSION

• •

UPPER SURFACE OF TRACK SHOE 853ILL8

MEASURING SAG DIMENSION

6. This dimension should be between 4" and 6" for normal operations.

830-7A

OPERATE MACHINE WITH FELLING HEAD OVER IDLERS

OPERATING THE MACHINE

NOTE: If track sag is less than specified, track chain wear will be accelerated. If track sag is excessive, it is possible for the track to jump off the sprocket.

Whenever possible the machine should always be operated with the felling head over the IDLERS and not over the SPROCKETS. Operating over the sprockets will result in overloading of the contact surfaces between the sprocket and the track bushings. Bushings could crack during sprocket impact.

11.16

Tigercat 822 Feller Buncher IDLER ADJUSTING 4 CYLINDER

Track drive TORQUING UNDERCARRIAGE BOLTS

•

It is important to check the torque values of the track shoe retaining bolts and the bottom roller retaining bolts at the NEW MACHINE MAINTENANCE time period (first 100 hours) and the EVERY 125 HOURS SCHEDULED MAINTENANCE time period.

3

•

DO NOT REMOVE

•

•

CW001-3

• 1

2

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

TRACK ADJUSTMENT TRACK SAG ADJUSTMENT

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

To tighten track, attach adjustment fitting adapter (3) onto valve body (1). Connect a grease gun to the grease fitting (2) on the adjustment fitting adapter (3). Add grease until track sag dimension is within recommended limits. Remove adjustment fitting adapter.

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

CAUTION: The grease is under very high pressure, DO NOT REMOVE the adjustment fitting valve body (1) from the idler adjusting cylinder (4).

When checking the torque values at the first 100 hours and every 125 hours thereafter use the CHECKING TORQUE values listed in the following paragraphs.

To loosen track, slowly loosen valve body (1) until grease begins to escape via a relief passage in the valve body housing, grease will be seen escaping from around valve body threads. When track sag is correct, tighten valve body.

If loose shoes or under torqued bolts are discovered during the FIRST 100 HOUR check, they should be removed, surfaces cleaned, and reused using the torque-turn method. If the shoe is not loose but a single bolt is low on torque, loosen the bolt and re torque-turn.

CW001-2

If loose or under torqued bolts are discovered any time after the 100 HOUR check, the bolts and nuts must be replaced with NEW ones, surfaces cleaned, and re torque-turned.

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

TORQUE 1

TRACK COMPONENT TORQUE VALUES 11.17

Tigercat 822 Feller Buncher

Track drive

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

Only bolts with grade '12.9' or '170' designation forged in the head are approved.

SINGLE GROUSER BERC-9

When checking the torque values at the first 100 hours and every 125 hours thereafter use the checking torque value.

DOUBLE GROUSER BERC-10

Track shoe bolts ~ 3/4" UNC TORQUE-TURN .............. 250LBF-FT. + 1/3 TURN. CHECKING TORQUE ........................ 450 LBF-FT.

TRIPLE GROUSER

Track shoe bolts ~ M24 BERC-1

TORQUE-TURN .............. 340LBF-FT. + 1/3 TURN.

GROUSER WEAR (HEIGHT)

CHECKING TORQUE ...................... 1040 LBF-FT.

WEAR LIMITS

BOTTOM ROLLER RETAINING BOLTS

TRACK SHOE GROUSER HEIGHT WEAR WEAR LIMITS New 75% wear 100% wear Single 2.82" (716.2mm) .... 1.37" (348mm) ......... 0.93" (236.2mm) Double 1.37"(348mm) ...... 0.71"(180.3mm)..... 0.43" (109.2mm) Triple 1.06" (269.2mm) .... 0.51" (129.5mm) ...... 0.36" (91.4mm)

The bottom rollers must be fastened to the lower frame applying the exact torque values shown below.

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

When checking the torque values at the first 100 hours and every 125 hours thereafter use the torque value(s) shown below.

NOTE: Allowable wear for soft ground conditions is 100%. Allowable wear for rocky ground conditions is 75%.

NOTE: Two sizes of bolts have been used to fasten the rollers to the lower frame; 3/4" UNC; and on later machines 7/8" UNC. Bottom roller bolts ~ 3/4" UNC TORQUE ........................................... 310 LBF-FT. Bottom roller bolts ~ 7/8" UNC TORQUE ........................................... 475 LBF-FT. BERC-2

For a complete maintenance check Refer to the PREVENTIVE MAINTENANCE SCHEDULE in SECTION 3 of this manual.

TRACK LINK WEAR (HEIGHT)

TRACK LINK WEAR WEAR LIMITS New link height ......................... 4.78" 50% wear ................................. 4.60" 75% wear ................................. 4.48" 100% wear ............................... 4.34"

11.18

(121.5mm) (116.8mm) (113.8mm) (110.2mm)

Tigercat 822 Feller Buncher

Track drive

PIN AND BUSHING WEAR

BUSHING WEAR, OUTSIDE DIAMETER

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

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

45°

45°

FORWARD SIDE VERTICAL WEAR WEAR BERC-3

MEASURING TRACK PITCH

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

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

INTERNAL PIN & BUSHING WEAR

ROTATION

MEASURING BUSHING WEAR

BERC-5

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

WEAR LIMITS New bushing O.D. ......................... 2.62" (66.6mm) 75% worn ...................................... 2.5" (63.5mm) 100% worn .................................... 2.43" (61.7mm) NOTE: Allowable wear in rocky ground is 75% BOTTOM ROLLER WEAR

180° EXTERNAL BUSHING WEAR

REVERSE SIDE WEAR

TURN PIN & BUSHING 180°

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

BERC-4 PIN/BUSHING INTERNAL WEAR NOTE: Wear to the pins and bushings only occurs in a small localised area, to extend the life of these components, the pins and bushings may be turned 180° or replaced provided other components are within specified wear limits:

1. Track link wear is 75% or less.

2. Change in track pitch is 32.50:" (825.5mm) per link or less.

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

BERC-6

MEASURING BTM. ROLLER WEAR

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

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

WEAR LIMITS New length of four sections .............. 32" (813.0mm) 75% worn .......................................... 32.37" (822.2mm) 100% worn ......................................... 32.50" (825.5mm)

WEAR LIMITS New roller. .................................... 8.26" (210.0mm) 75% worn ..................................... 7.64" (194.0mm) 100% worn ................................... 7.36" (187.0mm)

NOTE: Allowable wear in rocky ground is 75% NOTE: These wear limits are to be used as a guide for when to turn the pins and bushings. If pins and bushings are not to be turned, the chain can be run past the 100% wear limit, until chain failure.

11.19

Tigercat 822 Feller Buncher IDLER WEAR Measure the idler wheel side diameters (tread contact surface) at several points to obtain the worst wear condition. Position a depth gauge or measuring tape as close as possible toward the centre of the idler with the gauge flat on the centre flange and parallel to the idler shaft.

Track drive visible, the measuring may be done using a "go/no go" gauge made from a piece of 1/8" flat bar. The gauge is inserted down through the holes in the track and placed between the track guide and the track bushing. Make sure that dirt build-up does not interfere with the reading. Check at several locations. The ends of the track slides tend to wear first. The slides should be replaced if excessive wear is found.

'A'

BERC-7

'A'

MEASURING IDLER WEAR

WEAR LIMITS New idler dimension ...................... 0.85"(22.0mm) 100% wear .................................... 1.18"(30.0mm)

TRACK SLIDE WEAR

845-32

TRACK SLIDE WEAR

Track slide wear should be checked periodically to ensure that it does not go over the limit and cause damage to the chain link bushings.

CHAIN LINK

Since the checking area is not immediately

•

•

CHECK THIS DIMENSION

•

CHAIN LINK BUSHING TRACK GUIDE

•

TRACK SLIDE

845-33

SECTION A - A

1/8"

845-33A

SUGGESTED MEASURING GAUGE The wear occurs on the top of the track slide as the chain links slide along and this wear will reduce the clearance between the track guide and the chain link bushings. When this clearance disappears the chain link bushings will start to wear.

11.20

Tigercat 822 Feller Buncher

SECTION 12 - BOOM FUNCTIONS JUNE 2003

CONTENTS - SECTION 12 ADJUST OIL FLOW TO CYLINDERS (CYLINDER CYCLE TIMES ................ 12.8 BOOM CONTROL VALVE ............................................................................ 12.3 BOOM SYSTEM DESCRIPTION 'ER' BOOM SYSTEM ................................................................................ 12.2 STANDARD BOOM ................................................................................... 12.2

SEE ALSO SECTION 4

CIRCUIT DIAGRAM 'ER' BOOM SYSTEM ................................................................................ 12.5 'STANDARD' BOOM SYSTEM .................................................................. 12.4 CYLINDER CYCLE TIMES, TYPICAL ........................................................... 12.9 ENGINE ANTI-STALL .................................................................................... 12.3

SEE ALSO SECTION 4

LOAD SENSING ........................................................................................... 12.3

SEE ALSO SECTION 9

SET MAIN BOOM, STICK AND TILT PORT RELIEF VALVES ...................... 12.6 TILT CYLINDER FLOW ADJUSTMENT ............................................. 12.3, 12.10

Tigercat 822 Feller Buncher BOOM SYSTEM DESCRIPTION

Boom functions

STANDARD BOOM Two cylinders are used to raise and lower the main boom.

