TIGERCAT 822 L830 FELLER BUNCHER SERVICE MANUAL - PDF DOWNLOAD

SERVICE MANUAL TIGERCAT 822/L830 FELLER BUNCHER TABLE OF CONTENTS

ISSUE 1.0, SEPTEMBER 2007

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 LEVELLING ..................................................................................................................... 13 SWING ............................................................................................................................ 15 SAW DRIVE .................................................................................................................... 17 CLAMPS .......................................................................................................................... 18 WRIST ............................................................................................................................ 19

822 L830-SM00

Tigercat

822/L830 Feller Buncher Available Literature Operator's Manual, 822 ................................... Part No. 24544A Manuel de l'opérateur (Français), 822 ............ Part No. 24676A Operator's Manual, L830/LX830/X830 ............ Part No. 24545A Service Manual , 822/L830 (This Manual) ...... Part No. 24941A Parts Catalog, 822 ........................................... Part No. 18868A Parts Catalog, L830/LX830/X830 .................... Part No. 17866A

®

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

Fax: (519) 442-1855

Tigercat 822/L830 Feller Buncher

Introduction

ii

Tigercat 822/L830 Feller Buncher Tigercat 822/L830 Feller

Buncher

Introduction

INTRODUCTION An Operator's manual, Service manual and a Parts catalog are made available by Tigercat to assist the dealer, customer and operator in becoming familiar with the features of the 822 and L830 Feller Bunchers Serial numbers:822 82210191 to 82210999 (Open Loop) L830 83020191 to 83020999 (Levelling, Open Loop) The operator's manual will assist the operator with the techniques of proper and safe operation of the 822/ L830 Feller Bunchers. 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.

iii

Tigercat 822/L830 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/L830 Feller Buncher

SECTION 1 - SAFETY JULY 2007

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

Read and understand all manuals for any attachment or accessories.

CONTENTS - SECTION 1 BATTERY SAFETY ........................................................................................ 1.6 CAB EXITS .................................................................................................... 1.7 COOLING SYSTEM ..................................................................................... 1.15 EMERGENCY CAB EXITS ............................................................................ 1.7 ENGINE DOORS ......................................................................................... 1.17 ER BOOM SYSTEM PRECAUTIONS .......................................................... 1.16 EXHAUST FUMES ....................................................................................... 1.17 FELLING TREES ......................................................................................... 1.12 FIRE PREVENTION ..................................................................................... 1.19 WHAT ELSE TO DO BEFORE YOU EXPERIENCE A FIRE .................... 1.19 WHAT TO DO AFTER A FIRE ................................................................. 1.20 WHAT TO DO IN CASE OF A MACHINE FIRE ........................................ 1.19 FLUID LEAKS .............................................................................................. 1.15 HAZARD ZONE ............................................................................................. 1.3 HYDRAULIC PRESSURE HAZARD ............................................................ 1.15 LOOSE CLOTHING HAZARD ..................................................................... 1.15 MACHINE STABILITY AND TRACTION .............................................. 1.9, 1.10 PARKING BOOM ......................................................................................... 1.16 PARKING THE MACHINE ........................................................................... 1.12 PROTECTIVE CLOTHING ............................................................................. 1.3 SAFETY INTERLOCK SWITCHES ON CAB DOORS ................................... 1.8 SAFETY PRECAUTIONS, GENERAL ........................................................... 1.3 SAFETY PRECAUTIONS, OPERATING ....................................................... 1.6 SAFETY PRECAUTIONS, SERVICING ....................................................... 1.12 SAFETY SYMBOLS ....................................................................................... 1.2 SIGNAL WORDS ........................................................................................... 1.2 WORKING WITH OIL .................................................................................... 1.4

Tigercat 822/L830 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 indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

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

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

1.2

Tigercat 822/L830 Feller Buncher

Safety

GENERAL SAFETY PRECAUTIONS

KEEP BACK 500 FEET

Remember that safety is a prime responsibility of all.

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

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.

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

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

500 FEET

500 FEET

500 FEET

500 FEET

Follow all instructions from safety inspector and supervisors.

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

LH830-02

HAZARD ZONE

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.

Do not let untrained persons operate 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.

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/L830 Feller Buncher

Safety 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.

GENERAL SAFETY PRECAUTIONS continued

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.

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

Prolonged exposure to loud noise can cause impairment or loss of hearing. This machine exceeds 70dB(A) in the cab and exceeds 85dB(A) when servicing machine engine.

Check windows and door guards for damage.

Check protective windows for cracks, a damaged window has reduced strength to stop flying objects. All damaged windows must be replaced with original equipment.

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

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

Do not jump off the machine at any time.

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

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

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

Check all fluid levels.

Do not use the machine foot controls as steps.

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.

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

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

Some advice which should be observed: • • •

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.

1.4

Avoid contact with oil, particularly heated oil.

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

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

Tigercat 822/L830 Feller Buncher

Safety Maintain a charged fire extinguisher on the vehicle at all times and KNOW HOW TO USE IT.

GENERAL SAFETY PRECAUTIONS continued • • • • • •

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.

Don't put oily rags in your pockets.

Oil soiled clothing should be changes as soon as possible.

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

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

Avoid breathing in oil fumes.

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

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.

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

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

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

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

Maintain a distance of 10 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.

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

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

•

If these are found, Do Not Touch!!!

•

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

•

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

•

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.

Be aware when performing service and maintenance tasks that surfaces and grab handles in and around the engine and cooling system may become very hot when the engine has been running. Contact with hot surfaces may cause injury.

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

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

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/L830 Feller Buncher

Safety

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

Avoid Injury from Backover Accidents Before moving machine, be sure all persons are clear of the area.

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

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

To avoid backover accidents: •

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

Wash hands after handling.

• •

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

•

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

•

Disconnect battery before working on electrical systems. Remove ground terminal first when disconnecting. Connect ground terminal last when reconnecting.

• •

Do not short out battery terminals for any reason.

Serious burns or an explosion can result.

CAUTION

Always look around before you back up. Be sure that everyone is clear.

Keep reverse* warning alarm in working condition.

Be aware that the reverse* warning alarm sounds only when the machine is moving in reverse* regardless of the swing position of the rotating upper.

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

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

Keep windows, mirrors and lights in good condition.

Dust, heavy rain, fog, snow etc. can reduce visibility. As visibility decreases, reduce speed and use proper lighting. * Reverse is defined as the machine moving with the rear of the undercarriage at the leading edge of movement and is not necessarily related to the swing position of the rotating upper. The track gear box is located at the rear of the undercarriage.

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

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

1.6

Tigercat 822/L830 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. ALWAYS shut OFF engine before using the side door exit.

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.

This hatch is not equipped with a safety interlock switch and therefore when left open will not deactivate the pilot controls in the cab. ALWAYS shut OFF engine before using the escape hatch exit.

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

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

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.

Never use a liquid starting aid to start an engine.

IMPORTANT WARNING

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

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

1.7

Tigercat 822/L830 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.

1.8

Tigercat 822/L830 Feller Buncher

Safety

OPERATING SAFETY PRECAUTIONS continued MACHINE STABILITY AND TRACTION 822 MACHINES WITHOUT LEVELLER When working on slopes, travel straight up or down the slope to prevent roll-over.

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.

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

1.9

Tigercat 822/L830 Feller Buncher

Safety

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

MACHINE STABILITY AND TRACTION L830 MACHINES WITH LEVELLER

26°

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

Whenever possible work within the normal working range of the boom system as shown in FIG. 1. Note that in any boom position, both inside and outside of the normal operating range, there is a risk of instability and tipping. When it is necessary to work outside of the normal working range, be aware that the stability of the machine is reduced. The risk of tipping is increased while operating in the reduced stability working range.

UPHILL

NORMAL WORKING RANGE OF BOOM SYSTEM

REDUCED STABILITY WORKING RANGE

• TRACK GEAR BOX AT REAR OF UNDERCARRIAGE LH830-07

FIG. 1 WORKING RANGES

22° LH830-08 LH830-09

FIG. 2 UNDERCARRIAGE LEVELING ANGLES All efforts have been made in the design of the machine to reduce the risk of tipping, however it is not possible to eliminate the risk of tipping. To minimize the risk of tipping observe the following: • Do not attempt to operate this machine on slopes without first receiving proper training.

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

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

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

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

1.10

Tigercat 822/L830 Feller Buncher

Safety NORMAL WORKING RANGE OF BOOM SYSTEM

OPERATING SAFETY PRECAUTIONS continued •

•

Never travel across a STEEP slope or side hill.

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

•

Do not lift or move objects that exceed machine stability.

•

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

•

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

•

•

•

•

••

UPHILL

••

TRACK GEAR BOX AT REAR OF UNDERCARRIAGE

FIG. 1 WORKING RANGES

LH830-07

KEEP ATTACHMENT CLOSE TO GRADE

When crossing obstacles (boulders, stumps, ditches etc.) the machine can shift rapidly, greatly affecting the stability of the machine.

Move slowly over obstacles, and position the boom against the ground to reduce the risk of the machine shifting rapidly.

REDUCED STABILITY WORKING RANGE

BOOM TO FRONT

•

Backing over obstacles unexpectedly while traveling down a slope poses a tipping risk.

Know the path of the tracks whenever the machine is moved.

When climbing a slope the boom should face front and the attachment should be kept close to the ground (FIG. 3). When descending a slope the boom should face the rear and the attachment should be kept close to the ground (FIG.4). Be aware that the machine is in its least stable postion on a slope with the boom to the rear (see also FIG.1). Be particularly aware of machine stability when changing directions on, or travelling back down a slope.

••

TRACK GEAR BOX AT REAR OF UNDERCARRIAGE 830-52

CLIMBING SLOPE (FIG. 3)

BOOM TO REAR

As you gain experience, recognize that the maximum slope on which the machine can operate cannot be defined simply by an angle value. Variables in surface terrain, soil types, rocks, boulders, stumps, and fallen trees, changing weather conditions, and first and foremost the operator’s experience and skill levels greatly affect the maximum slope limitations. Be aware that these factors can result in a shallow slope posing greater risk than a relatively steeper slope. DO NOT attempt to work on slopes beyond your personal capability level.

KEEP ATTACHMENT CLOSE TO GRADE

•• TRACK GEAR BOX AT REAR OF UNDERCARRIAGE

830-53

1.11

•

DESCENDING SLOPE (FIG 4.)

Tigercat 822/L830 Feller Buncher OPERATING SAFETY PRECAUTIONS continued 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.

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

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

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

Always replace saw tooth retaining bolts when replacing saw teeth.

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

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

Shut down machine immediately if vibration occurs during cutting.

Check that the saw discharge area is clear and undamaged.

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.

Safety equipment and operator's are also moving in. Preplan to clear decks in advance before other equipment arrives.

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

Stop the saw blade before leaving the cutting area.

NOTE: The saw blade will continue to free wheel for several minutes after the saw 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 only and engage the swing brake.

•

Do not park on a hillside or incline.

•

Lower felling attachment onto level ground.

•

Stop the engine.

•

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

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

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

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

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

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

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

Never use this machine to clear a logging deck on a new tract of timber when the rest of the

EARLIER

LATER

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.

1.12

Tigercat 822/L830 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.

1.13

Tigercat 822/L830 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

1.14

IQAN XP MODULE DISCONNECT

Tigercat 822/L830 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 injury.

Never use your bare hand to check for fluid leaks.

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.

Fluid leaks under pressure may not be visible.

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

Wear safety goggles for eye protection.

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

Pressure can be maintained in a hydraulic system long after the power source and pump have been shut down. Lower the attachment to the ground, stop engine and relieve trapped pressure before performing work on components, or disconnecting any hoses. Refer to PARKING BOOM diagrams (FIG.5 & FIG.6). Accumulators will self drain within 2 minutes of stopping the engine on this MODEL. Also, for machines equipped with pressurized hydraulic tanks (82210191 to 82210345, 82210347 to 82210350, 82210611 to 82210999, 830*0191 to 830*0343, 830*0611 to 830*0999) , relieve pressure in the hydraulic reservoir by opening hydraulic tank vent valve and waiting until the sound of escaping air stops.

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.

1.15

Tigercat 822/L830 Feller Buncher SERVICING SAFETY PRECAUTIONS continued WARNING This machine may be equipped with an ER boom system. Because of this, it may behave in an unexpected manner compared to a conventional boom system.

Safety MACHINE MODELS EQUIPPED WITH A LEVELLING SYSTEM Always install support braces in the levelling mechanism while performing service and maintenance tasks. This area is a crush zone.

Keep clear to avoid personal injury or death.

DANGER

MACHINE MODELS EQUIPPED WITH AN ER BOOM SYSTEM Pay attention to the following when servicing the ER Boom System: 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:-

23526A R0

TO AVOID PERSONAL INJURY OR DEATH USE SUPPORT BRACE AS SHOWN WHEN SERVICING.

The boom system is intended for use in the tree felling applications only.

(a) The machine is parked on level ground with the head sitting flat on the ground.

•

Do not use the boom to service other equipment.

(b) The stick cylinders are fully extended (FIG. 5) or the hoist cylinder fully collapsed (FIG. 6).

•

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

c) The tip of the stick boom supported .

•

Do not modify the boom system.

d) Do NOT rely on the attachment to support the boom system during servicing. Slow leakage in the hydraulic components can cause the attachment to move unexpectedly.

•

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

•

Do not use the attachment for any purpose other than the intended felling function.

STICK CYLINDERS FULLY EXTENDED

• TIP OF STICK BOOM FULLY SUPPORTED 830-07

PARKING BOOM. FIG.5

HOIST CYLINDER FULLY RETRACTED

•

TIP OF STICK BOOM FULLY SUPPORTED 830-08

PARKING BOOM. FIG.6

1.16

Tigercat 822/L830 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.

1.17

Tigercat 822/L830 Feller Buncher

FIRE PREVENTION

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

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

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

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

3. Inspect the EXHAUST SYSTEM DAILY for any signs of LEAKAGE. Check for worn, cracked, broken, or damaged pipes or muffler. Also check for missing or damaged bolts or clamps. Should any exhaust leaks or defective parts be found, repairs must be made immediately. Engine exhaust leaks can cause fires, DO NOT OPERATE the machine until the exhaust leak is repaired.

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

Safety 5. Remove debris and blow out dust regularly from the air intake doors, engine radiator, hydraulic oil cooler, A/C condenser core and charge air cooler to prevent overheating of the engine and hydraulics.

Refer to CLEANING A/C CONDENSER AND COOLING ASSEMBLY in SECTION 2 of the OPERATOR’S MANUAL. 6. Blow off all debris and dust accumulated near hot engine exhaust components (turbocharger and exhaust manifold as well as exhaust pipes and muffler) at the completion of each work shift or more frequently depending on logging conditions.

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

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

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

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

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

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

1.18

Tigercat 822/L830 Feller Buncher FIRE PREVENTION continued

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

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

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

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

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

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

Safety WHAT ELSE TO DO BEFORE YOU EXPERIENCE A FIRE •

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

•

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

•

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

•

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

•

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

•

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

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

•

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

*NOTE: Dry chemical fire suppression

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

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.

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

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

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

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

WHAT TO DO IN CASE OF A MACHINE FIRE •

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

•

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

•

Activate the fire suppression system*

•

Shut the engine off.

•

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.

•

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

Continued on page 20

1.19

Tigercat 822/L830 Feller Buncher

Safety 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 machine components or debris in the area.

FIRE PREVENTION continued Continued from page 19

•

The dry chemical fire extinguisher should be used first, followed by the pressurized water extinguisher, if available.

•

Remain with the machine at a safe distance, until help arrives to ensure that the fire does not re-ignite.

•

Use the PASS method with most extinguishers.

•

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

•

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.

WHAT TO DO AFTER A FIRE •

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

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.

•

Inspect all extinguishers and water systems not used in fighting the fire for possible damage. Return extinguishers and water systems to a functional state if applicable.

•

•

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.

*NOTE: Dry chemical fire suppression

20229A

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

TYPICAL FIRE EXTINGUISHER ACCESS HOLE

•

Attempt to locate the source of the fire then 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 1.20

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

®

using high speed disc saws safely FORWARD:

Tigercat

®

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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using high speed disc saws safely

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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.

3

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.

4

using high speed disc saws safely

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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.

Tigercat

®

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.

Tigercat

®

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

Tigercat

16

®

Tigercat 822/L830 Feller Buncher SECTION 3 - LUBRICATION & MAINTENANCE JULY 2007

CONTENTS - SECTION 3 ACCESS DOOR, UNDERCARRIAGE, SWIVEL (LATER MACHINES ....... 3.24 AIR CONDITIONING, CHECKING THE SYSTEM ...................................... 3.14 AIR INTAKE MAINTENANCE ..................................................................... 3.22 APPROVED HYDRAULIC OILS ................................................................... 3.9 CHECKING THE AIR CONDITIONING SYSTEM ....................................... 3.14 EMERGENCY EXITS, CHECK MONTHLY ................................................... 3.3 ENGINE AIR CLEANER MAINTENANCE .................................................. 3.22 ER BOOM SYSTEM .................................................................................... 3.13 FILTER AND LUBRICATION SCHEDULE .................................................. 3.11 FILTERS CHANGING HYDRAULIC RETURN FILTERS ........................................ 3.18 ENGINE AIR FILTER .............................................................................. 3.22 FUEL FILTER/WATER SEPARATOR ..................................................... 3.16 FUEL TANK STRAINER .......................................................................... 3.17 HYDRAULIC OIL RETURN FILTERS ..................................................... 3.18 HYDRAULIC OIL RETURN STRAINERS/DIFFUSERS .......................... 3.21 PILOT, HIGH PRESSURE ....................................................................... 3.20 SERVICING GUIDELINES FOR OIL FILTERS ....................................... 3.18 FIRE PREVENTION ...................................................................................... 3.3 GENERAL MAINTENANCE .................................................................. 3.3, 3.4 HYDRAULIC OIL FILTERS ......................................................................... 3.18 HYDRAULIC OILS ........................................................................................ 3.9 LUBRICATION POINTS DIAGRAM .............................................................. 3.7 LUBRICATION SCHEDULE ........................................................................ 3.11 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 PARKING BOOM ........................................................................................ 3.13 PREVENTIVE MAINTENANCE SCHEDULE ................................................ 3.2 SCHEDULED MAINTENANCE FREQUENTLY .......................................................................................... 3.5 8 HOURS ................................................................................................... 3.5 24 HOURS ................................................................................................. 3.6 125 HOURS ............................................................................................... 3.6 250 HOURS ............................................................................................... 3.7 500 HOURS ............................................................................................... 3.8 1000 HOURS ............................................................................................. 3.8 2000 HOURS ............................................................................................. 3.8 LUBRICATION POINTS DIAGRAM .......................................................... 3.7 SWING DRIVE GEARBOX LUBRICATION OF LOWER BEARING ................................................... 3.12 TORQUE CHART ....................................................................................... 3.25 TORQUE CHART, GENERAL .................................................................... 3.26

Tigercat 822/L830 Feller Buncher

Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE FOR 822/L830 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 Check all leveller pivot bearing retaining bolts (If equipped with leveller) Engine mounting bolts

IMPORTANT

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

Track shoe bolts Track roller retaining bolts

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

Track sprocket retaining bolts

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

Track drive gearbox mounting bolts Track drive motor mounting bolts

OIL LOST FROM LEAKAGE

Swing gearbox mounting bolts Cab securing bolts

LEAKAGE RATE ONE DROP IN 10 SECONDS ONE DROP IN 5 SECONDS ONE DROP PER SECOND THREE DROP PER SECOND DROPS BREAK INTO STREAM

Any other loose nut, bolt or fitting

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/L830 Feller Buncher

Lubrication and Maintenance

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

CAUTION ALL HANDLES, STEPS AND PLATFORMS MUST BE KEPT FREE OF GREASE, OIL, FUEL, MUD, SNOW, ICE AND FOREST DEBRIS. Clean around filler caps before checking or adding fluids.

Always have a fire extinguisher at hand.

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

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

Clean up spills as soon as possible.

Always release pressure in hydraulic tank before breaking a connection. For machines with pressurized tanks only ( (82210191 to 82210345, 82210347 to 82210350, 82210611 to 82210999, 83020191 to 83020343, 83020611 to 83020999).

Always use clean oil and containers.

Always install door safety struts when working on machine.

Clean fire suppression system sensors.

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.

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.

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

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

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 to disconnect all electrical connections and follow all servicing safety precautions as outlined in the WELDING, PRIOR TO of SECTION 1 in THIS MANUAL. When welding, secure ground connection as close to working position as possible to prevent arcing across machined surfaces or through bearings.

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

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

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

Clean away all branches, bark and chips.

Clean up all traces of oil to avoid fires.

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

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

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 Continued on page 4

3.3

Tigercat 822/L830 Feller Buncher

Lubrication and Maintenance

GENERAL Continued from page 3

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 and if time permits, 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.

3.4

Tigercat 822/L830 Feller Buncher

Lubrication and Maintenance

SCHEDULED MAINTENANCE FREQUENTLY:~

• ‡ Boom joints:

• Check engine cooling air intake screens for possible restriction.

Standard Boom; 6-fittings - purge Standard w/Tilt Link; 12-fittings - purge

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

ER Boom System; 12-fittings - purge • ‡ Cylinders; boom, stick & tilt; Standard Boom; 8-fittings - purge

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

ER Boom System; 10-fittings - purge ‡ Lubricating cylinder pins and boom joints:1. Ensure machine is on level ground

• 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 may not get completely changed during normal vertical motion, so it is important that this procedure be followed at least once every hour.

2. Completely tilt felling head back 3. Fully extend stick boom cylinder 4. Force heel of felling head onto ground 5. While in this position lubricate all cylinder retaining pins and boom joints NOTE: This procedure will allow grease to flow to the normally "loaded side" of the pin/bearing surfaces.

LUBRICATING CYLINDER PINS AND BOOM JOINTS

EVERY 8 HOURS:~ • Perform "frequently" maintenance

• • • • •

And in addition:~ • Check engine coolant level

PARK MACHINE ON LEVEL GROUND COMPLETELY TILT FELLING HEAD BACK FULLY EXTEND STICK BOOM CYLINDER FORCE HEEL OF FELLING HEAD ONTO GROUND AS SHOWN WHILE IN THIS POSITION LUBRICATE ALL CYLINDER RETAINING PINS AND BOOM JOINTS

NOTE: THIS PROCEDURE WILL ALLOW GREASE TO FLOW TO THE NORMALLY "LOADED SIDE" OF THE PIN/BEARING SURFACES.

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

23873A R0

• Check air cleaner unloader valve

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

• Check air filter restriction indicator

• Remove potentially damaging limbs or sticks.

• Check hydraulic oil level

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

• Check air intake precleaner operation

Lubricate:~ • Swing pinion; 1-fitting - 10 shots • Cylinders, Levelling; 4-fittings total - purge (If equipped with leveller)

• For loose nuts, bolts and fittings.

• Condition and tension of fan belts.

• Thrust bearing, Levelling; 2-fittings - purge (If equipped with leveller)

• 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.

3.5

Tigercat 822/L830 Feller Buncher

Lubrication and Maintenance

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

EVERY 24 HOURS :~ • Perform "frequently" maintenance

• Tracks, track frames and carbody

• Perform 8 hour maintenance

• Swing bearing area

And in addition:~

• Attachment

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

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

EVERY 125 HOURS:~

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

• Perform "frequently" maintenance • Perform 8 hour maintenance

• Wear in any other components

• Perform 24 hour maintenance

• Signs of cracks beginning in booms and attachments. Failure to properly repair cracks in structures in a timely manner can result in component failure and costly repairs which are not covered under warranty.

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

Clean/replace:~ • Inspect for debris buildup between A/C condenser and cooling assembly

• Check pilot filter restriction indicator (when fitted) with engine running at high idle • Check track drive gearbox oil level with one level plug at 6 O'Clock and the other at 9 O'Clock

• Air conditioner re-circulation filter • Cab fresh air filter

• Check battery fluid level unless maintenance free

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

• Check engine rpm • Check hydraulic pump and motor securing bolts • Check torque tightening points as per new machine maintenance • Carry out A/C system inspection; Refer to CHECKING THE AIR CONDITIONING SYSTEM in THIS SECTION

3.6

Tigercat 822/L830 Feller Buncher

Lubrication and Maintenance

SCHEDULED MAINTENANCE • Check condition and tension of fan belts.

EVERY 250 HOURS:~ • Perform "frequently" maintenance

• Replace engine oil and filter.

• Perform 8 hour maintenance

• Replace engine fuel filter(s).

• Perform 24 hour maintenance

• Replace filter in fuel filter/water separator.

• Perform 125 hour maintenance

• Replace air intake primary element.

And in addition:~

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

• Check all hydraulic pressures • Lubricate leveller, intermediate pivot points; 2-fittings total - purge.

Remove/replace protection plugs to access.

(If equipped with leveller) • Lubricate leveller, upper pivot points; 4-fittings total - purge.

Remove/replace protection plugs to access.

(If equipped with leveller)

DANGER

• Lubricate swing drive gearbox lower bearing; 2-fittings - 5 shots each ‡ Do not use a power grease gun. ‡ 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.

23526A R0

TO AVOID PERSONAL INJURY OR DEATH USE SUPPORT BRACE AS SHOWN WHEN SERVICING.

LEVELLING CYLINDER 2 FTG/8

LEVELLING CYLINDER 2 FTG/8

• THRUST BEARING

• •

1 FTG/8

•

• • • •

UPPER PIVOT BEARING

THRUST BEARING

2 FTG/250

1 FTG/8

INTERMEDIATE PIVOT BEARING 1 FTG/250

2 SIDES 830-51

2 SIDES

LEVELLER COMPONENT LUBRICATION POINTS

3.7

Tigercat 822/L830 Feller Buncher

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 500 HOURS:~

EVERY 1000 HOURS:~

• Perform "frequently" maintenance

• Perform "frequently" maintenance

• Perform 8 hour maintenance

• Perform 8 hour maintenance

• Perform 24 hour maintenance

• Perform 24 hour maintenance

• Perform 125 hour maintenance

• Perform 125 hour maintenance

• Perform 250 hour maintenance

• Perform 250 hour maintenance

And in addition replace:~

• Perform 500 hour maintenance

• Air intake safety element.

And in addition check:~

• Hydraulic oil return filters. †

• Fuel in-tank strainer

• Hydraulic oil high pressure pilot filter. †

• Replace air cleaner unloader valve

Lubricate:~ • Power door hinges; 2 fittings - 1 shot

EVERY 2000 HOURS:~

• Door cylinder pins apply oil liberally

• Replace turbocharger rubber inlet elbow and coupling - High temperatures in this area can cause the rubber to harden

• Other door hinges; apply oil liberally Check:~ • Torque on swing bearing and swing gearbox retaining bolts.

• Check ALL air intake tubing, rubber couplings and band clamps for signs of wear and leakage

• Torque on track drive gearboxes and motor mounting bolts.