The stick boom and the tilt each use identical single cylinders.

These cylinders receive oil from the main pump via three spool sections on the main hydraulic valve.

Two joystick handles in the cab control the movement of each cylinder by directing pilot oil to the pilot end caps on each end of the appropriate spool sections to shift the spool and move the cylinder(s).

'ER' BOOM SYSTEM An additional REACH cylinder is plumbed into the above boom system to allow movement of the boom system to be controlled by the LEFT and RIGHT joystick levers. Simply pushing the LEFT joystick FORWARD moves the boom straight out or pulling back on the joystick moves the head towards the machine. The right joystick moves the boom system UP or DOWN. For additional information regarding SAFETY and OPERATING INSTRUCTIONS, Refer to ER BOOM SYSTEM in SECTION 1 of THIS MANUAL and SECTION 2 in the OPERATOR'S MANUAL.

12.2

Tigercat 822 Feller Buncher CONTROL VALVE MANIFOLD

Boom functions

TILT 'BACK' STICK 'IN' PORT RELIEF PORT RELIEF

HIGH PRESSURE LIMITING CONTROL

FLOW TANK ADJUSTING PORT 'T3' SCREW FOR PORT 'A' (TYPICAL)

MAIN BOOM 'DOWN' PORT RELIEF

•• ••

••

••

•

••

••

B

B

B

B

B

B

B

A

A

A

A

A

A

A

• LH DRIVE

•• RH DRIVE

• TILT 'FORWARD' PORT RELIEF

•

•

STICK 'OUT' PORT RELIEF

WRIST

• MAIN BOOM 'UP' PORT RELIEF

• SWING

MAIN CONTROL VALVE

822-D63

BOOM CONTROL VALVE The boom, stick and tilt spool sections each have port relief valves with anticavitation features.

These protect the circuit from abnormally high pressures induced by the load.

Adjustable spool travel stops on each pilot end cap of the spool sections can be adjusted to limit spool travel and control the flow of oil to the cylinder, which in turn controls the operating speed of the cylinders.

An additional flow control adjusting screw (restrictor) located on the top of the main valve manifold is used to regulate the flow of return oil from the rod end of the TILT cylinder.

This adjustment is to compensate for the weight of trees in the felling head causing the head to TILT FORWARD too fast. Tilting forward too fast can cause oil to cavitate in the base end of the tilt cylinder.

For adjusting procedure refer to TILT CYLINDER (ROD END) FLOW ADJUSTMENT in THIS SECTION. To adjust the relief valves, Refer to SET MAIN BOOM, STICK AND TILT PORT RELIEF VALVES in THIS SECTION. To adjust oil flow, Refer to ADJUST OIL FLOW TO CYLINDERS in THIS SECTION. LOAD SENSING\ENGINE ANTI-STALL The boom hydraulics along with the swing, track drive, wrist and track drive circuits are all under the control of the load sensing system incorporated into the main hydraulic circuit.

• •

• TOP OF CONTROL VALVE MANIFOLD

For a full description of the main hydraulic system including load sensing, the main pump and the main control valve, Refer to SECTION 4 in THIS MANUAL.

TILT 'BACK' PILOT END CAP

For a full description of the engine anti-stall, Refer to SECTION 9 in THIS MANUAL.

FLOW CONTROL ADJUSTING SCREW - TILT

For a full description of the pilot system including the joystick handles, Refer to SECTION 5 in THIS MANUAL.

870B-D16

ADJUSTING SCREW

12.3

Tigercat 822 Feller Buncher

822-12

Boom functions

'STANDARD' BOOM SYSTEM CIRCUIT DIAGRAM 12.4

Tigercat 822 Feller Buncher

822-13

Boom functions

'ER' BOOM SYSTEM CIRCUIT DIAGRAM 12.5

Tigercat 822 Feller Buncher WARNING

Boom functions SET MAIN BOOM, STICK AND TILT PORT RELIEF VALVES NOTE: Constant loosening and tightening of the locknut (sealnut) on the port relief valve adjusting screws will eventually cause the seal in the nut to break down and leak.

Because of this it is best to keep the adjusting procedure brief.

'ER' BOOM SYSTEM When setting up a machine equipped with an (ER) boom system, the following points must be noted.

The main and stick boom cylinder circuits are connected hydraulically. Thus, disconnecting a hydraulic line to a boom cylinder may cause either boom to move unexpectedly. The boom may also move unexpectedly if a port relief adjusting screw is unscrewed (counterclockwise) too far and the pressure drops below that which is required to hold the weight of the boom and head. Ensure that the attachment is resting squarely on a solid footing, tank pressure is relieved and engine is shut off before disconnecting any hydraulic lines. See FIG. 1.

Also note that because of the hydraulic connection between the main boom and ER cylinders, the ER cylinder can overpower the stick cylinder under certain conditions, causing the stick boom to move unexpectedly.

This most often occurs when setting the MAIN BOOM UP relief valve, causing the stick to extend, but it may also happen at other times if the relief settings are not correct. Ensure that all personnel and equipment are clear of the boom path and that there is sufficient overhead clearance for the head to rise before making any adjustments.

STICK CYLINDERS FULLY EXTENDED

1. With hydraulic oil at operating temperature, LINDE MAIN VALVE MANIFOLD

•• ••

•

•• L.S. GAUGE TEST PORT

'P' GAUGE TEST PORT LS PRESSURE ADJUSTMENT P2

• LINDE MAIN VALVE MANIFOLD 2. Connect a 0-5000 psi pressure gauge on 'P' test port of Linde main valve manifold.

103-17A

3. Start engine and place throttle control in IDLE position. NOTE; It may be necessary to increase the engine RPM sufficiently to prevent the engine from stalling.

SPOOL TRAVEL STOP • 19mm WRENCH • 6mm ALLEN KEY

•

•

830-07

SERVICE POSITION FIG.1

•

PORT RELIEF VALVE

90744-3

• •

LOCKNUT • 17mm WRENCH

MAIN VALVE BODY

PILOT END CAP

•

ADJUSTING SCREW • 5mm ALLEN KEY

TIP OF STICK BOOM FULLY SUPPORTED

HIGH PRESSURE LIMITING CONTROL

•

MAIN VALVE PORT RELIEF VALVE

4. From inside the cab close and latch the front door and press the PILOT RESET switch to activate the pilot system.

12.6

Tigercat 822 Feller Buncher

Boom functions NOTE: Observe the pressure gauge at 'P' port when making these adjustments, it will fall and rise as the adjusting screw is being turned and should show 4700 psi as the hissing sound begins to subside or until engine stops lugging.

5. Place ANTI-STALL switch in OFF position.

6. Turn port relief valve adjusting screws for functions being set fully IN (clockwise). Do not overtighten or breakage will result.

7. With the aid of an assistant, bottom out the cylinder of the function being set and adjust L.S. pressure relief valve on Linde main valve manifold to 4700 psi on pressure gauge at 'P' port. Tighten locknut on adjusting screw.

10. Tighten locknut on adjusting screw taking care NOT to turn the adjusting screw at the same time.

11. Check the setting again by ensuring that the hissing noise is still absent after tightening the locknut.

MAIN BOOM PORT RELIEFS: NOTE: When making these relief adjustments, the upper should be positioned with the boom in the straight ahead position between the tracks.

12. With an assistant holding R.H. joystick in MAIN BOOM DOWN position (fully retracted), loosen locknut on the main boom DOWN port relief valve cartridge and slowly unscrew adjusting screw (counterclockwise) until oil can be heard (hissing noise) flowing through the relief valve or engine begins to lug slightly.

WARNING When adjusting the port relief valves, the boom will fall if the relief adjusting screw is unscrewed (counterclockwise) out too far.

13. Slowly raise setting (clockwise) until hissing noise stops or until engine stops lugging.

8. With an assistant holding R.H. joystick in MAIN BOOM UP position (fully extended), loosen locknut on the main boom UP port relief valve cartridge and slowly unscrew adjusting screw (counterclockwise) until oil can be heard (hissing noise) flowing through the relief valve or engine begins to lug slightly.

NOTE: Observe the pressure gauge at 'P' port when making these adjustments, it will fall and rise as the adjusting screw is being turned and should show 4700 psi as the hissing sound begins to subside or until engine stops lugging.