• Drain and refill hydraulic oil tank with recommended hydraulic oil. See "approved hydraulic oils"

• Track rollers for leakage. Earlier rollers were filled with oil and later rollers filled with grease, both cases are considered to be maintenance free. If a lubricant leakage is detected the rollers must be removed, repaired and replaced.

It is strongly recommended that a program of regular oil testing be used. Oil change intervals can be established from oil test results

• Check track idler assembly for leakage, the bearing is filled with oil and is considered to be maintenance free. If a lubricant leakage is detected the idler must be removed, repaired and replaced.

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

3.8

Tigercat 822/L830 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.

3.9

Tigercat 822/L830 Feller Buncher

Lubrication and Maintenance

3.10

Tigercat 822/L830 Feller Buncher

Lubrication and Maintenance

Tigercat® Model L830/822 FELLER BUNCHER FILTER AND LUBRICATION SCHEDULE

15

23.7 19.9

6.26 5.25

QTY

USG

57

REMARKS/LUBRICANT

1

COOLING SYSTEM

CHK

2

CHK

REP

3 4 5

ENGINE OIL/FILTER; CUMMINS QSL9 CUMMINS QSC FUEL FILTER (ENGINE) FUEL/WATER SEPARATOR IN-TANK FUEL STRAINER

DRN

REP REP

6

AIR INTAKE PRECLEANER

7

AIR INTAKE PRIMARY ELEMENT

8

AIR INTAKE SAFETY ELEMENT

9

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

10

RETURN FILTERS

CHK

REP

5 1

11

PRESSURE FILTER, PILOT*

CHK

REP †

1

12

TRACK DRIVE GEARBOX; ‡ CHECK OIL WITH LEVEL PLUGS AT 6 O'CLOCK AND 9 O'CLOCK POSTIONS TRACK ROLLERS AND IDLERS CHECK FOR OIL LEAKAGE

CHK ‡

13

60/40 ANTIFREEZE ** SEE ENGINE MANUFACTURER’S SERVICE MANUAL 1 1

CHK CHK

1 REP

1 REP

1

CHK

D/R

D/R

CHK

14

SWING BEARING ***

15

SWING PINION

16

SWING GEARBOX LOWER BEARING ³ REFER TO 250 HOURS SCHEDULED MAINTENANCE FOR DETAILS

17

BOOM,STICK AND TILT JOINTS: - STANDARD - STANDARD W/TILT LINK - ER BOOM SYSTEM

LUB

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

LUB

19

LEVELLER CYLINDERS (IF EQUIPPED WITH LEVELLER)

20

LEVELLER THRUST BEARING (IF EQUIPPED WITH LEVELLER)

21

LEVELLER PIVOTS (IF EQUIPPED WITH LEVELLER)

18

CHANGE COOLANT EVERY 2 YEARS

LITRE

2000

CAPACITY

1000

500

250

DESCRIPTION

125

SERVICE EVERY

8

SERVICE POINT NO.

REFER TO Tigercat OPERATOR'S MANUAL FOR FURTHER INFORMATION

LUB 24HR *** LUB LUB³

134 ..250

35 ..66

6

1.5

7.6

2

1

1

10 SHOTS

1

10 SHOTS

1

5 SHOTS EACH FITTING

2

PURGE

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. DRAIN AND REFILL AS REQ’D

BY SEASONAL OIL CHANGE SEE APPROVED HYDRAULIC OILS* *Tigercat RECOMMENDS REGULAR USE OF AN OIL TESTING PROGRAM 5 STANDARD FILTERS 1 WATER ABSORBING FILTER (COLOUR BLUE) *CHECK RESTRICTION INDICATOR (IF EQUIPPED) FILL WITH S 75W-90 (SPEC) RECOMMENDED SYNTHETIC GEAR OIL FOR SEVERE DUTY APPLICATIONS IF LEAKING REMOVE AND REPAIR FILL WITH SAE 30 OR 40 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

PURGE PURGE

8 10

LUB

PURGE

4

LITHIUM BASE EP2 GREASE

LUB

PURGE

2

LITHIUM BASE EP2 GREASE

PURGE

6

LITHIUM BASE EP2 GREASE

LUB

22

DOOR HINGES

LUB

1 SHOT

20

LITHIUM BASE EP2 GREASE

23

DOOR CYLINDER PINS

LUB

LUB

2

APPLY OIL LIBERALLY

24

ATTACHMENT

SEE MANUFACTURER'S MAINTENANCE SCHEDULE

LITHIUM BASED EP2 GREASE CONTAINING MOLYBDENUM DISULFIDE ** ANTIFREEZE MUST MEET GM 6038M SPECIFICATIONS SEE ENGINE MANUFACTURER'S MAINTENANCE MANUAL † Use of filters other than genuine Tigercat replacement filters is not recommended.

822 L830 LUBCHART.XLS 03/2006

3.11

LEGEND: CHK = CHECK DRN = DRAIN D/R = DRAIN AND REFILL LUB = LUBRICATE REP = REPLACE

Tigercat 822/L830 Feller Buncher LUBRICATION OF SWING DRIVE GEARBOX

Lubrication and Maintenance STICK CYLINDERS FULLY EXTENDED

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'.

• TIP OF STICK BOOM FULLY SUPPORTED 830-07

PARKING BOOM. FIG.5

HOIST CYLINDER FULLY RETRACTED

LOWER BEARING LUBRICATION

•

Ensure that the boom is properly parked for service (see fig. 5 & fig. 6) and engine is shut off before performing this procedures.

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

TIP OF STICK BOOM FULLY SUPPORTED 830-08

LUBE FITTINGS

••

•

845B-D33

EARLY MACHINES LUBRICATE GEARBOX LOWER BEARINGS On earlier machines to gain access to the lube fitting, remove the hoist cylinder cover.

LUBE FITTINGS

•• •

LH830-31

LATER MACHINES LUBRICATE GEARBOX LOWER BEARINGS On later machines lube fittings are remotely mounted for easy access.

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 3.12

PARKING BOOM. FIG.6

Tigercat 822/L830 Feller Buncher ER BOOM SYSTEM

Lubrication and Maintenance STICK CYLINDERS FULLY EXTENDED

WARNING This machine may be equipped with an ER boom system. Because of this, it may behave in an unexpected manner compared to a conventional boom system.

• TIP OF STICK BOOM FULLY SUPPORTED

When performing maintenance procedures or setting up a machine equipped with an ER boom system, the following points must be noted:

830-07

PARKING BOOM. FIG.5

HOIST CYLINDER FULLY RETRACTED

•

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 boom is properly parked for service (as described on this page, see also fig. 5 & fig. 6) and engine is shut off before disconnecting any hydraulic lines.

Also, for machines equipped with pressurized hydraulic tanks (82210191 to 82210345, 82210347 to 82210350, 82210611 to 82210999, 83020191 to 83020343, 83020611 to 83020999) , relieve pressure in the hydraulic reservoir by opening hydraulic tank vent valve and waiting until the sound of escaping air stops.

TIP OF STICK BOOM FULLY SUPPORTED 830-08

Before attempting to disconnect hydraulic hoses or perform work on the boom system, ensure that:-

PARKING BOOM. FIG.6

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.

(a) The machine is parked on level ground with the head sitting flat on the ground. (b) The stick cylinders are fully extended (fig. 5) or the hoist cylinder fully collapsed (fig. 6). c) The tip of the stick boom supported . d) Do NOT rely on the attachment to support the boom system during servicing. Slow leakage in the hydraulic components can cause the attachment to move unexpectedly.

For additional safety precautions refer to ER BOOM SYSTEM PRECAUTIONS in SECTION 1 OF THIS MANUAL.

3.13

Tigercat 822/L830 Feller Buncher CHECKING THE AIR CONDITIONING SYSTEM

Lubrication and Maintenance CAUTION

Any service work must be performed by a certified A/C technician. The system should be charged with R134a refrigerant only. PAG (polyalkylene glycol) oil should be present in the system and must be used on 'O' rings and fittings during assembly.

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

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

Always use personal protective equipment to guard against flying debris

A/C SYSTEM TOTAL CAPACITIES R134a REFRIGERANT

PAG OIL (polyalkylene glycol)

3 LBS. 0 OZ.

7 OZ.

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

The compressor and charge valves are accessed on the top left side of the engine. The receiver dryer is mounted to the back of the engine compartment.

Perform following inspection along with 125 HOURS inspection outlined in SCHEDULED MAINTENANCE in THIS SECTION. a. Check re-circulating and fresh air filters in operator's cab. Refer to SECTION 2 of the OPERATOR'S MANUAL.

OIL COOLER/ RADIATOR/CAC ASSEMBLY

c. Check for dirt and debris; on the evaporator coil located inside the A/C-heater unit and also the inside of the A/C-heater unit. Clean as required. d. Check and adjust compressor drive belt tension.

CHECK A/C CONDENSER CORE

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

Run air conditioning system for 3 - 5 minutes.

IMPORTANT

••

•

• SLIDE DEBRIS SCREEN OUT AND REMOVE

LH830-09

CHECK A/C CONDENSER CORE

b. Check the condenser core for dirt and debris.

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

It is recommended that during cold weather, when the A/C system is not in use, the system be run for a period of 5 minutes every two weeks. This will circulate oil to all components of the A/C system. g. Check air temperature exiting vents in cab. h. Listen to compressor and blower motor for abnormal noises.* i.

3.14

Check to see that compressor clutch will engage.*

Tigercat 822/L830 Feller Buncher j.

Lubrication and Maintenance

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

•• ••

BINARY SWITCH, SYSTEM PROTECTION

•

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

• A/C RECEIVER/DRYER

A/C RECEIVER/DRYER Check colour in moisture indicator; BLUE is OK. PINK indicates desiccant material in dryer is saturated with moisture. In this situation replace receiver/dryer, evacuate system and recharge system with both refrigerant and PAG oil.*

870-

* Indicates that these repairs must only be carried out by a certified A/C technician.

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

3.15

Tigercat 822/L830 Feller Buncher FILTERS - REMOVE AND REPLACE

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

IMPORTANT

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.

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

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

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.

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

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.

PRIMING PUMP

••

FUEL SHUT-OFF VALVE

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.

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

DRAIN TAP

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

•• •• FUEL LINE WATER SEPARATOR Changing the filter: 1. Park machine on level ground with felling head resting on the ground and stop engine.

830-D47

2. Open engine enclosure doors fully.

3. Turn battery disconnect switch to the OFF position.

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

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

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.

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.

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

3.16

Tigercat 822/L830 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

••

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

822-D56

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

FUEL TANK CLEANOUT COVER

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

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

2. Stop engine. Turn battery disconnect switch to the OFF position. Always install a “DO NOT START ENGINE” sign on the operator’s cab door and in the engine compartment when making repairs to the machine.

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

9. Reinstall the strainer using the hex on end.

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.

REMOVE THE LIGHT HOUSING/STEP DOOR AND ADJACENT CORNER PANEL

•

830-D41

••

ACCESS TO FUEL TANK

3. Remove the light housing fasteners and swing out the light housing panel to access the fuel tank cleanout cover.

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

3.17

Tigercat 822/L830 Feller Buncher

HYDRAULIC FILTER SERVICING GUIDELINES

Lubrication and Maintenance HYDRAULIC TANK PRESSURE GAUGE

IMPORTANT

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.

IMPORTANT Direct contact with oil implies a risk of skin complaints. Oil on skin should be washed off immediately with soap and water. Refer also to WORKING WITH OIL in SECTION 1 of THIS MANUAL.

••

•

NEVER PRE-FILL HYDRAULIC FILTERS 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.

RETURN MANIFOLD

5 - HYDRAULIC RETURN FILTERS

••

• • •

••

• 1 - WATER ABSORBING RETURN FILTER (COLOUR BLUE)

HYDRAULIC OIL FILTERS HYDRAULIC OIL RETURN FILTERS 422-07

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.

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.

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.

4. For machines with pressurized tanks only (82210191 to 82210345, 82210347 to 82210350, 82210611 to 82210999, 83020191 to 83020343, 83020611 to 83020999).

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 debris in tray.

3.18

Tigercat 822/L830 Feller Buncher

Lubrication and Maintenance 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

DRIP TRAY DRAIN HOLE/HOSE

FILTER HEAD

•

•

•

HYDRAULIC OIL TANK

•

GASKET

822-D35

(PRESSURIZED TANKS ONLY, 82210191 TO 82210345, 82210347 TO 82210350, 82210611 TO 82210999, 83020191 TO 83020343, 83020611 TO 83020999)

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

FILTR_SEALS

Remove used gasket and clean gasket seat in head.

Apply clean oil to new gasket surfaces.

HYDRAULIC OIL FILTERS

••

Install new gasket on inside lip of filter.

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)

•

DRIP TRAY DRAIN HOSE

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

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.

FILTER HEAD

• •

GASKET

•

FILTER ELEMENT

SQUARE SECTION GASKET INSTALLATION FILTR_SEALS

'O' RING GASKET INSTALLATION

z 'O' Ring Gasket

••

822-D69

FILTER ELEMENT

Square Section Gasket

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

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

9. Start the engine and check for leaks.

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.

11. Recheck oil level.

12. For machines with pressurized tanks only (82210191 to 82210345, 82210347 to 82210350, 82210611 to 82210999, 83020191 to 83020343, 83020611 to 83020999). Close air vent ball valve. *Refer to HYDRAULIC FILTER SERVICING GUIDELINES on PREVIOUS PAGE.

Remove used gasket and clean groove in head.

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.

3.19

Tigercat 822/L830 Feller Buncher CLOG INDICATOR SIGHT GLASS (IF EQUIPPED)

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

•

2. Turn BATTERY DISCONNECT SWITCH to ‘OFF’ position. Always install a “DO NOT START ENGINE” sign on the operator’s cab door and in the engine compartment when making repairs to the machine.

3. For machines with pressurized tanks only (82210191 to 82210345, 82210347 to 82210350, 82210611 to 82210999, 83020191 to 83020343, 83020611 to 83020999).

Wearing face protection, release air from the hydraulic reservoir by opening the AIR VENT VALVE.

HIGH PRESSURE PILOT FILTER 822-D47 HYDRAULIC HIGH PRESSURE PILOT FILTER 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 to pilot system.

The pilot filter should be changed regularly as a part of scheduled maintenance. A clogged filter will result in low pilot pressure. When a clogged condition is indicated by a loss of controls or slow response or by the clog indicator (if equipped) the pilot filter element will need to be changed at an earlier interval.

4.

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.

Refer to FILTER AND LUBRICATION SCHEDULE in THIS SECTION for recommended servicing intervals.

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

6. Place rags below to catch any spilt oil.

EARLIER MACHINES ONLY

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.

On earlier machines this filter incorporates a clog indicator.

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

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.

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

Refer also to SECTION 5 of the SERVICE MANUAL for more information.

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. 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.

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

11. For machines with pressurized tanks only (82210191 to 82210345, 82210347 to 82210350, 82210611 to 82210999, 83020191 to 83020343, 83020611 to 83020999). Close air vent ball valve. *Refer to HYDRAULIC FILTER SERVICING GUIDELINES in THIS SECTION.

3.20

Tigercat 822/L830 Feller Buncher

Lubrication and Maintenance

HYDRAULIC OIL RETURN STRAINERS/DIFFUSERS

'O' RING

STRAINERS

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.

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 822-06

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

•

DRAIN PLUG (ONLY ACCESSIBLE WITH MAIN CONTROL VALVE REMOVED)

HYDRAULIC OIL TANK

6. 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.

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

2. Stop engine.

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

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

4. For machines with pressurized tanks only (82210191 to 82210345, 82210347 to 82210350, 82210611 to 82210999, 83020191 to 83020343, 83020611 to 83020999).

Wearing face protection, release air from the hydraulic reservoir 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).

AIR VENT VALVE

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

DRIP TRAY DRAIN HOLE/HOSE

12. Reinstall the strainers using the hex on end.

Note: Repair any burrs created when removing the strainer before reinstalling.

••

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

822-D35

HYDRAULIC OIL TANK

14. Connect sensor wires to sensors on access cover.

(PRESSURIZED TANKS ONLY, 82210191 TO 82210345, 82210347 TO 82210350, 82210611 TO 82210999, 83020191 TO 83020343, 83020611 TO 83020999)

15. Refill and check for leaks.

5. Turn BATTERY DISCONNECT SWITCH to the OFF position. Always install a “DO NOT START ENGINE” sign on the operator’s cab door and in the engine compartment when making repairs to the machine.

16. For machines with pressurized tanks only (82210191 to 82210345, 82210347 to 82210350, 82210611 to 82210999, 83020191 to 83020343, 83020611 to 83020999). Close air vent ball valve.

3.21

Tigercat 822/L830 Feller Buncher AIR INTAKE MAINTENANCE

Lubrication and Maintenance 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

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

•

354-15

•

AIR CLEANER OUTLET TUBE

•

PRIMARY ELEMENT

•

•

•

•

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

SAFETY ELEMENT

ONLY THE PURIFIED AIR GOES TO THE AIR FILTER

PRECLEANER OPERATION AIRCLEANER

AIR FILTER ELEMENTS

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

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

DISCHARGE PORT AREA

The most common and most damaging air intake servicing problems are:

218-21B

PRECLEANER

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

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.

3.22

Tigercat 822/L830 Feller Buncher

Lubrication and Maintenance

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

FILTER RESTRICTION INDICATOR

••

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.

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

822-D42 FILTER RESTRICTION INDICATOR FILTER RESTRICTION INDICATOR

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

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.

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.

CLEAN OUT COVER

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.

421-15A

AIR CLEANER UNLOADER VALVE

AIR INTAKE CLEANOUT COVER

AIR INTAKE CLEANOUT COVER PLATE

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.

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 accumulation.

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 accumulation of debris.

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.

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.

3.23

Tigercat 822/L830 Feller Buncher

••

CHECK CONDITION OF SEAL

•• 822-D58

Lubrication and Maintenance UNDERCARRIAGE SWIVEL ACCESS DOOR (LATER MACHINES) The undercarriage swivel access door is used on later machines. The notch in the door indicates the position of the bolt at the swivel point. The bolt at the swivel point is longer and is equipped with a clamp to prevent it from being fully removed from the undercarriage.

PRECLEANER NOTCH IN DOOR INDICATES POSITION OF PIVOT POINT

AIR INTAKE SEAL

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.

Refer to SCHEDULED MAINTENANCE - 2000 HOURS in THIS SECTION for required maintenance in this area.

830-D45

SWIVEL ACCESS DOOR SWIVEL BOLT: LOOSEN ONLY ENOUGH TO ALLOW DOOR TO SWIVEL FREELY

NOTCH IN DOOR INDICATES POSITION OF PIVOT POINT

•• RUBBER ELBOWS AND TUBING

•

• • ••

822-D58

INTAKE TUBING AND JOINTS

INTAKE TUBING AND JOINTS Replace turbocharger rubber inlet elbow and coupling - High temperatures in this area can cause the rubber to harden.

830-D44

SWIVEL ACCESS DOOR

Loosen the swivel bolt enough to allow the access door to swing freely. Do not attempt to use excess force to fully remove the swivel bolt. The access door is heavy. A falling access door could cause serious injury or death.

Check ALL air intake tubing, rubber couplings and band clamps for signs of wear and leakage.

DANGER Do not fully remove the access door swivel bolt. A falling access door could cause serious injury or death.

3.24

Tigercat 822/L830 Feller Buncher

Lubrication and Maintenance

TORQUE CHART LOCATION Cylinder, Hoist, (9442B) Piston nut Cylinder end cap bolts Cylinder, Hoist, (19666B) Piston nut Retaining bolt Cylinder end cap bolts Cylinder, Stick, (15733B & 15734B) Piston nut Cylinder end cap bolts Cylinders, Leveller Piston nut Cylinder end cap bolts

THREAD DIAMETER

TORQUE (LUBRICATED) lbf-ft Nm

M18

6980 270

9460 367

M8 M16

hand tight 18 225

hand tight 24 305

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

M16

200

275

M24 M22 M12 5/8" UNC

675 540 80 160-175

925 725 110 215-235

1/2" 7/16" UNC GR5

80-88 40

109-119 54

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

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

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

M24

675

925

Cab securing bolts Swing bearing Swing bearing bolts Swing gearbox mounting bolts Engine mounting Cummins QSL9 Engine Bolts, bracket/mount to chassis rear Bolts, bracket/mount to chassis front Bolts, bracket to engine, front Bolts, bracket to gearbox, rear Pump Drive Torsional drive coupler mounting Pump drive gearbox mounting Undercarriage Track shoe bolts (D6) Track shoe bolts (FH400) Track shoe bolts (F8) Idler bolts Idler bolts Roller mounting bolts Roller mounting bolts Sprocket bolts Gearbox mounting bolts Drive motor mounting bolts Leveller, fore/aft pivot shaft and housing bolts TORQUECHART R1.XLS 03/06

*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.

3.25

Tigercat 822/L830 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

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

DRY lbf-ft Nm 11 - 12 15 - 16 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 DRY LUBRICATED COARSE THREAD lbf-ft Nm lbf-ft Nm lbf-ft Nm 8 - 10 11 - 13 1/4" - 20 7- 8 10 - 11 8 - 10 11 - 13 26 - 30 35 - 40 5/16" - 18 14 - 18 19 - 24 38275 13 - 20 33 - 36 45 - 49 3/8" - 16 31 - 34 42 - 46 23 - 25 31 - 34 52 - 57 71 - 77 7/16" - 14 49 - 54 66 - 73 37 - 41 50 - 55 80 - 88 109 - 119 1/2" - 13 75 - 83 102 - 112 57 - 63 77 - 85 115 - 127 156 - 172 9/16" - 12 109 - 120 148 - 162 82 - 90 111 - 122 159 - 175 216 - 237 5/8" - 11 150 - 165 204 - 223 113 - 124 152 - 168 282 - 310 393 - 420 3/4" - 10 266 - 293 360 - 397 200 - 220 271 - 298 455 - 501 617 - 679 7/8" - 9 394 - 433 535 - 586 296 - 326 402 - 441 682 - 750 925 - 1016 1" - 8 591 - 649 802 - 879 443 - 489 601 - 663 966 - 1062 1310 - 1441 1 1/8" - 7 794 - 873 1077 - 1183 596 - 656 808 - 889 1360 - 1496 1844 - 2027 1 1/4" - 7 1120 - 1232 1519 - 1670 840 - 924 1139 - 1252 LUBRICATED FINE DRY LUBRICATED THREAD lbf-ft Nm lbf-ft Nm lbf-ft Nm 10 - 13 14 - 17 1/4" - 28 9 - 10 12 - 13 9 - 10 12 - 13 18 - 25 25 - 33 5/16" - 24 17 - 22 23 - 29 16 - 20 21 - 27 37 - 41 50 - 55 3/8" - 24 35 - 39 48 - 53 26 - 29 35 - 39 58 - 64 79 - 86 7/16" - 20 55 - 61 75 - 83 41 - 45 56 - 61 90 - 99 122 - 134 1/2" - 20 85 - 94 116 - 127 64 - 70 87 - 95 128 - 141 174 - 191 9/16" - 18 121 - 133 164 - 180 91 - 100 124 - 135 180 - 198 244 - 268 5/8" - 18 170 - 187 231 - 253 128 - 141 174 - 191 315 - 347 427 - 470 3/4" - 16 297 - 327 403 - 443 223 - 245 303 - 332 501 - 550 679 - 745 7/8" - 14 434 - 477 589 - 646 326 - 359 442 - 486 746 - 821 1012 - 1113 1" - 12 646 - 711 876 - 965 484 - 534 657 - 724 1083 - 1191 1469 - 1613 1 1/8" - 12 891 - 980 1208 - 1328 668 - 735 906 - 996 1509 - 1660 2046 - 2250 1 1/4" - 12 1240 - 1364 1682 - 1849 931 - 1024 1262 - 1387

METRIC

METRIC BOLT TORQUE SPECIFICATIONS SIZE

CLASS 4.8 LUBRICATED Nm lbf-ft Nm

DRY lbf-ft

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

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

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

M6 M8 M10

4.8 12.0 23.0

3.5 8.5 17.0

6.0 15.0 29.0

4.5 11.0 21.0

9.0 22.0 43.0

6.5 16.0 32.0

11.0 28.0 55.0

8.5 20.0 40.0

13.0 32.0 63.0

9.5 24.0 47.0

17.0 40.0 80.0

12.0 30.0 60.0

15.0 37.0 75.0

11.5 28.0 55.0

19.0 47.0 95.0

14.5 35.0 70.0

M12 M14 M16

40.0 63.0 100.0

29.0 47.0 73.0

50.0 80.0 125.0

37.0 60.0 92.0

75.0 120.0 190.0

55.0 88.0 140.0

95.0 150.0 240.0

70.0 110.0 175.0

110.0 175.0 275.0

80.0 130.0 200.0

140.0 225.0 350.0

105.0 165.0 225.0

130.0 205.0 320.0

95.0 150.0 240.0

165.0 260.0 400.0

120.0 190.0 300.0

M18 M20 M22

135.0 190.0 260.0

100.0 140.0 190.0

175.0 240.0 330.0

125.0 180.0 250.0

260.0 375.0 510.0

195.0 275.0 375.0

330.0 475.0 650.0

250.0 350.0 475.0

375.0 530.0 725.0

275.0 400.0 540.0

475.0 675.0 925.0

350.0 500.0 675.0

440.0 625.0 850.0

325.0 560.0 460.0 800.0 625.0 1,075.0

410.0 580.0 800.0

M24 M27 M30

330.0 490.0 675.0

250.0 360.0 490.0

425.0 625.0 850.0

310.0 650.0 450.0 950.0 625.0 1,300.0

M33 900.0 M36 1,150.0

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

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

3.26

Tigercat 822/L830 Feller Buncher

SECTION 4 - HYDRAULIC SYSTEM CONTENTS - SECTION 4

SEPTEMBER 2007

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

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

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

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

VENT/BREATHER, HYDRAULIC TANK ................................................................................................................