14. Tighten locknut on adjusting screw taking care NOT to turn the adjusting screw at the same time.

9. Slowly raise setting (clockwise) until hissing noise stops or until engine stops lugging.

CONTROL VALVE MANIFOLD

TILT 'BACK' PORT RELIEF

STICK 'IN' PORT RELIEF

HIGH PRESSURE LIMITING CONTROL

FLOW TANK ADJUSTING PORT 'T3' SCREW FOR PORT 'A' (TYPICAL)

MAIN BOOM 'DOWN' PORT RELIEF

•• ••

••

822-D63

•

••

••

B

B

B

B

B

B

B

A

A

A

A

A

A

A

•• LH DRIVE

••

•• RH DRIVE

• TILT 'FORWARD' PORT RELIEF

•

••

STICK 'OUT' PORT RELIEF

WRIST

MAIN CONTROL VALVE 12.7

• MAIN BOOM 'UP' PORT RELIEF

• SWING

Tigercat 822 Feller Buncher

Boom functions

15. Check setting again by ensuring that the hissing noise is still absent after tightening the locknut.

4. Place ANTI-STALL switch in OFF position.

MAIN BOOM CYLINDER(S); 5. Fully retract cylinder(s).

STICK AND TILT PORT RELIEFS 16. Repeat steps 8 thru' 15 to set the port relief valves for the STICK 'IN' and 'OUT' and the TILT 'FORWARD' and 'BACK' functions.

6. Place MAIN BOOM joystick lever in 'FULL UP' position and fully ** extend cylinders. Record cycle time from stop to stop.

17. Readjust L.S. pressure relief valve on Linde main valve manifold to read 4300 psi on pressure gauge at 'P' port (4000 psi at 'LS' port). Refer to SET LOAD SENSE RELIEF VALVE in SECTION 4 of THIS MANUAL.

7. Place MAIN BOOM joystick lever in 'FULL DOWN' position and fully ** retract cylinders.

Record cycle time from stop to stop.

STICK BOOM CYLINDER; 8. Repeat steps (5), (6) and (7) using STICK BOOM joystick lever.

18. Stop engine, remove all gauges and reinstall plugs and caps.

TILT CYLINDER; NOTE: Before the TILT cylinder cycle times can be recorded, the rod end flow control adjusting screw must first be set correctly.

ADJUST OIL FLOW TO CYLINDERS (CYLINDER CYCLE TIMES) NOTE: Constant loosening and tightening of the locknut (sealnut) on the adjusting screws will eventually cause the seal in the nut to break down and leak. Because of this it is best to keep the adjusting procedure brief.

1. Ensure hydraulic oil is at operating temperature.

See TILT CYLINDER (ROD END) FLOW ADJUSTMENT in THIS SECTION. 9. Repeat steps (5), (6) and (7) using TILT joystick lever. ** When extending or retracting cylinders to record the time, stop the cylinder just before it gets to the end of it's stroke rather than let it bottom out and impose unnecessary loads on the cylinder parts and boom structures.

2. Start engine and place engine throttle control in FULL position.

3. From inside the cab close and latch the front door and press the PILOT RESET switch to activate the pilot system.

CONTROL VALVE MANIFOLD

TILT 'BACK' STICK 'IN' PORT RELIEF PORT RELIEF

HIGH PRESSURE LIMITING CONTROL

FLOW TANK ADJUSTING PORT 'T3' SCREW FOR PORT 'A' (TYPICAL)

MAIN BOOM 'DOWN' PORT RELIEF

•• ••

••

822-D63

•

••

••

B

B

B

B

B

B

B

A

A

A

A

A

A

A

•• LH DRIVE

••

•• RH DRIVE

• TILT 'FORWARD' PORT RELIEF

•

••

STICK 'OUT' PORT RELIEF

WRIST

MAIN CONTROL VALVE 12.8

• MAIN BOOM 'UP' PORT RELIEF

• SWING

Tigercat 822 Feller Buncher

Boom functions

TYPICAL CYLINDER CYCLE TIMES The chart below lists typical cylinder cycle times and is based on recommended factory settings and with hydraulic oil at operating temperature. It should be noted that over adjusting to provide faster cycle times will increase the stress on boom components and the hydraulic system.

CYCLE TIMES - 822/H822/L830/LH830 ER BOOM BOOM FUNCTIONS TIME W/STD TILT TIME W/4-LINK MAIN BOOM UP SEE NOTE* SEE NOTE* MAIN BOOM DOWN 8 sec.

8 sec.

STICK BOOM OUT 4.5 sec.

4.5 sec.

STICK BOOM IN 4.5 sec.

4.5 sec.

TILT FORWARD 3.8 sec.

4.0 sec.

TILT BACK 3.8 sec.

4.0 sec.

30° WRIST RIGHT 2.5 sec.

2.5 sec.

30° WRIST LEFT 2.5 sec.

2.5 sec.

340° WRIST RIGHT 9.5 sec.

9.5 sec.

340° WRIST LEFT 9.5 sec.

9.5 sec.

2 CYL WRIST RIGHT (110° ROTATION) 6 sec.

6 sec.

2 CYL WRIST LEFT (110° ROTATION) 6 sec.

6 sec.

TELESCOPIC STICK OUT 4 sec. n/a TELESCOPIC STICK IN 4 sec. n/a

To adjust cycle times; Loosen locknut on spool adjusting screw on main control valve and turn adjusting screw IN (clockwise) to slow down and OUT (counterclockwise) speed up. Tighten locknut on adjusting screw and re-check times.

PORT CONNECTIONS: The 'A' ports (bottom ports) are connected to the base end of the cylinders and the 'B' ports (top ports) are connected to the rod end of the cylinders.

To adjust the flow rate at 'A' PORTS, adjust spool travel stop adjusting screw located at TOP of valve and vice-versa for 'B' ports. See figure 822-D63.

*

NOTE : The main boom UP on the ER' boom system is not set by a cycle time; The spool stop adjusting screw must be adjusted so that the felling head will rise slightly as the boom system is moving OUT. If set too LOW the felling head will fall to the ground as the boom system is moving OUT or, if set too HIGH the felling will rise too fast.

12.9

NON-ER BOOM TIME W/STD TILT TIME W/4-LINK 5.5 sec.

5.5 sec.

6 sec.

6 sec.

4.6 sec.

4.6 sec.

4.8 sec.

4.8 sec.

5.6 sec.

5.6 sec.

5.0 sec.

5.0 sec.

2.5 sec.

2.5 sec.

2.5 sec.

2.5 sec.

9.5 sec.

9.5 sec.

9.5 sec.

9.5 sec.

6 sec.

6 sec.

6 sec.

6 sec.

4 sec. n/a 4 sec. n/a

Tigercat 822 Feller Buncher

Boom functions

TILT CYLINDER (ROD END) FLOW AND SPEED ADJUSTMENT This adjusting screw restricts the flow of oil leaving the rod end of the TILT cylinder when tilting FORWARD.

7. Loosen locknut on restriction adjustment screw. While holding joystick in the fully TILT FORWARD position, observe pressure gauge and record the TILT travel speed from stop to stop**. Use the restriction adjustment screw to adjust the speed and use the spool travel stop adjustment on the main control valve to maintain 800-1000 psi pump pressure.

If the TILT speed is too fast, screw restriction adjustment screw IN. If the TILT speed is too slow, screw the restriction adjustment screw OUT.

• •

• TOP OF CONTROL VALVE MANIFOLD

If the pump pressure reading is too low increase flow by screwing TILT spool travel stop adjusting screw (bottom adjuster) OUT. Or if the pressure is too high, decrease the flow by screwing the adjusting screw IN.

TILT 'BACK' PILOT END CAP ADJUSTING SCREW

870B-D16

NOTE: The Tilt restriction and (to a lesser extent) the spool travel stop adjustment both affect the TILT forward speed. Similarly, the TILT restrictor has a small affect on the pump pressure. Alternate between adjustments making moderate changes until the desired speed and pressure ranges are achieved.

FLOW CONTROL ADJUSTING SCREW - TILT When correctly set, this restriction will prevent cylinder damage.

1. Ensure hydraulic oil is at operating temperature.

LINDE MAIN VALVE MANIFOLD

HIGH PRESSURE LIMITING CONTROL

8. Tighten locknut on restriction adjustment screw taking care NOT to turn the adjusting screw at the same time.

9. Check the pressures again after tightening the locknut.

• ••

••

••

10. Stop engine and remove gauge.

L.S. GAUGE TEST PORT 'P' GAUGE TEST PORT LS PRESSURE ADJUSTMENT P2

•• 103-17A

LINDE MAIN VALVE MANIFOLD

2. Connect a 0-5,000 psi pressure gauge on 'P' test port of Linde main valve manifold.

3. Start engine and place throttle control in FULL. 4. From inside the cab close and latch the front door and press the PILOT RESET switch to activate the pilot system.

5. Place ANTI-STALL switch in OFF position.

6. Raise boom and place felling head in fully TILT BACK position (cylinder fully retracted).

12.10

Tigercat 822 Feller Buncher

SECTION 15 - SWING JUNE 2003

CONTENTS - SECTION 15 ADJUST OIL FLOW TO SWING MOTOR(SWING MOTOR SPEED) ............. 15.5 CIRCUIT SCHEMATIC ................................................................................... 15.3 LUBRICATE GEARBOX LOWER BEARINGS ............................................... 15.4 SET SWING MOTOR SPEED ....................................................................... 15.5 SWING BEARING WEAR LIMITS ................................................................. 15.8 SWING DRIVE SWING HYDRAULICS ............................................................................... 15.2 SET CROSSLINE RELIEF VALVES ...................................................... 15.4 SWING DRIVE GEARBOX LUBRICATION OF LOWER BEARING ....................................................... 15.4 SUN GEAR INSTALLATION ...................................................................... 15.7 SWING MOTOR REMOVAL FROM GEARBOX ............................................ 15.6

Tigercat 822 Feller Buncher MOTOR

Swing R.H. ROTATION

CROSSLINE RELIEF VALVES

•• •••

•

L.H. ROTATION

SWING BRAKE

The swing gearbox upper gearing is lubricated by hydraulic oil which flows from the oil cooler bypass/return manifold into the 'U' port on the swing drive gearbox. A 1/16 inch orifice/connector installed in the 'U' port regulates the flow of oil through the gearbox at approximately 1 GPM. Oil is returned to tank via flushing port 'T'.