4.5 4.6 4.5 4.6 4.4

HAND FILL PUMP, HYDRAULIC OIL ........................................................................................................................ 4.7 HIGH PRESSURE LIMITING CONTROL VALVE SET LOAD SENSE RELIEF VALVE .................................................................................................................... 4.32 HYDRAULIC OIL LEVEL SIGHT GAUGES ............................................................................................................... 4.5 HYDRAULIC OIL TANK DESCRIPTION ....................................................................................................................................................... 4.4 OIL LEVEL SIGHT GAUGES ................................................................................................................................. 4.5 HYDRAULIC PUMPS CLAMPS AND FAN PUMP ................................................................................................................................... 4.10 MAIN PUMP ............................................................................................................................................................ 4.8 MAIN PUMP CONTROL VALVE ....................................................................................................................... 4.28 MAIN PUMP WEAR TEST ................................................................................................................................. 4.8 SAW PUMP .......................................................................................................................................................... 4.10 HYDRAULIC SYSTEM OPERATION CIRCUIT DESCRIPTION ..................................................................................................................................... 4.19 CLAMPS AND ACCUMULATING ARMS CIRCUIT ............................................................................................... 4.2 FAN DRIVE SYSTEM ............................................................................................................................................. 4.3 FLOW ON DEMAND AND LOAD COMPENSATION .......................................................................................... 4.19 MAIN HYDRAULIC SYSTEM; BOOM, SWING, WRIST, DRIVE .......................................................................... 4.2 MARGIN PRESSURE ............................................................................................................................................. 4.9 MARGIN PRESSURE, SET ................................................................................................................................. 4.29 PILOT CIRCUIT ...................................................................................................................................................... 4.3 PRESSURE GAUGE CONNECTIONS ................................................................................................................ 4.30 SAW CIRCUIT ........................................................................................................................................................ 4.3 SWING SYSTEM .................................................................................................................................................... 4.2 TRACK DRIVE SYSTEM ........................................................................................................................................ 4.2 HYDRAULIC TANK .................................................................................................................................................... 4.4 LOAD SENSING BASIC DESCRIPTION ......................................................................................................................................... 4.12 BASIC PRINCIPLES ............................................................................................................................................ 4.11 OPERATING TIPS ................................................................................................................................................ 4.14 SET LOAD SENSE RELIEF VALVE .................................................................................................................... 4.32 SET MARGIN PRESSURE ................................................................................................................................... 4.29 MAIN CONTROL VALVE/MANIFOLD CONTROL SPOOL SECTIONS ........................................................................................................................... 4.20 CONTROL VALVE SECTIONS ............................................................................................................................ 4.21 CONTROL VALVE SPOOL OPERATION ............................................................................................................ 4.23 HIGH PRESSURE LIMITING CONTROL VALVE ................................................................................................ 4.28 MAIN CONTROL VALVE DESCRIPTION ............................................................................................................ 4.20 PORT RELIEF AND ANTICAVITATION VALVE .................................................................................................. 4.22 ADJUSTING PROCEDURE ............................................................................................................................. 4.22 SWING AND DRIVE MOTOR SPOOL SECTIONS ............................................................................................. 4.20 PILOT FILTER, HIGH PRESSURE ............................................................................................................................ 4.6 PRESSURE SETTINGS .......................................................................................................................................... 4.33 SCHEMATIC DIAGRAMS HIGH PRESS. LIMITING CONTROL ................................................................................................................... 4.28 HYDRAULIC SCHEMATIC ................................................................................................................................... 4.15 LOAD SENSING (FLOW ON DEMAND) ............................................................................................................. 4.11 LOAD SENSING SYSTEM CIRCUIT DIAGRAM ....................................................................................... 4.17, 4.18 MAIN PUMP ............................................................................................................................................................ 4.8 MAIN VALVE WITH HIGH PRESS. LIMITING CONTROL .................................................................................. 4.20

Tigercat 822/L830 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. Also included in this circuit when applicable are the levelling functions of the L830.

Swing system

2. Variable displacement circuit for the saw.

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 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.

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

4. 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.

Levelling system (L830 only) Two levelling cylinders are used to operate the levelling function. Each cylinder is equipped with a counterbalance valve or pilot operated check valve for crossline relief and load holding.

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.

A electro-hydraulically operated levelling control valve is operated by the IQAN control system. For a detailed description of the levelling system refer to SECTION 13 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.

Track drive system The track drive hydraulic circuit is incorporated in the main hydraulic load sensing system and utilizes high-torque, axialpiston 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, multiple-disc, 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. 4.2

Tigercat 822/L830 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. The saw valve has both main and port reliefs.

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.

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

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

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 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 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 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

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

4.3

Tigercat 822/L830 Feller Buncher HYDRAULIC OIL TANK

Hydraulic system

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

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.

O-RING

REUSABLE STRAINERS/ DIFFUSERS (3 PLACES)

ROUND ACCESS COVER

•

•

•

• FIRST SIGHT GAUGE

•• • • SECOND SIGHT GAUGE

830-11

AIR VENT FILTER

• 822-D35X

AIR VENT VALVE

HYDRAULIC OIL TANK (PRESSURIZED TANKS ONLY)

VENT/BREATHER, HYDRAULIC TANK PRESSURIZED TANKS ONLY (82210191 TO 82210345, 82210347 TO 82210350, 82210611 TO 82210999, 830*0191 TO 830*0343, 830*0611 TO 830*0999) The air space in the top of the hydraulic tank is vented to atmosphere via a check valve and spinon 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.

SERVICE NOTE:

•

LOW LEVEL SENDING UNIT, FOR WARNING BUZZER DRAIN PLUG

••

•

LOW LEVEL SENDING UNIT, FOR WARNING LIGHT

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

AIR VENT FILTER

DRAIN PLUG (ONLY ACCESSIBLE WITH MAIN CONTROL VALVE REMOVED)

CONNECTION TO PRESSURE GAUGE

HYDRAULIC TANK

SOME COMPONENTS REMOVED FOR CLARITY

AIR VENT VALVE

• •• CHECK VALVE 10 PSI. 822-D41

TOP OF HYDRAULIC TANK

•• ••

VENT, HYDRAULIC TANK (PRESSURIZED TANKS)

IMPORTANT Direct contact with oil implies a risk of skin complaints. Oil on skin should be washed off immediately with soap and water. Refer also to WORKING WITH OIL in SECTION 1 of THIS MANUAL. 4.4

Tigercat 822/L830 Feller Buncher

Hydraulic system 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.

SOME COMPONENTS REMOVED FOR CLARITY BREATHER FILTER

TOP OF HYDRAULIC TANK

••

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.

• H822-03

BREATHER, HYDRAULIC TANK (NON-PRESSURIZED TANKS)

BREATHER, HYDRAULIC TANK NON-PRESSURIZED TANKS (82210346, 82210351 TO 82210610, 830*0344 TO 830*0610) The air space in the top of the hydraulic tank is vented to atmosphere via a spin-on filter. The hydraulic tanks on machines serial numbers 82210346, 82210351 to 82210610 and 830*0344 to 830*0610 are not pressurized.

•

FIRST SIGHT GAUGE

PRESSURE SWITCH

•

• •• TANK AIR PRESSURE GAUGE IF EQUIPPED) 422-07

SECOND SIGHT GAUGE

••

•

••

•

•• ••

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.

•• ••

5 - HYDRAULIC RETURN FILTERS

RETURN MANIFOLD

LOW LEVEL SENDING UNIT, FOR WARNING LIGHT

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

FILTER SERVICE NOTE

TEMPERATURE GAUGE (EARLIER MACHINES ONLY)

422-05

•• ••

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

LOW LEVEL SENDING UNIT, FOR WARNING BUZZER

RETURN STRAINERS/DIFFUSERS

HYDRAULIC OIL LEVEL SIGHT GAUGES

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

OIL LEVEL SIGHT GAUGES 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 (earlier machines also incorporated 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.

Continued on next page

4.5

Tigercat 822/L830 Feller Buncher

Hydraulic system

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. CLOG INDICATOR SIGHT GLASS (IF EQUIPPED)

822-D47

••

HIGH PRESSURE PILOT FILTER

HIGH PRESSURE PILOT FILTER 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.

The pilot filter should be changed regularly as a part of scheduled maintenance. A clogged filter will result in low pilot pressure. When a clogged condition is indicated by a loss of controls or slow response or by the clog indicator (if equipped) the pilot filter element will need to be changed at an earlier interval.

Refer to FILTER AND LUBRICATION SCHEDULE and FILTERS, PILOT in SECTION 3 of THIS MANUAL for recommended servicing intervals and filter servicing information.

EARLIER MACHINES ONLY On earlier machines this filter incorporates a clog indicator.

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 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.

4.6

Tigercat 822/L830 Feller Buncher

Hydraulic system

FEMALE QUICK DISCONNECT

•• •• SUCTION TUBE

822-D46 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 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.

RETURN MANIFOLD

••

•• ••

RETURN MANIFOLD PORT

CONNECT THE QUICK DISCONNECT TO THE RETURN MANIFOLD PORT

822-D40

FILLING HYDRAULIC TANK

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 water but will not protect the system from careless use. Dust left on the suction tube will significantly reduce the life of the filters.

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.

4.7

Tigercat 822/L830 Feller Buncher

Hydraulic system

SAW PUMP PRESSURE COMPENSATOR

CLAMPS AND SAW PUMP FAN DRIVE PUMP (PISTON PUMP) (DOUBLE GEAR PUMP)

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

•• ••

•• ••

••

•• •• ••

822-D70

••

••

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

COOLING FAN CONTROL VALVE

HYDRAULIC PUMPS

PILOT SUPPLY VALVE

HYDRAULIC PUMPS All hydraulic functions are powered by three pumps mounted one behind the other and attached to the flywheel housing of the engine.

The first pump (main pump) is a piston pump with load sensing and horsepower limiting controls used for main hydraulic circuit (travel, swing, boom, wrist and levelling - if equipped).

Driven off the PTO of the main pump is the saw pump. It is a pressure compensated piston pump.

Driven off the PTO of 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 approximately 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.

3. Position the machine so that the upper is perpendicular to the tracks. Lower the felling head and raise one track clearly above the 4.8

Tigercat 822/L830 Feller Buncher

4

5

Hydraulic system

ground. Tilt the felling head back fully and turn the swing brake ON.

by a small amount. This difference is known as margin pressure (differential pressure or Delta P).

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.

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 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.

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.

••

GAUGE TEST PORT 'X1' ANTI-STALL SIGNAL PRESSURE

HORSEPOWER CALIBRATION DO NOT ADJUST

•• ••

• GAUGE TEST PORT 'L.S.'

• •

Also refer to ENGINE ANTI-STALL in SECTION 9 of THIS MANUAL.

ENGINE ANTI-STALL SOLENOID VALVE

••

•

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.

LINDE MAIN VALVE MANIFOLD

PILOT SUPPLY 'P1'PORT

••

••

MARGIN PRESSURE ADJUSTING SCREW

MAIN PUMP

GAUGE TEST PORT ANTI-STALL SIGNAL PRESSURE

•

L.S. GAUGE TEST PORT 'P' GAUGE TEST PORT

(QSC 8.3 ENGINE - 82210191 TO 82210600 ONLY)

ENGINE ANTI-STALL SOLENOID VALVE

•

•

MAIN PUMP CONTROLLER (LS CONTROL) 822-D75

HIGH PRESSURE LIMITING CONTROL

••

EARLIER DESIGN

LINDE MAIN VALVE MANIFOLD

103-17A

••

MAIN PUMP

• •

••

••

GAUGE TEST PORT 'L.S.'

•• 822-D80

'P' GAUGE TEST CONN.

L.S. GAUGE TEST CONN.

MAIN VALVE MANIFOLD

•

'LS' CONNECTION FROM MAIN VALVE

••

MARGIN PRESSURE ADJUSTING SCREW

•• •

MAIN PUMP CONTROLLER (LS CONTROL)

HIGH PRESSURE LIMITING CONTROL

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.

LATER DESIGN 860C-035

LINDE 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.

The pump then adjusts its output volume until the pump output pressure exceeds the LS pressure 4.9

Continued on next page

Tigercat 822/L830 Feller Buncher

Hydraulic system

SAW PUMP For the operation and adjustments of this pump refer to SECTION 17 of THIS MANUAL. CLAMPS AND FAN PUMP The clamps and fan pump is a dual gear pump driven off the back of the saw pump. For detailed information on this pump, refer to SECTION 10 and SECTION 18 of THIS MANUAL.

4.10

Tigercat 822/L830 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.

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.

853SM18

FLOW

WASTED

W USED PRESSURE

FIG. 1

FIXED DISPLACEMENT PUMP

853SM16

FIG. 2

HP =CO

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.

NS 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

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) 4.11

FIG.6

853SM16

Tigercat 822/L830 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.

4.12

Tigercat 822/L830 Feller Buncher

Hydraulic system

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.

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; 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.

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

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.

4.13

Tigercat 822/L830 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. When operating the swing function move the lever slowly. Operating the swing harshly or quickly reversing direction wastes power and generates excessive heat, as oil is dumped over the crossline reliefs.

4.14

Hydraulic system

822-48

HYDRAULIC SCHEMATIC LOAD SENSING CIRCUIT

Tigercat 822/L830 Feller Buncher

4.15

Tigercat 822/L830 Feller Buncher

Hydraulic system

4.16

Tigercat 822/L830 Feller Buncher

822-16X

Hydraulic system

LOAD SENSING SYSTEM CIRCUIT DIAGRAM (QSC 8.3 ENGINE - 82210191 TO 82210600 ONLY) 4.17

Tigercat 822/L830 Feller Buncher

822-37

Hydraulic system

LOAD SENSING SYSTEM CIRCUIT DIAGRAM 4.18

Tigercat 822/L830 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. Also included in this circuit when applicable are the levelling functions of the L830.

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.

The levelling control valve (if equipped) is also supplied by the main pump. A load sensing signal is sent back from levelling control valve (LS port) to the main pump regulator (LS port) to control the pump output pressure. Refer to SECTION 13 for more complete information about the levelling circuit.

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.

4.19

Tigercat 822/L830 Feller Buncher CONTROL VALVE MANIFOLD

DRIVE, LEFT

TILT CYLINDER

DRIVE, RIGHT

Hydraulic system 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 4.20

Tigercat 822/L830 Feller Buncher MAKE UP OR ANTICAVITATION VALVE

Hydraulic system MAKE UP OR ANTICAVITATION VALVE

WORK PORTS

•

•

PILOT CHECK

•

PILOT END CAP

•

SPOOL TRAVEL STOP (ADJUSTABLE)

AIR BLEED PLUG

• • • • 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) 4.21

Tigercat 822/L830 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

• •

ORIFICE 'A'

•

•

RETURN

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.

•

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

90744-5A

RETURN

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

4.22

ADJUSTING SCREW • 5MM ALLEN KEY

MAIN VALVE PORT RELIEF VALVE

Tigercat 822/L830 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.

4.23

Tigercat 822/L830 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 CONTROL VALVE VALVE MOVES LEFT 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.

4.24

Tigercat 822/L830 Feller Buncher PILOT OIL

(1) COMPENSATOR VALVE

Hydraulic system CONTROL SPOOL FULLY SHIFTED TO RIGHT

SHUTTLE VALVE

•

•• •

•

•

•

•

•

•

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.

4.25

Tigercat 822/L830 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’.

4.26

Tigercat 822/L830 Feller Buncher PILOT OIL

Hydraulic system (1) CONTROL SPOOL FULLY SHIFTED TO RIGHT

(2) COMPENSATOR VALVE SETTLES IN A BALANCE POSITION

•

• •

•

•

•

•

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

•

• LOAD SENSING PASSAGE 'LS'

RETURN PASSAGE 'T'

(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.

4.27

Tigercat 822/L830 Feller Buncher

Hydraulic system

HIGH PRESSURE LIMITING CONTROL VALVE The main pump is protected by a High Pressure Limiting control. The H.P.L. control is attached to the main control valve manifold. The earlier design contains three relief valves. The later design contains two relief valves.

The first relief valve (P2) limits L.S. pressure to approximately 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. Margin pressure is the differance between 'P' port pressure and L.S. port pressure, observed while a function is operating.

HIGH PRESSURE LIMITING CONTROL

LINDE MAIN VALVE MANIFOLD

EARLIER DESIGN

••

•

•

••

L.S. GAUGE TEST PORT 'P' GAUGE TEST PORT

SYSTEM RELIEF VALVE NON-ADJUSTABLE

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

•• ••

'P' GAUGE TEST CONN.

L.S. GAUGE TEST CONN.

MAIN VALVE MANIFOLD

•

The third relief valve (P1) is screwed fully in and is not used. This third relief is present only on early machines.

••

••

L.S. PRESSURE LIMIT, SET AT 300 BAR(4300 PSI) WITH GAUGE ON 'P' TEST PORT • 4MM ALLEN KEY • 13MM WRENCH SYSTEM RELIEF VALVE NON-ADJUSTABLE

•• •• 860C-035

H.P.L. CONTROL, MANIFOLD/ VALVE SECTION SCHEMATIC WITH PORT RELIEFS 4.28

LATER DESIGN

LINDE MAIN VALVE MANIFOLD

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

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

853SM24

••

LINDE MAIN VALVE MANIFOLD

103-17A

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

Tigercat 822/L830 Feller Buncher

Hydraulic system

SET MARGIN PRESSURE

ENGINE ANTI-STALL SOLENOID VALVE

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.

••

GAUGE TEST PORT ANTI-STALL SIGNAL PRESSURE

••

••

••

MAIN PUMP

**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.

••

GAUGE TEST PORT 'L.S.'

'LS' CONNECTION FROM MAIN VALVE

••

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

MARGIN PRESSURE ADJUSTING SCREW

822-D80

MAIN PUMP CONTROLLER (LS CONTROL)

Continued on next page

MARGIN PRESSURE ADJUSTING SCREW

• •

••

GAUGE TEST PORT 'X1' ANTI-STALL SIGNAL PRESSURE

HORSEPOWER CALIBRATION DO NOT ADJUST

•• ••

ENGINE ANTI-STALL SOLENOID VALVE

••

•• GAUGE TEST PORT 'L.S.'

•• MAIN PUMP

••

PILOT SUPPLY 'P1'PORT MARGIN PRESSURE ADJUSTING SCREW

MAIN PUMP CONTROLLER (LS CONTROL) 822-D75

860C-003.AI

(QSC 8.3 ENGINE - 82210191 TO 82210600 ONLY)

MAIN PUMP CONTROLLER VALVE

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'

• •

••

••

•

••

• •• •

PUMP OUTLET PRESSURE PUMP SWASH CONTROL PASSAGE

90669

TANK

CROSS SECTION OF MAIN PUMP CONTROL VALVE (QSC 8.3 ENGINE - 82210191 TO 82210600 ONLY) 4.29

8mm

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

Tigercat 822/L830 Feller Buncher

Hydraulic system

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.

LINDE MAIN VALVE MANIFOLD

HIGH PRESSURE LIMITING CONTROL

•• •

•

•

L.S. GAUGE TEST PORT 'P' GAUGE TEST PORT

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

103-17A

EARLIER DESIGN

••

LINDE 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.'

•• •• PRESSURE TEST PORTS ON MAIN PUMP AND CONTROLLER 822-D66

(QSC 8.3 ENGINE - 82210191 TO 82210600 ONLY) 4.30

MARGIN PRESSURE ADJUSTING SCREW

Tigercat 822/L830 Feller Buncher 'P' GAUGE TEST CONN.

L.S. GAUGE TEST CONN.

Hydraulic system 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.

MAIN VALVE MANIFOLD

•

• •

••

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

L.S. PRESSURE LIMIT, SET AT 300 BAR(4300 PSI) WITH GAUGE ON 'P' TEST PORT • 4MM ALLEN KEY • 13MM WRENCH

5. Press PILOT RESET button to activate pilot system and turn anti-stall switch OFF.

SYSTEM RELIEF VALVE NON-ADJUSTABLE

•• •• 860C-035

3. Close and latch the cab front door.

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).

LATER DESIGN

LINDE MAIN VALVE MANIFOLD

MAIN PUMP

• ENGINE ANTI-STALL SOLENOID VALVE

•• ••

GAUGE TEST PORT ANTI-STALL SIGNAL PRESSURE

•• PUMP OUTLET MANIFOLD

•• GAUGE TEST PORT 'L.S.'

••

MARGIN PRESSURE ADJUSTING SCREW

•• GAUGE TEST PORT 'P'

822-D81

PRESSURE TEST PORTS ON MAIN PUMP AND CONTROLLER 4.31

Tigercat 822/L830 Feller Buncher

Hydraulic system

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.

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.

LINDE MAIN VALVE MANIFOLD

• ••

••

••

L.S. GAUGE TEST PORT 'P' GAUGE TEST PORT

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

'P' GAUGE TEST CONN.

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.

EARLIER DESIGN

••

LINDE MAIN VALVE MANIFOLD

103-17A

SET LOAD SENSE RELIEF VALVE

L.S. GAUGE TEST CONN.

MAIN VALVE MANIFOLD

•

••

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.

••

L.S. PRESSURE LIMIT, SET AT 300 BAR(4300 PSI) WITH GAUGE ON 'P' TEST PORT • 4MM ALLEN KEY • 13MM WRENCH SYSTEM RELIEF VALVE NON-ADJUSTABLE

•• ••

2. Close and latch the cab front door.

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

HIGH PRESSURE LIMITING CONTROL

860C-035

4. Press PILOT RESET button to activate pilot system and turn anti-stall switch OFF. 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.

4.32

LATER DESIGN

LINDE MAIN VALVE MANIFOLD

Tigercat 822/L830 Feller Buncher

Hydraulic system

PRESSURE AND SPEED SETTINGS Model: 822 L830 Machine Function ENGINE RPM (With Cummins QSL9 Engine) FULL THROTTLE, NO LOAD MAXIMUM LOW IDLE, NO LOAD RATED WORKING ENGINE RPM (With Cummins QSC8.3 Engine) FULL THROTTLE, NO LOAD MAXIMUM LOW IDLE, NO LOAD RATED WORKING R.H. AND L.H. FINAL DRIVE CROSSLINE RELIEFS START OF REGULATION BRAKE RELEASE SPEED: MAIN PUMP (Linde 160cc) ANTI-STALL SET POINT RPM (QSC) STAND-BY PRESSURE MARGIN PRESSURE MAIN PUMP (Linde 210cc) ANTI-STALL SET POINT RPM (QSL9) STAND-BY PRESSURE MARGIN PRESSURE MAIN VALVE (Linde) FELLER BUNCHER MAIN RELIEF LOAD SENSE RELIEF P1 LOAD SENSE RELIEF P2 BOOM PORT RELIEFS STICK PORT RELIEFS TILT PORT RELIEFS WRIST PORT RELIEFS LEVEL FORE/AFT PORT RELIEFS (LINDE) LEVEL RIGHT/LEFT PORT RELIEFS (LINDE) MAIN VALVE (Linde) HARVESTER MAIN RELIEF LOAD SENSE RELIEF P1 LOAD SENSE RELIEF P2 BOOM PORT RELIEFS STICK PORT RELIEFS LEVEL FORE/AFT PORT RELIEFS (LINDE) LEVEL RIGHT/LEFT PORT RELIEFS (LINDE) TELESCOPIC BOOM OUT TELESCOPIC BOOM IN PUMP 2 PILOT SUPPLY MAIN RELIEF LEVELER PILOT RELIEF (FOR LINDE ONLY) SWING CROSSLINE RELIEFS SPEED SAW PUMP PRESSURE OVERRIDE - Saw, Tigercat & KW PRESSURE OVERRIDE - Shear, Tigercat PRESSURE OVERRIDE - Harvester 822 L830 PRESSURE SETTINGS.XLS

Setting 1900 RPM 950 RPM 1800 RPM 2300 RPM 950 RPM 2200 RPM 4700 PSI + 1/8 turn 3600 PSI 500 PSI (WITH TRACK STALLED) 10 RPM MAX. 28 RPM MAX.

LOW DRIVE

2000 RPM 500 PSI MEASURED @ 'P' (LOW IDLE) 300 PSI 1700 RPM 500 PSI MEASURED @ 'P' (LOW IDLE) 300 PSI NON-ADJUSTABLE SCREW IN FULLY (LOCKED OUT) 4300 PSI AT 'P' PORT (4000 PSI AT 'LS' PORT) 4700 PSI (CRACKING PRESSURE) 4700 PSI (CRACKING PRESSURE) 4700 PSI (CRACKING PRESSURE) 3000 PSI @ 'LS' PORT (FULL THROTTLE) 4700 PSI (CRACKING PRESSURE) 4700 PSI (CRACKING PRESSURE) NON-ADJUSTABLE SCREW IN FULLY (LOCKED OUT) 4300 PSI AT 'P' PORT (4000 PSI AT 'LS' PORT) 4700 PSI (CRACKING PRESSURE) 4700 PSI (CRACKING PRESSURE) 4700 PSI (CRACKING PRESSURE) 4700 PSI (CRACKING PRESSURE) 3000 PSI AT 'LS' PORT (FULL THROTTLE) 4700 PSI (CRACKING PRESSURE) 3600 PSI AT 'LS' PORT (FULL THROTTLE) 425 PSI 260 PSI 3000 PSI AT 'LS' PORT (3300 PSI AT 'P' PORT) 6 RPM 3600 PSI 3600 PSI 3200 PSI

4.33

Continued on next page

Tigercat 822/L830 Feller Buncher

Hydraulic system

SAW CONTROL VALVE MAIN RELIEF - Saw set-up 4000 PSI SAW PORT RELIEF Full in MAIN RELIEF - Shear set-up Full In SHEAR PORT RELIEF - Open & Close 4000 PSI SAW MOTOR (Tigercat DT5001) START OF REGULATION 3200 PSI SPEED 1250-1300 RPM MOTOR 'X' DIMENSION 9.5mm (0.37") OF 110mm (4.33") SAW MOTOR (Tigercat DT5501, DT5601, ST/DT5701, ST/DT5401) START OF REGULATION 3200 PSI SPEED 1125-1175 RPM MOTOR 'X' DIMENSION 9.5mm (0.37") OF 110mm (4.33") SAW MOTOR (Koehring/Warratah) START OF REGULATION 3200 PSI SPEED 1150-1200 RPM MOTOR 'X' DIMENSION 16mm (0.63") OF 90mm (3.56") ATTACHMENT VALVE, STANDARD - Saw 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) ATTACHMENT VALVE, STANDARD - Shear MAIN RELIEF 2700 PSI (SET AT FULL THROTTLE) CLAMP ARM PORT RELIEFS - Open 3200 PSI (SET AT LOW IDLE) CLAMP ARM PORT RELIEFS - Close Full In ACCUMULATOR ARMS PORT RELIEFS 3200 PSI (SET AT LOW IDLE) ATTACHMENT VALVE, HIGH PRESSURE - Saw MAIN RELIEF 3300 PSI (SET AT FULL THROTTLE) CLAMP ARMS PORT RELIEFS 4000 PSI (SET AT LOW IDLE) ACCUMULATOR ARMS PORT RELIEFS 4000 PSI (SET AT LOW IDLE) ATTACHMENT VALVE, HIGH PRESSURE - Shear MAIN RELIEF 3200 PSI (SET AT FULL THROTTLE) CLAMP ARM PORT RELIEFS - Open 3600 PSI (SET AT LOW IDLE) CLAMP ARM PORT RELIEFS - Close Full In ACCUMULATOR ARMS PORT RELIEFS 3600 PSI (SET AT LOW IDLE) FAN VALVE - Standard MAIN RELIEF 3000 PSI PRESET PORT RELIEFS 3300 PSI PRESET MAX. FORWARD SPEED AT FULL THROTTLE 2400 RPM (ADJUST SPOOL STOP) MAX. REVERSE SPEED AT FULL THROTTLE 2100 RPM (ADJUST SPOOL STOP) FAN VALVE - HIGH PRESSURE Saw / Shear MAIN RELIEF 3000 PSI PRESET PORT RELIEFS 3300 PSI PRESET MAX. FORWARD SPEED AT FULL THROTTLE 2100 RPM (ADJUST SPOOL STOP) MAX. REVERSE SPEED AT FULL THROTTLE 2100 RPM (ADJUST SPOOL STOP) ER VALVE (COUNTERBALANCE VALVE) TURN FULLY COUNTER-CLOCKWISE DOOR PUMP MAIN RELIEF 3000 PSI LEVELING CYLINDER LOCK VALVES LOCK VALVE RELIEFS 5 1/2 TURNS CCW FROM FULLY CW NOTES: All Hydraulic settings to be done with the hydraulic oil at operating temperature 140 Degrees F for summer oil or 100 Degrees F for winter oil