ALTERNATE BRAKE RELEASE PORT 'Z' (PLUGGED)

STEEL DISC FRICTION DISC

FLUSHING PORT 'T'

1/16" DIA. ORIFICE CONNECTOR PORT 'U'

• ••

CONNECTOR/ ORIFICE 0.062" DIA

FLUSHING PORT 'U'

• •

• •

• •

GEARBOX

• BRAKE RELEASE PORT 'Y'

•• 845B-D32

SWING DRIVE GEARBOX BK005-8

CROSS SECTION OF SWING BRAKE

SWING DRIVE -SWING HYDRAULICS

CONNECTOR/ ORIFICE 0.062" DIA

The swing function is controlled by the left joystick valve which sends proportional pilot signals to the main valve which, in turn, supplies oil to the swing motor.

SWING BRAKE

•

The swing motor is a piston motor with crossline relief valves mounted on the input end. The crossline relief valves provide a cushion to the high forces that occur during start and stop of the boom swing.

GEARBOX FLUSHING OIL SUPPLY FROM OIL COOLER BYPASS/ RETURN MANIFOLD

FROM BRAKE RELEASE PILOT

Power is transmitted from the motor to a double reduction planetary gearbox which has a springapplied, hydraulic-release, multi-disc brake on the input shaft. This brake is normally ON. Placing the swing brake switch in the OFF position energizes the swing brake solenoid pilot valve on the pilot manifold and allows pilot oil pressure to flow to the swing brake via port 'Y', to release the swing brake.

•

• CROSS LINE RELIEF VALVES

PRESSURE LINES FROM MAIN CONTROL VALVE

WARNING Never drive machine with swing brake applied. If felling head makes contact with an immoveable object, forces could damage swing drive gearbox.

830-16

Port 'Z' contains an internal orifice but the port is plugged and not used.

In the event that electrical power to the solenoid pilot valve or hydraulic pressure to the pilot valve is lost, the swing brake will engage (ON) automatically.

15.2

SWING DRIVE MOTOR SCHEMATIC

Tigercat 822 Feller Buncher

Swing

SWING DRIVE CIRCUIT 822-11

15.3

Tigercat 822 Feller Buncher

Swing

LUBRICATION OF SWING DRIVE GEARBOX LOWER BEARINGS The cavity in the lower portion of the gearbox where the two lower bearings are housed is completely filled with grease.

SET CROSSLINE RELIEF VALVES 1. Ensure that the hydraulic oil is at operating temperature.

2. Install a 0-5000 psi pressure gauge in the 'L.S.' test port on the back of the main valve manifold.

LUBE FITTINGS

•

LINDE MAIN VALVE MANIFOLD

••

HIGH PRESSURE LIMITING CONTROL

• •

••

L.S. GAUGE TEST PORT

845B-D33

LUBRICATE GEARBOX LOWER BEARINGS To gain access to the lube fitting, remove the cover plate directly below the gearbox. Using a hand grease gun, pump 5 shots of grease into each grease fitting. Follow the lubricating procedure on the label located beside the grease fittings and also refer to SCHEDULED MAINTENANCE - 250 HOURS, in SECTION 3 of THIS MANUAL

••

'P' GAUGE TEST PORT

103-17A MAIN VALVE MANIFOLD 3. Start engine and place throttle control in FULL.

4. Turn anti-stall switch OFF and the swing brake ON. 5. While operating the L.H. joystick lever fully in both the LEFT and RIGHT directions, loosen locknut on each crossline relief adjusting screw and turn adjusting screw until the reading on pressure gauge in 'L.S.' test port is 3300 psi. for each direction.

If pressure gauge is installed in 'P' test port, reading on gauge would be 3600 psi.

CROSSLINE RELIEF VALVES L.H. ROTATION

•• ADJUSTING SCREWS 111-6

••••

R.H. ROTATION

• • •• • CROSSLINE RELIEF

6. Retighten locknut on each adjusting screw taking care not to disturb adjusting screw and recheck pressure setting before removing pressure gauge.

7. Stop engine, remove gauge and reinstall plug.

15.4

Tigercat 822 Feller Buncher

Swing

ADJUST OIL FLOW TO SWING MOTOR (SWING MOTOR SPEED)

SPOOL TRAVEL STOP • 19MM WRENCH • 6MM ALLEN KEY

NOTE: Constant loosening and tightening of the locknut (sealnut) on the adjusting screws will eventually cause the seal in the nut to break down and leak. Because of this it is best to keep the adjusting procedure brief.

PILOT END CAP

•

MAKE UP VALVE

1. Ensure that the hydraulic oil is at operating temperature.

2. Start engine and place engine throttle control in FULL position.

•

MAIN VALVE BODY

3. Raise felling head off ground and place L.H. joystick lever in 'FULL LEFT' position and rotate the upper. Record time for one complete revolution.

• 90919-1

4. Repeat step (3) with L.H. joystick lever in 'FULL RIGHT' position.

MAIN VALVE SPOOL TRAVEL STOP

5. To adjust swing speed; (Refer to main valve photo and fig. 90919-1) Loosen locknut on spool travel stop adjusting screw and turn adjusting screw IN (clockwise) to slow down and OUT (counterclockwise) speed up. Tighten locknut on adjusting screw and re-check times.

The recommended factory setting is between 6 and 7 RPM. It should be noted that over adjusting to provide a faster swing speed increases the stress on boom components and increases the heat load in the hydraulic system.

CONTROL VALVE MANIFOLD

•

HIGH PRESSURE LIMITING CONTROL

••

FLOW ADJUSTING SCREW FOR PORTS ON 'A' SIDE OF VALVE (TYPICAL)

FLOW ADJUSTING SCREW FOR SWING LEFT

•

•

•• B

B

B

B

B

B

B

A

A

A

A

A

A

A

••

••

•

•

•

••

•• LH DRIVE 822-D63

RH DRIVE

TILT

STICK

WRIST

MAIN CONTROL VALVE 15.5

MAIN BOOM

FLOW ADJUSTING SCREW FOR SWING RIGHT

TANK PORT 'T3'

•

Tigercat 822 Feller Buncher •

SWING DRIVE MOTOR M16 HEX. HD. RETAINING BOLTS TORQUE TO 150 LBF/FT (205 NM) SWING BRAKE ASSY.

Swing CROSS LINE RELIEF HOUSING

•

PROCEDURE: 1. Remove the swing drive motor from the swing drive gearbox.

SUN GEAR M12 HEX. HD. RETAINING BOLTS TORQUE TO 62 LBF/FT

• •

ALIGNMENT MARKS

•

••

GEARBOX

•

•

AQ009-4

2. Make alignments mark on the sun gear and brake housing to facilitate reassembly of the sun gear back into the swing drive gearbox.

These alignment marks should guarantee that both the brake disc and the first stage planetary gear teeth will be in alignment with the sun gear splines and bottom gear teeth, provided nothing has moved.

SWING PINION

• BK010-2

SWING DRIVE ASSEMBLY

DISASSEMBLY AND ASSEMBLY OF SWING MOTOR FROM GEARBOX When the swing drive motor is removed from the swing drive gearbox for inspection or repair, there is a possibility that the sun gear may not mesh properly with the first stage planetary gears when it is reinstalled. This will cause premature failure of the swing drive gearbox.

Installing the sun gear involves lining up all of the brake discs so that the outer splines on the sun gear can slide through the brake discs allowing the bottom gear teeth to mesh properly with the first stage planet gears.

BRAKE HOUSING WITH MOTOR REMOVED

3. Remove the sun gear from the swing drive gearbox and inspect the gear teeth at the bottom of the sun gear for abnormal damage or wear.

If there is no visible damage to the gear teeth, proceed to step (6). If there is visible damage to the sun gear, it must be replaced, proceed to step (4).

4. If the sun gear in step (3) has visible signs of damage, then the first stage planetary gears must also be inspected. Remove the brake assembly and inspect the first stage planetary gears for visible damage. If there is no visible damage, proceed to step (5). If there is visible damage to the first stage planetary gears, then the entire swing drive gearbox should be replaced.

5. Assuming that there is no visible damage to the first stage planetary gears, reassemble the brake assembly back onto the swing drive gearbox and secure it by reusing the six M12x30mm hex head bolts. Torque each hex head bolt to 62 lbf/ft (84 Nm).