4.34

Tigercat 822/L830 Feller Buncher

SECTION 5 - PILOT SYSTEM JUNE 2007

CONTENTS - SECTION 5 ACCUMULATOR CHARGING .............................................................................................. 5.11 CHECK PRE-CHARGE PRESSURE ........................................................ 5.11 GENERAL DESCRIPTION ......................................................................... 5.5 TESTING DEVICE .................................................................................... 5.11 CIRCUIT DESCRIPTION ............................................................................... 5.9 CIRCUIT DIAGRAM ....................................................................................... 5.8 CIRCUIT HYDRAULIC SCHEMATIC ............................................................. 5.7 ELECTRICAL CIRCUIT ................................................................................. 5.9 PILOT MANIFOLD ................................................................................. 5.2, 5.4 PILOT SYSTEM COMPONENTS ACCUMULATOR .............................................................................. 5.5, 5.11 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 .............................................................................. 5.10

Tigercat 822/L830 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 PILOT FAN PILOT VALVE (FWD) VALVE (REV) PILOT FILTER

•• •• •• •• ••

•

ACCUMULATOR

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

822-D70

COOLING FAN CONTROL VALVE

••

•• PILOT GAUGE TEST PORT

PILOT SYSTEM COMPONENTS 5.2

PILOT SUPPLY VALVE

Tigercat 822/L830 Feller Buncher

Pilot system

CLOG INDICATOR (IF EQUIPPED)

••

ADJUSTING SCREW LOCKNUT PRESSURE REDUCING/RELIEVING VALVE CARTRIDGE

822-D47

•• ••

••

PILOT FILTER - HIGH PRESSURE

HIGH PRESSURE FILTER 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.

822-D72

PILOT SUPPLY VALVE

PILOT SUPPLY VALVE (PRESSURE REDUCING/RELIEVING VALVE)

The pilot filter should be changed regularly as a part of scheduled maintenance. A clogged filter will result in low pilot pressure. When a clogged condition is indicated by a loss of controls or slow response or by the clog indicator (if equipped) the pilot filter element will need to be changed at an earlier interval.

The pilot supply valve is a pressure reducing relief valve located below the clamps control valve.

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.

Refer to FILTER AND LUBRICATION SCHEDULE and FILTERS, PILOT in SECTION 3 of THIS MANUAL for recommended servicing intervals and filter servicing information.

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.

EARLIER MACHINES ONLY On earlier machines this filter incorporates a clog indicator.

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 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.

5.3

Tigercat 822/L830 Feller Buncher 'P2' PORT TO ACCUMULATOR

CLAMP CLOSE ACCUM. OPEN CLAMP OPEN ACCUM. CLOSED * WRIST CCW * WRIST CW

* NOTE: Wrist function uses this pilot manifold for 822 machines only. Refer also to SECTION 19 in THIS MANUAL for more information about wrist controls for both 822 and L830 machines 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.

••

TRACK LOW SWING BRAKE

•

PILOT SHUT OFF VALVE 'P2' PORT TO JOYSTICKS, FOOT PEDALS AND SAW PILOT VALVE

••

• • • • •• •

'T' TANK PORT

Pilot system

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

•

PILOT SHUT OFF VALVE

••

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.

••

'IN' INLET PORT

822-D68

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.

•

'T' TANK CONNECTION

PILOT MANIFOLD

PILOT MANIFOLD

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.

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.

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

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.

(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/L830 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.

ACCUMULATOR

221-18A

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 ACCU-1

•

•• POPPET (Seats against oil port after oil evacuation)

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/L830 Feller Buncher

Pilot system

JOYSTICKS AND FOOT PEDALS 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 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.

OPERATING DESCRIPTION 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.

RR-12

JOYSTICK PILOT VALVE

•

• •

4 3

• •

•

2

•

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

'P' PORT

AU013-2

5.6

•

5

•

WORK PORTS 1, 2, 3 OR 4

SPOOL ARRANGEMENT

1

Tigercat 822/L830 Feller Buncher

822-49

Pilot system

PILOT SYSTEM HYDRAULIC SCHEMATIC 5.7

Tigercat 822/L830 Feller Buncher

822-38

Pilot system

PILOT SYSTEM CIRCUIT DIAGRAM 5.8

Tigercat 822/L830 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 (CLEAN) 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 this machine) and eight solenoid operated control valves. A pilot shut-off valve installed in the manifold controls the flow of pilot oil into the manifold.

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

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.

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.

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

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 lockout relay coil and latches the function lock out relay in the energized position after the pilot reset switch has been released.

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.

• 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 (822 machines only).

5.9

Tigercat 822/L830 Feller Buncher

Pilot system

SET PILOT PRESSURE

••

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

ADJUSTING SCREW

ACCUMULATOR

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.

••

• •• ••

LOCKNUT PRESSURE REDUCING/RELIEVING VALVE CARTRIDGE

GAUGE TEST PORT, 0-1000 PRESSURE GAUGE

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.

4. Start engine and set throttle in IDLE position.

822-D72

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

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.

8. Stop engine, and remove pressure gauge.

5.10

PILOT SUPPLY VALVE

Tigercat 822/L830 Feller Buncher

Pilot system

CHARGING THE ACCUMULATOR

CHECKING THE PRE-CHARGE PRESSURE

NOTE: A detailed instruction sheet is provided with the charging and testing device. The following is only a suggested guide.

•

After the accumulator has been put in service, the pre-charge pressure should be checked with an accumulator charging and testing device.

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*

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.

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.

5.11

Tigercat 822/L830 Feller Buncher

Pilot system

5.12

Tigercat 822/L830 Feller Buncher

SECTION 6 - ELECTRICAL, GAUGES, ALARMS AND COMPUTERS JULY 2007

CONTENTS - SECTION 6 CHANNELS ..............................................................................................................................

INPUTS DIGITAL IN (DIN) ..............................................................................................................

FREQUENCY IN (FIN) ......................................................................................................

VOLTAGE IN (VIN) ............................................................................................................

OUTPUTS CURRENT OUT (COUT) ..................................................................................................

DIGITAL OUT (DOUT) ......................................................................................................

PWM OUT (PULSE WIDTH MODULATION) ....................................................................

COMPUTER CONTROL SYSTEM ............................................................................................................

IQAN CONTROL SYSTEM COMPONENTS ........................................................................

COMPUTER SYSTEM OVERVIEW ........................................................................................

CURRENT OUT - TROUBLESHOOTING FOR OPEN CIRCUITS ..........................................

6.30 6.30 6.30 6.30 6.30 6.30 6.30 6.18 6.18 6.18 6.31

DATE TIME SETTINGS ........................................................................................................... 6.29 DOWNLOADING APPLICATIONS FROM DEALER WEBSITE .............................................. 6.44 ELECTRICAL INSTALLATION - CAB ......................................................................................

ELECTRICAL KIT - SERVICE AND DIAGNOSTICS ...............................................................

ELECTRICAL SCHEMATIC DIAGRAM ......... 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 6.10, 6.11, ERROR MESSAGES AND ALARMS FAULT CODES : ERROR MESSAGES ...............................................................................

MAIN SYSTEM ERRORS .....................................................................................................

6.15 6.42 6.12

FAULT CODES : ERROR MESSAGES ...................................................................................

ERROR :INPUT HIGH ..........................................................................................................

ERROR: INPUT LOW ..........................................................................................................

ERROR: OUTPUT HIGH ......................................................................................................

ERROR: OUTPUT LOW ......................................................................................................

INTERPRETING ERROR MESSAGES ................................................................................

6.40 6.40 6.40 6.40 6.40 6.40

6.40 6.38

GAUGES AND ALARMS .......................................................................................................... 6.16 GET APPLICATION ................................................................................................................. 6.50 GET ERROR/EVENT LOG ...................................................................................................... 6.54 IQAN COMPUTER DISPLAY .........................................................................................................

MAIN SYSTEM ERRORS .....................................................................................................

MDM MODULE BLANK SCREEN .....................................................................................

MODULE IS OFFLINE ......................................................................................................

XP-A0 MODULE OFFLINE ERROR ................................................................................

SYSTEM DIAGNOSTICS MENUS .......................................................................................

ADJUST DATE TIME SETTINGS .....................................................................................

ADJUST LCD DISPLAY BRIGHTNESS ............................................................................

ADJUST LCD DISPLAY CONTRAST ...............................................................................

ADJUST SOUND SETTINGS ...........................................................................................

DIAGNOSTICS MENU DESCRIPTIONS ..........................................................................

DIAGNOSTICS MENU OPERATION ................................................................................

6.22 6.38 6.38 6.38 6.39 6.23 6.29 6.27 6.27 6.28 6.24 6.25

Tigercat 822/L830 Feller Buncher

Electrical, gauges, alarms and computers

SYSTEM WARNING MESSAGES MODULE IS OFFLINE SYSTEM WARNING ....................................................................

IQAN MODULES CONTROL SYSTEM OVERVIEW ........................................................................................

IQAN CONTROL SYSTEM COMPONENTS ........................................................................

MDM DISPLAY MODULE .....................................................................................................

SCHEMATIC ........................................................................................................................

XP-A0 MODULE ...................................................................................................................

IQAN SOFTWARE ...................................................................................................................

DOWNLOADING APPLICATIONS FROM DEALER WEBSITE ...........................................

GET APPLICATION (DOWNLOAD FROM MDM) USING A PC/LAPTOP .......................................................................................................

USING A PDA ...................................................................................................................

GET ERROR/EVENT LOG USING A PC/LAPTOP .......................................................................................................

USING A PDA ...................................................................................................................

GRAPHING AND MEASUREMENT OF CHANNELS USING A PC/LAPTOP .......................................................................................................

USING A PDA ...................................................................................................................

PDA REGISTRATION ..........................................................................................................

UPDATING THE IQAN APPLICATION FROM A PC/LAPTOP .....................................................................................................

FROM A PDA ....................................................................................................................

6.38 6.18 6.18 6.19 6.21 6.20 6.44 6.44 6.51 6.50 6.55 6.54 6.53 6.52 6.44 6.48 6.46

MODULE IS OFFLINE ............................................................................................................. 6.38 PDA REGISTRATION .............................................................................................................. 6.44 REAR ELECTRICAL PANEL ................................................................................................... 6.14 SOLENOID DRIVERS .............................................................................................................. 6.16 SWITCH AND SENSOR LOCATIONS .................................................................................... 6.17 UPDATE APPLICATION .......................................................................................................... 6.46 WIRE COLOUR CODE CHART ............................................................................................... 6.13

6.2

Tigercat 822/L830 Feller Buncher

830-61 (18542B R8)

Electrical, gauges, alarms and computers

MACHINE ELECTRICAL SCHEMATIC DIAGRAM PAGE 1 OF 10 6.3

Tigercat 822/L830 Feller Buncher

830-62 (18542B R8)

Electrical, gauges, alarms and computers

MACHINE ELECTRICAL SCHEMATIC DIAGRAM PAGE 2 OF 10 6.4

Tigercat 822/L830 Feller Buncher

830-63 (18542B R8)

Electrical, gauges, alarms and computers

MACHINE ELECTRICAL SCHEMATIC DIAGRAM PAGE 3 OF 10 6.5

Tigercat 822/L830 Feller Buncher

830-64 (18542B R8)

Electrical, gauges, alarms and computers

MACHINE ELECTRICAL SCHEMATIC DIAGRAM PAGE 4 OF 10 6.6

Tigercat 822/L830 Feller Buncher

830-65 (18542B R8)

Electrical, gauges, alarms and computers

MACHINE ELECTRICAL SCHEMATIC DIAGRAM PAGE 5 OF 10 6.7

Tigercat 822/L830 Feller Buncher

830-66 (18542B R8)

Electrical, gauges, alarms and computers

MACHINE ELECTRICAL SCHEMATIC DIAGRAM PAGE 6 OF 10 6.8

Tigercat 822/L830 Feller Buncher

830-67 (18542B R8)

Electrical, gauges, alarms and computers

MACHINE ELECTRICAL SCHEMATIC DIAGRAM PAGE 7 OF 10 6.9

Tigercat 822/L830 Feller Buncher

830-68 (18542B R8)

Electrical, gauges, alarms and computers

MACHINE ELECTRICAL SCHEMATIC DIAGRAM PAGE 8 OF 10 6.10

Tigercat 822/L830 Feller Buncher

830-69 (18542B R8)

Electrical, gauges, alarms and computers

MACHINE ELECTRICAL SCHEMATIC DIAGRAM PAGE 9 OF 10 6.11

Tigercat 822/L830 Feller Buncher

830-96 (18542B R8)

Electrical, gauges, alarms and computers

MACHINE ELECTRICAL SCHEMATIC DIAGRAM PAGE 10 OF 10 6.12

Tigercat 822/L830 Feller Buncher

Electrical, gauges, alarms and computers

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)

6.13

Tigercat 822/L830 Feller Buncher

IQAN MDM CONTROL MODULE (IF EQUIPPED)

Electrical, gauges, alarms and computers

ENGINE ANTI-STALL DISCONNECT PLUG (REFER TO SECTION 9)

•

IQAN HARNESS

••

•

IQAN MODULE XP (822/L830) XT2 (X830/LX830) (XP SHOWN)

•

••

• REAR FUSE PANEL

••

ENGINE ANTI-STALL MODULE (REFER TO SECTION 9)

••

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

•• ••• • • •• •

830-58

•• •

SOLENOID DRIVERS (QUANTITY 7)

TERMINAL BLOCK 26 - 12 GAUGE

IQAN TERMINAL BLOCK

•• •• PANEL ALARM AND SOCKET

••

TO TERMINAL RAILS 'A' AND 'B'

REAR ELECTRICAL PANEL

6.14

RELAY PANEL

Tigercat 822/L830 Feller Buncher

Electrical, gauges, alarms and computers REAR PANEL

ENGINE ANTI-STALL MODULE

ENGINE ANTI-STALL DISCONNECT PLUG

TERMINAL RAIL 'C' REAR FUSE PANEL

FIRE SUPPRESSION CONTROL PANEL

••

CONTROL PANEL

••

PILOT SHUT-OFF LIMIT SWITCH ON FRONT DOOR

RELAY PANEL

• ••

INSTRUMENT PANEL

•

• • STEREO RADIO

• • ••

POWER CONVERTER (HARVESTER)

••

•• ••

•

CB RADIO

•

• •

••

TERMINAL RAIL 'A' (BEHIND COVER)

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

830-57

ELECTRICAL INSTALLATION - CAB 6.15

Tigercat 822/L830 Feller Buncher GAUGES AND ALARMS The 822/L830 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 hood is being operated.