15.6

Tigercat 822 Feller Buncher M12 HEX. HD. RETAINING BOLTS

SUN 'O' RING BRAKE HOUSING GEAR

Swing MOTOR MOUNTING SURFACE

MOTOR

• •

•

• 1-5/16" ± 1/16"

• • 'O' RING

• • • BRAKE DISCS

FIRST STAGE PLANETARY GEARS (3)

• BOTTOM GEAR TEETH ON SUN GEAR

BK005-6

VERIFY SUN GEAR IS FULLY INSTALLED 6. Reinstall the sun gear into the swing drive gearbox using the alignment marks made in step (2). Verify that the sun gear is properly and fully engaged into the swing drive gearbox, i.e.; That the outer splines on the sun gear have passed through all of the brake discs.

This can be done by measuring the distance between the swing motor mounting surface and the top of the flat surface of the sun gear (1 5/16” ± 1/16”).

7. Verify that the O-ring is properly seated and secured on the swing motor. If there is any difficulty in securing it in place, use a small amount of petroleum jelly on the O-ring for assistance.

8. Center the spacer ring on top of the sun gear and install the swing drive motor. Torque the two M16 mounting bolts to 150 lbf/ft (205 Nm).

15.7

Tigercat 822 Feller Buncher SWING BEARING WEAR LIMITS It is important that the swing bearing be periodically inspected for wear. Any significant wear will be noticeable by observing too much "tilting" of the upper frame relative to the lower frame. A small amount of designed-in clearance in the bearing is normal and is present in a new machine.

Too much clearance will affect the backlash between the ring gear and the drive pinion and if left unchecked will cause damage to the gear teeth and ultimately the swing drive gearbox.

The main cause of wear in the ball race can be due to a lack of lubricant or not following the proper lubricating procedure. A damaged or missing peripheral seal will also contribute to early wear by allowing dirt particles to enter the ball race.

Swing The following procedure will verify the amount of wear in the ball race: 1. Position machine with boom fully extended as in position 1.

2. Set indicator to zero.

3. Lower boom as in position 2.

4. Note tilt reading on indicator.

5. Return machine to position 1.

6. Check to see if reading on indicator has returned to zero, if not repeat steps 1 thru 4.

7. Rotate upper frame 90 deg. and repeat steps 1 thru 6.

8. The bearing is considered to be worn when the total play is 0.105" or greater.

Regular inspection of the seal should be carried out and the proper lubricating procedure should be followed. Refer to FILTER AND LUBRICATION SCHEDULE in SECTION 3 of THIS MANUAL.

••

15.8

NOTE: MAGNETIC BASE OF DIAL INDICATOR MUST BE MOUNTED TO BEARING MOUNTING FLANGE AS SHOWN AND NOT TO UNDERCARRIAGE CROSS FRAME.

Tigercat 822 Feller Buncher SECTION 17 - SAW DRIVE JUNE 2003

CONTENTS - SECTION 17 CIRCUIT DESCRIPTION ................................................................................ 17.6 CIRCUIT DIAGRAM ....................................................................................... 17.7 CONTROL VALVES SAW PILOT VALVE .................................................................................. 17.4 FELLING HEAD .......................... SEE ORIGINAL MANUFACTURERS MANUAL PRESSURE SETTINGS ................................................................................ 17.8 SAW CONTROL VALVES MAIN SAW CONTROL VALVE .................................................................. 17.4 MAIN SAW CONTROL VALVE OPERATING DESCRIPTION .................... 17.4 SAW PILOT VALVE .................................................................................. 17.4 SAW PUMP ................................................................................................. 17.2

Tigercat 822 Feller Buncher

Saw drive

SAW PUMP The saw pump is an axial-piston variable displacement pump controlled by a pressure compensator. The pressure compensator is mounted directly onto the pump and has a STANDBY pressure adjustment and a P.O.R. adjustment.

The STANDBY adjusting screw is screwed completely in and is NOT used for this application. The P.O.R. is adjusted to operate at 3600 psi.

Until system pressure reaches 3600 psi, the compensator valve will be in the "return" position blocking oil flow to the swashplate control piston leaving the pump at maximum displacement.

SAW PUMP SCHEMATIC

822-17

The pump is mounted and driven off the end of the main pump attached to the bell housing of the engine.

A separate fixed displacement pump is mounted on the back of the saw pump for the clamp and cooling fan functions.

SAW PUMP PRESSURE COMPENSATOR SAW PUMP

• 422-08

•

••

PUMP ASSEMBLY

17.2

MAIN PUMP

•

CLAMPS/FAN PUMP

Tigercat 822 Feller Buncher

Saw drive

•

SAW PUMP PRESSURE COMPENSATOR VALVE

INPUT SHAFT CONNECTION TO MAIN PUMP

•

AP098

SAW PUMP ~ SIDE VIEW

17.3

Tigercat 822 Feller Buncher

Saw drive

SAW CONTROL VALVES

DIN CONNECTOR

VALVE BODY

The saw circuit is controlled by a solenoid operated pilot valve and a pilot operated main control valve.

•

1

•

• 3

•

•

SAW PILOT VALVE CLAMPS/ SAW CONTROL VALVE

••

1

SOLENOID

SAW PILOT VALVE

AT022

MAIN SAW VALVE The main saw valve, located above the Linde main valve bank, is part of the clamps/saw valve.

It consists of an open center spool section and an inlet section containing a relief valve.

SAW PILOT VALVE

822-D67

CONTROL VALVE CARTRIDGE

SAW PILOT VALVE The saw pilot valve, mounted below the clamps/ saw control valve, consists of an aluminum body which is houses a solenoid operated control valve cartridge.

Two other spool sections along with one mid inlet section control the clamp and accumulator functions. Each spool section is pilot operated.

An electrical signal from the saw switch in the cab energizes the solenoid in the saw pilot valve to shift the spool and direct pilot oil to one end of the spool section of the main saw valve.

An outlet section directs return oil back to tank.

For further description of clamps/saw valve refer to SECTION 18 of THIS MANUAL. MAIN SAW VALVE OPERATING DESCRIPTION Oil (system pressure) enters the end inlet section of the main control valve. When the spool is centered (at rest) the oil is allowed to pass through the saw spool section into a common tank passage of the clamp and accumulating

RELIEF VALVE PORT 'A'

SEAL GROOVES

A

RELIEF VALVE PORT 'B'

B

SPOOL CENTERING SPRINGS

•

• • •

•

•

•

• •

•

• PILOT END CAP

AT047IL2

•

•

•

• SPOOL TANK PASSAGE

PARALLEL PASSAGE

LOAD CHECK VALVE

THRU' NEUTRAL PASSAGE

WORK PORT BRIDGE

CROSS SECTION OF SPOOL SECTIONS 17.4

TANK PASSAGE

PILOT END CAP

Tigercat 822 Feller Buncher

Saw drive These port relief valves must be screwed IN completely for proper operation of the saw circuit.

spool sections and back to tank via the outlet section. From the tank passage, the oil leaves the valve through the outlet section and returns to tank.

The relief valve installed in the saw inlet section of the main saw valve is set higher than the saw pump compensator pressure setting and will limit the pressure should a pump regulator or "swashing" failure occur.

The saw spool section has a self centering, three position spool which is open centered. A spring in the spool end cap holds the spool in the center neutral position.

The relief valve diverts oil to tank via the tank passages in the spool sections and the outlet section of the clamps/saw valve. It also functions as an anti-cavitation relief valve.

The spool is shifted by pilot pressure being applied to one end of the spool from the pilot valve. Shifting the spool directs oil from the saw pump to the saw motor.

The saw spool section is equipped with port relief valves which are NOT used in this application.

PILOT END CAPS MAIN (MID) RELIEF VALVE

•

SAW SECTION

GAUGE TEST PORT (FOR SAW ONLY)

••

OUTLET SECTION

•

•• CLAMPS

•

SAW

•

ACCUM.

• ••

MID INLET SECTION

822-D64

GAUGE TEST PORT (FOR CLAMPS)

SAW CONTROL VALVE (WITH CLAMPS SECTION) 17.5

END INLET SECTION (SAW)

Tigercat 822 Feller Buncher SAW CIRCUIT DESCRIPTION The saw blade (typically) is driven by a variable displacement hydraulic motor (axial piston, bent axis) which is mounted directly above the saw blade and coupled to the saw blade through a drive shaft.

The variable displacement saw pump supplies oil flow to the motor via the saw control valve. The main saw control valve is pilot operated and controls the flow of hydraulic oil from the saw pump to the saw motor. A relief valve is installed in the inlet section of the main saw control valve.

A solenoid operated pilot valve controls the flow of pilot oil to the end of the spool in the main saw control valve.

The saw switch located on the control panel in the cab is used to turn the saw ON or OFF. It is a two position switch controlling the flow of electrical current via a relay to the saw pilot valve solenoid.

An electrical signal from the saw switch energizes the solenoid in the saw pilot valve to shift the spool and direct pilot oil to one end of the spool section of the main saw control valve.

NOTE: Saw will not operate with pilot system OFF. Saw will not function properly with low pilot pressure.

NOTE: If the engine has been turned off or the pilot shut off system tripped (door opened) with the saw switch left in the ON position, the saw will not start up when the engine is restarted or the door closed. In this case press the PILOT RESET button and turn the saw switch OFF and then ON.

Saw drive With the main saw control valve spool in this neutral position, the hydraulic oil is directed through the open centre of the main control valve and back to tank. This prevents the saw pump from generating system pressure to rotate the blade, it also causes the saw pump to shift to maximum displacement.

When the saw switch is placed in the ON position, the solenoid operated saw pilot valve will be placed in the energized position directing pilot oil to shift the spool in the main saw control valve.

This will direct oil from the saw pump to the saw motor, causing the system pressure to rise and the saw blade to begin to rotate.

When the pressure (system pressure) builds up to 3600 psi the spool in the pump compensator valve shifts to direct oil to the pump swashplate control piston. The piston moves the swashplate towards the neutral position to cut back the flow of oil while at the same time maintaining the pressure and continuing to rotate the blade.

This system has a lower horsepower requirement and generates less heat since the pump reduces it's output flow instead of dumping hydraulic oil over relief valves.

The saw motor adjusts its displacement in response to system pressure, this is only true with variable displacement motors.

Return oil from the saw motor is directed back to tank through a return line with a 1 psi check valve installed at the tank connection.

For explanation of saw motor, refer to saw head manufacturers manual.

IMPORTANT: To maximize pump and motor life, do not shut the engine off until the saw blade has come to a complete stop.

With the saw switch in the OFF position, the solenoid operated pilot valve is in the deenergized position preventing pilot oil flow from shifting the spool in the main saw control valve.

17.6

Tigercat 822 Feller Buncher

822-09

Saw drive

SAW CIRCUIT 17.7

Tigercat 822 Feller Buncher

Saw drive

PRESSURE SETTINGS:

P.O.R. VALVE (3600 PSI)

PUMP AND SAW CONTROL VALVE

STANDBY VALVE

1. Park machine on level ground, lower the felling head to the ground, engage the swing brake and stop engine.

2. Block saw blade from rotating as per method outlined in saw head manufacturer’s manual.

•

3. Ensure that the hydraulic oil is at operating temperature.

217-21

•

PRESSURE COMPENSATOR VALVE

4. Install a 0-5000 PSI pressure gauge on saw valve gauge test port.

SAW PUMP PRESSURE COMPENSATOR

5. On the pump compensator valve; •

Slacken jamnut on P.O.R. adjusting screw, and turn adjusting screw all the way in.

CAUTION: Do not use excessive force; stop when the resistance increases sharply. Tighten the jamnut.

•

The STANDBY valve adjusting screw is screwed fully IN (factory set) and must remain this way. This portion of the compensator is NOT USED.

SAW PUMP

••

••

6. On saw control valve, loosen locknut and on saw control relief valve and turn adjusting screw OUT until spring pressure is relieved.

422-08

OUTLET SECTION

MID INLET SECTION

SAW PUMP

•

OPEN

CLAMPS

CLOSE

CLOSE

ACCUMULATOR

OPEN

• SAW

•

•

GAUGE TEST PORT (FOR SAW)

AT097-1

SAW MAIN RELIEF (4000 PSI)

SAW VALVE (WITH CLAMP AND ACCUMULATOR SECTIONS)

17.8

Tigercat 822 Feller Buncher 7. Start the engine** and put throttle control to the IDLE position.

Saw drive SET MOTOR BEGIN OF REGULATION TO 3200 PSI Refer to felling attachment manufacturer’s service literature for this procedure.

**CAUTION: Before starting engine, ensure saw relief valve is unscrewed as stated in step 6, otherwise damage could occur to the piston pump.

IMPORTANT: The motor begin of stroke setting must be at least 400 PSI lower than the pump P.O.R. setting.

8. Reset pilot system and turn the saw switch ON. NOTE: Saw will not operate with pilot system OFF.

SET MOTOR MINIMUM DISPLACEMENT Refer to felling attachment manufacturer’s service literature for this information.

Saw will not function properly with low pilot pressure.

NOTE: If the engine has been turned off or the pilot shut off system tripped (door opened) with the saw switch left in the ON position, the saw will not start up when the engine is restarted or the door closed. In this case press the PILOT RESET button and turn the saw switch OFF and then ON. 9. Set the saw control valve relief pressure to 4000 psi by slowly screwing the relief valve adjusting screw in until the required pressure reading is obtained.

10. Re-tighten locknut, taking care not to turn the adjusting screw.

11. Set P.O.R. on pump compensator to 3600 psi. (or to saw head manufacturers recommended value, which ever is lower) by slowly screwing the relief valve adjusting screw out until the required pressure reading is obtained.

IMPORTANT: Saw relief valve must be set at least 400 psi. above pump P.O.R. to avoid generation of excessive heat.

12. Re-tighten jamnut, making sure adjusting screw does not turn.

13. The adjusting screw on the STANDBY valve must remain screwed fully IN. 14. Remove all pressure gauges.

17.9

Tigercat 822 Feller Buncher

Saw drive

17.10

Tigercat 822 Feller Buncher

SECTION 18 - CLAMPS MARCH 2003

CONTENTS - SECTION 18 CIRCUIT DESCRIPTION ................................................................................ 18.6 CIRCUIT DIAGRAM ....................................................................................... 18.7 CONTROL VALVE ........................................................................................ 18.4 PRESSURE SETTINGS ................................................................................ 18.8 AIR IN PILOT END CAPS .......................................................................... 18.8 PUMP CLAMPS/FAN ................................................................................... 18.3

Tigercat 822 Feller Buncher

Clamps

18.2

Tigercat 822 Feller Buncher

Clamps The operation of a typical external gear pump (so called because the gear teeth are on the external surface of the hub) is shown in Figure gear1.

CLAMPS/FAN PUMP THRUST PLATES DRIVE GEAR ON INPUT SHAFT

•

THRUST PLATES DRIVE GEAR ON INPUT SHAFT

CONNECTING SHAFT

• • •

•

OUTLET DRIVEN (IDLER) GEAR

• • •

DRIVE GEAR

•

• •

INPUT DRIVE SHAFT (CONNECTED TO SAW PUMP)

AP140

•

• GEAR HOUSINGS

PORT PLATE, REAR

CLAMPS/FAN PUMP

INLET

This is a two cartridge dual gear pump driven off the power take-off of the saw pump . The input drive shaft is connected to the saw pump drive shaft by a drive coupling.

One of the two cartridges in the clamps/fan pump provides hydraulic oil flow to the clamp and accumulating arm functions. The second cartridge provides hydraulic oil flow to the cooling fan circuit.

GEAR1

TYPICAL GEAR PUMP

A gear pump carries oil from the inlet to the outlet in the spaces between gear teeth. The pumping chamber is formed by the gears, the pump housing, and thrust plates. One of the two gears, called the drive gear, will be connected to the drive shaft. The other idler gear is driven by the drive gear.

CLAMPS/FAN PUMP SAW PUMP MAIN PUMP

•

422-08

PUMP ASSEMBLY 18.3

•

••

Tigercat 822 Feller Buncher

Clamps

CONTROL VALVES

Oil enters the mid inlet section and is allowed to pass through the two spool sections (clamp/ accumulating) and back to tank via the outlet section. Each of the spool sections has a self centering 3-position spool which is open center. 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 two functions (or all at the same time if required but with reduced flow to each).

For a detailed description of the pilot manifold refer to SECTION 5 of THIS MANUAL. CLAMP/ACCUMULATING VALVE The valve consists of three open center spool sections, an end inlet section, a mid inlet section and an outlet section. The inlet (end) section feeds a single spool which is used for the saw function. The mid inlet section feeds the remaining two spools which are used for the clamp and accumulating arms functions. Each spool is pilot operated. The outlet section is common to all three sections and returns oil to the hydraulic tank.

PILOT END CAPS MAIN (MID) RELIEF VALVE (CLAMPS AND ACCUM.)

••

SAW SECTION

GAUGE TEST PORT (FOR SAW ONLY)

••

OUTLET SECTION

••

•• CLAMPS

•

SAW

••

ACCUM.

• •

MID INLET SECTION

822-D64

GAUGE TEST PORT (FOR CLAMPS)

CLAMPS CONTROL VALVE (WITH SAW SECTION) 18.4

END INLET SECTION (SAW)

Tigercat 822 Feller Buncher

Clamps A main relief valve is installed in the mid inlet section of the valve. It controls the pressure to the two spool sections and is set lower than the PORT RELIEF VALVES.

IMPORTANT: Holding the CLAMP CLOSE button down on the joystick after the clamp cylinders are fully closed will not increase the clamping force on the trees, but will generate heat in the hydraulic system.

A MAIN RELIEF VALVE is also installed in the end inlet section of the saw section. This relief valve is set higher than the saw pump compensator pressure setting and will limit the pressure should a pump regulator or "swashing" failure occur.

To protect components and hoses when the valve is closed, each work port in the valve sections have a PORT RELIEF VALVE with an anti-cavitation function.

OUTLET SECTION

• •

OPEN

PORT RELIEF VALVES

MID INLET SECTION

PORT RELIEF VALVES

OPEN

ACCUMULATOR

CLOSE

•

•

CLOSE

CLAMPS

• MAIN RELIEF VALVE

•

• •

•

SAW SECTION

CLAMP/ACCUMULATING VALVE (WITH SAW SECTION)

AT097-1

RELIEF VALVE PORT 'A'

RELIEF VALVE PORT 'B'

SEAL GROOVES

A

B

SPOOL CENTERING SPRINGS

•

• • •

•

•

•

• •

•

• PILOT END CAP

AT047IL2

•

•

•

• SPOOL TANK PASSAGE

PARALLEL PASSAGE

LOAD CHECK VALVE

THRU' NEUTRAL PASSAGE

WORK PORT BRIDGE

CROSS SECTION OF SPOOL SECTIONS 18.5

TANK PASSAGE

PILOT END CAP

Tigercat 822 Feller Buncher

Clamps IMPORTANT

This manual is applicable to factory installed machine functions and controls. It does not take into account any changes or modifications made after shipment. Verify all functions before operating this machine.

CLAMP AND ACCUMULATING ARMS CIRCUIT DESCRIPTION The clamp and accumulating arms are each operated by independent hydraulic cylinders. The cylinders receive oil from the fixed displacement clamps/fan pump via two spool sections in the clamp/accumulating control valve.

The clamp arm is operated by a 3 position thumb switch (OPEN/CLOSE, self centering to OFF) located on the right joystick control handle. The switch operates two solenoid pilot valves which direct pilot oil to the clamp arm spool section of the control valve, to shift the spool. The spool directs oil from the pump to either end of the cylinder and from the cylinder back to tank.

The accumulating arms are operated by a 3 position thumb switch (OPEN/CLOSE, self centering to OFF) located on the left joystick control handle. The switch operates two solenoid pilot valves which direct pilot oil to the accumulating arms spool section of the control valve, to shift the spool. The spool directs oil from the pump to either end of the cylinder and from the cylinder back to tank.

18.6

Tigercat 822 Feller Buncher

822-08

Clamps

CLAMP AND ACCUMULATING ARMS CIRCUIT DIAGRAM 18.7

Tigercat 822 Feller Buncher

Clamps

PRESSURE SETTINGS WARNING:. Ensure that no one is near the felling head during this procedure. Have the felling head on the ground during this procedure. The swing brake should be applied at all times during this procedure.

IMPORTANT: Avoid blowing oil over the relief for longer than 5 seconds, as this will cause excessive heating of the hydraulic fluid and possible damage to the pump.

Air in pilot end caps

Air accumulation in the pilot end caps of the clamp/accumulating control valve can cause the clamp arms to behave in a sluggish manor. To bleed the air: Pressurize the hydraulic tank to approximately 5 psi and loosen the suspected pilot end cap fitting to release the air. After completion, tighten the fittings and re-adjust the pressure in the hydraulic tank.

WARNING Accumulator and clamp arms open and close very rapidly. Operator must ensure that no one is near the felling head during these procedures.

7. With the aid of an assistant. Press and hold the joystick thumb switch in the ACCUMULATING ARMS CLOSE position (cylinder fully extended), check gauge pressure reading.

If less than 3200 psi, turn accumulating arms close port relief adjusting screw in until 3200 psi is obtained on the gauge.

IMPORTANT: During these procedures, Do Not hold thumb switch in the ON position for longer than 5 seconds.

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

SET CLAMP AND ACCUMULATOR RELIEF VALVES Midinlet main relief valve setting .........2700 psi Accumulator close port relief setting ..3200 psi Accumulator open port relief setting ...3200 psi Clamp close port relief setting .............3200 psi Clamp open port relief setting ..............3200 psi 1. Park machine on level ground, lower the felling head to the ground, engage the swing brake and stop engine.

2. Ensure that hydraulic oil is at operating temperature.

3. Connect a 0 - 5000 psi pressure gauge to the clamp/accumulating control valve test port.

The control valve is accessed through the left hand rear enclosure door and is mounted above the hydraulic tank cleanout cover.

4. Loosen locknut on the mid inlet main relief valve and turn main relief adjusting screw all the way in, tighten locknut.

5. Turn both port relief valve adjusting screws on the clamp and accumulating arms spool sections of the control valve out until spring pressure is relieved and then turn adjusting screws one full turn in.

6. Start the engine and set throttle to IDLE. NOTE: It may be necessary to increase the engine speed sufficiently to prevent the engine from stalling.

8. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

9. Press and hold the joystick thumb switch in the ACCUMULATING ARMS OPEN position (fully retracted), check gauge pressure reading.

If less than 3200 psi turn accumulating arms open port relief adjusting screw in until 3200 psi is obtained on the gauge.

10. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

11. Press and hold the joystick thumb switch in the CLAMP ARM CLOSE position (cylinder fully extended), check gauge pressure reading.

If less than 3200 psi turn clamp close port relief adjusting screw in until 3200 psi is obtained on the gauge.

12. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

13. Press and hold the joystick thumb switch in the CLAMP ARM OPEN position (cylinder fully retracted), check gauge pressure reading.

If less than 3200 psi, turn clamp open port relief adjusting screw in until 3200 psi is obtained on the gauge.

18.8

Tigercat 822 Feller Buncher

Clamps

OUTLET SECTION

UPPER CLAMP ARMS 'OPEN' PORT RELIEF (3200 PSI)

• •

ACCUM. ARMS 'CLOSE' PORT RELIEF (3200 PSI)

•

OPEN

CLAMPS ACCUMULATOR

CLOSE

MID INLET SECTION

•

•

CLOSE

OPEN

• •

•

ACCUM. ARMS 'OPEN' PORT RELIEF (3200 PSI) MAIN RELIEF (2700 PSI)

SAW

GAUGE TEST PORT

UPPER CLAMP ARMS 'CLOSE' PORT RELIEF (3200 PSI)

• GAUGE TEST PORT (FOR SAW)

AT097-1

CLAMP/ACCUMULATING VALVE (WITH SAW SECTION) SUMMARY

14. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

1. Ensure that hydraulic oil is at operating temperature.

15. Repeat steps 7, 9, 11 and 13 to verify settings.

3. Connect gauge to the clamp/accumulating control valve.

RESET MID INLET MAIN RELIEF VALVE

4. Turn mid inlet main relief all the way in.

16. With throttle control in the FULL position; Loosen the locknut on the mid inlet main relief and unscrew adjusting screw 3 full turns.

5. Turn both clamp and accumulating arms sections out and then one full turn in.

6. Start the engine and set throttle to IDLE.

17 Press and hold the joystick thumb switch in the ACCUMULATING ARMS OPEN position, check gauge pressure reading.

7. Set ACCUMULATING ARMS CLOSE port relief.

If less than 2700 psi, turn mid inlet main relief adjusting screw in until 2700 psi is obtained on the gauge.

8. Set ACCUMULATING ARMS OPEN port relief 9. Set CLAMP ARM CLOSE port relief

18. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

13. Set CLAMP ARM OPEN port relief

19. Repeat step 17 to verify setting.

14. Set throttle to FULL.

20. Stop engine and remove pressure gauge.

14. Reset main relief.

18.9

Tigercat 822 Feller Buncher

Clamps

18.10

Tigercat 822 Feller Buncher

SECTION 19 - WRIST JUNE 2003

CONTENTS - SECTION 19 ADJUST OIL FLOW TO WRIST (CYCLE TIME) ............................................ 19.4 CIRCUIT DIAGRAM ....................................................................................... 19.3 CYCLE TIMES 340° WRIST ADDITIONAL NOTES ............................................................. 19.5 TYPICAL ................................................................................................... 19.4 ENGINE ANTI-STALL .................................................................................... 19.4 LOAD SENSING ........................................................................................... 19.4 MAIN CONTROL VALVE .............................................................................. 19.4 SET WRIST PORT RELIEF VALVES ........................................................... 19.4 WRIST DESCRIPTION .................................................................................. 19.2 TIGERCAT OPTIONAL 110° WRIST .......................................................... 19.2 TIGERCAT OPTIONAL 340° WRIST .......................................................... 19.2 TIGERCAT STANDARD 30° WRIST ........................................................... 19.2

Tigercat 822 Feller Buncher WRIST DESCRIPTION TIGERCAT STANDARD 30° WRIST One cylinder is used to rotate the wrist through 30° of rotation, 15° each side of the vertical position.

This cylinder receives oil from the main pump via the wrist spool section on the main hydraulic valve.

The wrist is operated by trigger switches on the joystick handles. The right hand trigger switch rotates the felling head in the counter-clockwise direction and the left hand trigger switch rotates the head in the clockwise direction. The switches operate solenoid pilot valves which direct pilot oil to the pilot end caps at each end of the wrist section of the main hydraulic valve and move the cylinder.

Wrist TIGERCAT OPTIONAL 340° WRIST Three hydraulic motors are used to rotate the wrist through 340° of rotation, 170° each side of the vertical position. Refer to OPERATING AND SERVICE MANUAL-TIGERCAT SAWS for more detailed information.

These motors receive oil through a distribution manifold from the main pump via the wrist spool section on the main hydraulic valve.

The wrist is operated by trigger switches on the joystick handles. The right hand trigger switch rotates the felling head in the counter-clockwise direction and the left hand trigger switch rotates the head in the clockwise direction. The switches operate solenoid pilot valves which direct pilot oil to the pilot end caps on each end of the wrist section of the main hydraulic valve.

The wrist cylinder extends or retracts to provide a counter-clockwise or clockwise rotation of the felling head. The cylinders receive oil from the main pump via the wrist section of main hydraulic valve.

The motors receive oil from the main pump via the wrist section of main hydraulic valve and the distribution manifold. Oil is directed to either side of the three motors rotate to provided a clockwise or counter-clockwise rotation of the felling head.

TIGERCAT OPTIONAL 110° WRIST Two cylinders are used to rotate the wrist through a maximum of 110° of rotation. The rotation position of wrist depends on the attachment point of cylinders on the boom adapter. Refer to OPERATING AND SERVICE MANUAL-TIGERCAT SAWS for more detailed information.

For additional information regarding setup, operation, maintenance and service of the WRIST ASSEMBLIES refer to the OPERATING AND SERVICE MANUAL-TIGERCAT SAWS or ATTACHMENT MANUFACTURER'S MANUALS.

These cylinders receive oil through a wrist manifold from the main pump via the wrist spool section on the main hydraulic valve.

Refer to SECTION 18 of THIS MANUAL for information about the operation of attachment clamp and accumulating arms.

The wrist is operated by trigger switches on the joystick handles. The right hand trigger switch rotates the felling head in the counter-clockwise direction and the left hand trigger switch rotates the head in the clockwise direction. The switches operate solenoid pilot valves which direct pilot oil to the pilot end caps on each end of the wrist section of the main hydraulic valve and move the cylinders.

The wrist cylinders work together one extending and the other retracting to provide a clockwise or counter-clockwise rotation of the felling head. The cylinders receive oil from the main pump via the wrist section of main hydraulic valve.

19.2

Tigercat 822 Feller Buncher

822-07

Wrist

WRIST CIRCUIT 19.3

Tigercat 822 Feller Buncher

Wrist

MAIN CONTROL VALVE

ADJUST OIL FLOW TO WRIST (CYCLE TIME)

The wrist spool section has port relief valves with anticavitation features.

NOTE: Constant loosening and tightening of the locknut (sealnut) on the adjusting screws will eventually cause the seal in the nut to break down and leak. Because of this it is best to keep the adjusting procedure brief.

These protect the circuit from abnormally high pressures induced by the load.

Adjustable spool travel stops on each pilot end cap of the spool section can be adjusted to limit spool travel and control the flow of oil to the wrist, which in turn controls the operating speed of the wrist.

1. Hydraulic oil must be at operating temperature.

To adjust the relief valves, Refer to SET WRIST PORT RELIEF VALVES in THIS SECTION.

2. Start engine and place engine throttle control in FULL position.

To adjust oil flow, Refer to ADJUST OIL FLOW TO WRIST in THIS SECTION.

3. Rotate wrist fully to the LEFT (CCW) 4. From this position rotate wrist fully RIGHT (CW). Record cycle time from stop to stop.

LOAD SENSING\ENGINE ANTI-STALL

NOTE: When extending or retracting cylinders to record the time, stop the cylinder just before it gets to the end of it's stroke rather than let it bottom out and impose unnecessary loads on the cylinder parts and boom structures.

The wrist hydraulics along with the boom, swing, track drive and levelling circuits are all under the control of the load sensing system incorporated into the main hydraulic circuit.

For a full description of the main hydraulic system including load sensing, the main pump and the main control valve, Refer to SECTION 4 in THIS MANUAL. For a full description of the engine anti-stall, Refer to SECTION 9 in THIS MANUAL. For a full description of the pilot system including the joystick handles, Refer to SECTION 5 in THIS MANUAL.

FLOW ADJUSTING SCREW FOR PORT 'A' (TYPICAL)

WRIST LEFT (CCW) PORT RELIEF

CONTROL VALVE MANIFOLD

• ••

•• B

B

B

B

B

B

B

A

A

A

A

A

A

A

•• LH DRIVE 822-D63

• RH DRIVE

• TILT

STICK

• WRIST RIGHT (CW) PORT RELIEF

MAIN CONTROL VALVE 19.4

•

MAIN BOOM

••

•• SWING

Tigercat 822 Feller Buncher

Wrist

TYPICAL CYCLE TIMES

SET WRIST PORT RELIEF VALVES

The following chart lists typical cycle times and is based on recommended factory settings. It should be noted that over adjusting to provide faster cycle times could increase the stress on components and the hydraulic system.

NOTE: Constant loosening and tightening of the locknut (sealnut) on the port relief valve adjusting screws will eventually cause the seal in the nut to break down and leak. Because of this it is best to keep the adjusting procedure brief.

To adjust cycle times; Loosen locknut on spool adjusting screw on main control valve and turn adjusting screw IN (clockwise) to slow down and OUT (counterclockwise) speed up. Tighten locknut on adjusting screw and re-check times.

1. With hydraulic oil at operating temperature, LINDE MAIN VALVE MANIFOLD

NOTE: The 'A' port (bottom port) is connected to the WRIST LEFT (CCW) function and the 'B' ports (top ports) are connected to the WRIST RIGHT (CW) function.

•• •

LS PRESSURE ADJUSTMENT P2

• 103-17A

WRIST CYCLE TIMES

MAIN VALVE MANIFOLD

2. Connect a 0-5000 psi pressure gauge on 'LS' test port of Linde main valve manifold.

CYCLE TIMES

.......................... 2.5 SEC. 110° ROTATION ... 6.0 SEC. 90° ROTATION .... 5.0 SEC. 340° WRIST .......................... 9.5 SEC.*

•

'P' GAUGE TEST PORT

Refer also to OPERATING AND SERVICE MANUAL-TIGERCAT SAWS for more detailed information about TIGERCAT SAWS and OPTIONAL WRISTS.

30 ° WRIST 110° WRIST

•• L.S. GAUGE TEST PORT

To adjust the flow rate at 'A' PORTS, adjust spool travel stop adjusting screw located at TOP of valve and vice-versa for 'B' ports. See figure 830-D22X.

WRIST TYPE

HIGH PRESSURE LIMITING CONTROL

STOP TO STOP STOP TO STOP STOP TO STOP STOP TO STOP

3. Start engine and place throttle control in FULL position.

4. Turn anti-stall switch OFF. 5. With an assistant operate the right hand joystick trigger switch until the wrist turns fully to the LEFT (COUNTERCLOCKWISE), loosen locknut on the wrist LEFT (CCW) port relief valve cartridge and adjust to 3000 psi. on gauge at 'LS' port.

340° WRIST OPTION ADDITIONAL NOTES * Note: For the 340° wrist faster cycle times will result in lower torque available to rotate a loaded head. This should be considered when setting wrist cycle times. Slower cycle times may be required when operating with larger loads to allow proper operation of the wrist.

WARNING

Note Also: For the 340° wrist additional flow control valves are located on the wrist distribution manifold. These flow control valves can be used to fine tune the wrist rotation speed and should be used together with the main control valve adjustments described above. Refer also to TIGERCAT SAW OPERATING AND SERVICE MANUAL for more detailed information.

The felling head will be rotated side to side during this procedure. Operator must ensure that no one is near the felling head during this procedure.

The swing brake should be applied at all times during this procedure.

Continued on page 6

19.5

Tigercat 822 Feller Buncher

Wrist

Continued from page 5 SPOOL TRAVEL STOP • 19mm WRENCH • 6mm ALLEN KEY

•

10. Check the setting again.

11. Stop engine, remove all gauges and reinstall plugs and caps.

• •

LOCKNUT • 17mm WRENCH

•

PORT RELIEF VALVE

90744-3

PILOT END CAP

•

ADJUSTING SCREW • 5mm ALLEN KEY

MAIN VALVE BODY

9. Tighten locknut on adjusting screw taking care NOT to turn the adjusting screw at the same time.

•

MAIN VALVE PORT RELIEF VALVE

6. Tighten locknut on adjusting screw taking care NOT to turn the adjusting screw at the same time.

7. Check the setting again.

8. With an assistant operate the left hand joystick trigger switch until the wrist turns fully to the RIGHT (CLOCKWISE), loosen locknut on the wrist RIGHT (CW) port relief valve cartridge and adjust to 3000 psi. on gauge at 'LS' port.

FLOW ADJUSTING SCREW FOR PORT 'A' (TYPICAL)

WRIST LEFT (CCW) PORT RELIEF

CONTROL VALVE MANIFOLD

•• • • B

B

B

B

B

B

B

A

A

A

A

A

A

A

•• LH DRIVE 822-D63

•• RH DRIVE

•• TILT

STICK

•• WRIST RIGHT (CW) PORT RELIEF

MAIN CONTROL VALVE 19.6

••

MAIN BOOM

•

• SWING