Electrical, gauges, alarms and computers 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.

SENSOR FUNCTION

GAUGE RANGE

LIGHT

HORN

TRIGGER OR RANGE INFO

Engine coolant level probe Hydraulic oil temperature sender and switch

None 100°F - 250°F (38°C - 121°C)

ON ON

SOUNDS SOUNDS @ 205°F (96°C)

Engine coolant temperature (from engine via MDDM) Engine oil pressure (from engine via MDDM) Volts (from engine via MDDM) Fuel level sender Hydraulic oil - low switch Hydraulic oil -Very low switch Hydraulic oil filter bypass switch Back-up alarm Motion alarm (optional) Horn, safety alert

100°F - 250°F (38°C - 121°C) 0 - 100 psi

None

None

None

None

Low coolant level, STOP ENGINE. Stop machine above temperature operating range. See HYDRAULIC OILS chart in SECTION 3.

Operating range 183°F-196°F (84°C-91°C) MDDM transmitted information MDDM transmitted information

8v - 18v

None

None

'E' - 'F' None None None

None ON ON ON

None None SOUNDS None

Normal operating range 12-13.5 volts MDDM transmitted information Capacity (US gal/L): 100/378 standard 10 Gal. (38L) below Full 18 Gal. (68L) below Full Return filter restriction, 15 psi or greater

N/A N/A N/A

N/A N/A N/A

sounds sounds sounds

One or both drive pedals in reverse One or both drive pedals in forward or reverse Push button on LH 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 BLOCKS 26 - 12 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.

••

TERMINAL BLOCK 6 GAUGE

• 830-32A

SOLENOID DRIVERS ON TERMINAL RAIL 'C' 6.16

Tigercat 822/L830 Feller Buncher

Electrical, gauges, alarms and computers POWER DOOR PUMP/ MOTOR

ALTERNATOR

ENGINE START SOLENOID RELAY

BATTERY DISCONNECT SWITCH

BOOST CONNECTION

DOOR PUMP RELAY

BATTERIES

•

•

•

ENGINE COOLANT LEVEL PROBE (LIGHT AND HORN)

• • •

• •

• •

A/C COMPRESSOR

HYDRAULIC OIL TEMPERATURE SWITCH (LIGHT AND HORN)

ENGINE SPEED SENSOR (REFER TO SECTION 9)

BACKUP/MOTION ALARM HORN (DRIVE PEDAL ACTIVATED)

TO REAR PANEL IN CAB TO REAR PANEL IN CAB

••

•

HYDRAULIC OIL TEMPERATURE SENDER (GAUGE)

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

• • • TO BOOM LIGHTS

•• BACKUP/ MOTION ALARM SWITCH(ES) (ALARM HORN)

••

FUEL TANK

••

TO CONNECTOR BLOCK IN CAB

•• FUEL LEVEL SENDER (GAUGE) NEGATIVE GROUND CABLE HORN (SWITCH ON CONTROL PANEL)

830-95

SWITCH AND SENSOR LOCATIONS 6.17

•

HYDRAULIC OIL TANK

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

OPERATOR'S CAB

HYDRAULIC OIL FILTER BYPASS SWITCH (LIGHT)

Tigercat 822/L830 Feller Buncher Electrical, gauges, alarms and computers IQAN COMPUTER CONTROL SYSTEM Inputs: (IF EQUIPPED, L830 ONLY) The computer monitors analogue, digital, and The IQAN computer control system electronically controls the levelling function, wrist function and fan pump.

frequency inputs and CAN Bus inputs. CAN Bus is a data bus system that allows several input signals to be sent to the MDM through a reduced number of wires.

IQAN SYSTEM COMPONENTS

Outputs:

1. MDM Display/Control Module 2. XP-A0 Module The operator can view input and output information and enter function parameter settings for various modules using the MDM Display Terminal.

The computer directs a proportional output to the solenoids on the proportional pilot manifold and to the electronic displacement controller (EDC) on the fan drive pump.

The computer also monitors and analyzes inputs and produces outputs (as defined in its program) to control the machine proportional valve functions.

Proportional valve functions are: • •

Levelling Wrist

• F1 BUTTON 630C-31

IQAN CONTROL SYSTEM COMPONENTS 830-71

••

••

• ••

•

F2 BUTTON

F3 BUTTON

ESCAPE BUTTON

MDM COMPUTER MODULE

The IQAN MDM computer display is the operator interface with the IQAN control system. The IQAN MDM (master display module) is the central unit in the IQAN control system, which works as both a master and a display unit. It has a backlit graphic LCD display. Three function buttons (F1, F2 and F3), a scrolling up/down button and an escape button are used by the operator to move through menus and adjust the settings of the IQAN control system.

APPLIES ONLY TO MACHINES WITH IQAN CONTROL SYSTEM

IQAN DISPLAY

APPLIES ONLY TO MACHINES WITH IQAN CONTROL SYSTEM 830-D37

SCROLL UP/DOWN BUTTON

LCD DISPLAY

IQAN XP MODULE 6.18

Tigercat 822/L830 Feller Buncher MDM DISPLAY MODULE 6

5

2

5

••

••

1014-032

3

•• •

• •• 1

• 5

Electrical, gauges, alarms and computers

•

••

4

5 ALARM OUT (NOT USED)

REAR OF MDM MODULE The back of the MDM Module consists of the following.

RED 20

1. Tag with serial number and part number.

MDM

CLOCK

2. RS-232 serial port, 8 pin for PC connection.

3. Voltage supply indicator. LED with green light ON indicates supply voltage is activated. LED light OUT indicates supply voltage is OFF. ACCESSORIES

4. Main connector for voltage supply, CAN communication and alarm output.

830-03

5. Snap on attachment for mounting in panel.

6. Membrane valve for condensation prevention inside unit.

MDM MODULE WIRING PIN ASSIGNMENT 1. CAN LOW 2. ALARM OUT IQAN DISPLAY

3. BATTERY GROUND 4. CAN HIGH 5. POWER SUPPLY - Real Time Clock 6. POWER SUPPLY NOTE: Refer to the IQAN MODULES SCHEMATIC and ELECTRICAL SCHEMATIC in THIS SECTION for detailed pin and wiring assignment.

MDM MODULE REPLACEMENT 1. Turn battery disconnect switch OFF. 2. Remove 4 screws holding MDM frame plate.

3. Lift the module out of the instrument panel carefully.

4. Disconnect the wiring harness at the module.

5. Remove module from frame plate (4 screws).

6. Install module in reverse order as removed.

NOTE: Refer to IQAN SOFTWARE - UPDATE APPLICATION in THIS SECTION for procedure to update the application in an MDM module.

6.19

Tigercat 822/L830 Feller Buncher XP-A0 MODULE

Electrical, gauges, alarms and computers

2 1

• •••• •• •

••

4

3

XP MODULE

1014-037

XP-A0 MODULE LED INDICATORS

XP-A0 MODULE WIRING PIN ASSIGNMENT

1. Supply Voltage LED. LED with green light ON indicates supply voltage is ON. LED OFF indicates supply voltage is OFF.

NOTE: Refer to the Wiring Schematic and Electrical Schematics in this section for detailed pin and wiring assignment.

2. Arrow and Heart Status Indicator LEDs. LED for Heart and Arrow flash alternately (solid green) indicates Status is Correct.

When LED for Heart is out and LED for arrow flashes, this indicates the following errors: •

One flash indicates fault on inputs/outputs or that supply voltage is to low or to high.

•

Two flashes in a row indicates that the internal temperature of the unit is to high or to low.

• •

Three flashes in a row indicates that the fault is related to the CAN-bus.

APPLIES ONLY TO MACHINES WITH IQAN CONTROL SYSTEM 830-D37

Four flashes in a row indicates an internal fault on the hardware of the unit.

XP Module Error code

Blink (Arrow only gre e n light)

I/O and voltage errors Low/High temperature CAN error VREF error

3. Connectors CAN1 and CAN2 for CAN-bus.

4. C1 connector for inputs and outputs.

6.20

IQAN XP MODULE

Tigercat 822/L830 Feller Buncher

830-67 (18542B R8)

Electrical, gauges, alarms and computers

IQAN MODULES SCHEMATIC 6.21

Tigercat 822/L830 Feller Buncher

Electrical, gauges, alarms and computers

IQAN MDM COMPUTER DISPLAY

IQAN DISPLAY The IQAN- MDM computer display is the operator interface with the IQAN control system. The IQAN MDM (master display module) is the central unit in the IQAN control system, which works as both a master and a display unit.

SCROLL UP/DOWN BUTTON

LCD DISPLAY

• F1 BUTTON 630C-31

••

••

•• ••

•

F2 BUTTON

F3 BUTTON

ESCAPE BUTTON

MDM COMPUTER MODULE

The IQAN MDM has a backlit graphic LCD display. Three function buttons (F1, F2 and F3), a SCROLL UP/DOWN button and an ESCAPE button are used by the operator to move through the menu displays and adjust the settings of the IQAN control system.

NOTE: The IQAN control system is softwarebased. This software may be updated after the machine is in service as a part of on-going product improvement programs and service newsletters. The information contained in this manual is accurate at the time of printing.

Improvements to the machine and/or software are on-going and may not be covered. In these cases contact your Tigercat dealer for appropriate information.

6.22

Tigercat 822/L830 Feller Buncher SYSTEM DIAGNOSTICS MENUS

Electrical, gauges, alarms and computers

IQAN DISPLAY TIME

SOFTWARE PROGRAM AND VERSION

••

• • • F1 BUTTON

630C-65

SCROLL UP/DOWN BUTTON

DATE

•• •• F2 BUTTON

•

•• ••

F3 BUTTON

ESCAPE BUTTON

MDM COMPUTER MODULE

The home screen display will appear as shown.

The display should show the current date and time, software program and version identification.

1014-D001B

Press the ESCAPE button to display one of 5 menus (MODE, INFORMATION, SETTINGS, MEASURE and PROPERTIES) that access system diagnostics and function adjustment menus.

Use the SCROLL UP/DOWN buttons to scroll through the menus.

Use the F1, F2, and F3 buttons to select the highlighted menu options located above each button in the LCD menu display.

Use the ESCAPE button to move back to the previous menu display.

6.23

Tigercat 822/L830 Feller Buncher Electrical, gauges, alarms and computers DIAGNOSTICS MENU DESCRIPTIONS

4. MEASURE MENU DESCRIPTION 1. MODE MENU DESCRIPTION

A. Input channel measurement can be viewed.

This menu is not used by machine operators for the 830 application at this time.

B. Output channel measurement can be viewed.

C. EVENT COUNTER can be viewed.

2. INFORMATION MENU DESCRIPTION A. Software application information can be displayed, including comments.

5. PROPERTIES MENU DESCRIPTION

B. Module information can be displayed including status, software information and hardware information.

A. Selected outputs can be adjusted.

B. Function parameters can be adjusted.

3. SETTINGS MENU DESCRIPTION A. Display CONTRAST can be adjusted.

B. Display BRIGHTNESS can be adjusted.

C. Computer SOUND volumes can be adjusted.

D. Computer DATE and TIME can be adjusted.

6.24

Tigercat 822/L830 Feller Buncher DIAGNOSTICS MENU OPERATION

Electrical, gauges, alarms and computers B. VIEW MODULE INFORMATION

1. MODE MENU OPERATION This menu is not used by machine operators for the 830 application at this time.

2. INFORMATION MENU OPERATION Machine software application and module status information can be viewed in this menu.

A.

VIEW APPLICATION INFORMATION Press MODULES (F2) to select MODULES.

Press APPLIC (F1) to select APPLICATION INFORMATION.

Choose an IQAN module using UP/DN (MDM shown as an example).

Press STATUS (F1) to select STATUS. Note: Status (enabled/disabled) refers to the enabling or disabling of the MODULE IS OFFLINE warning function for a module. For some modules it is possible for an operator or technician to disable this warning message. It is recommended that all available modules ALWAYS be set to ENABLED. Refer to MODULE IS OFFLINE in THIS SECTION for more more information.

Press MORE (F1) and COMMENT (F2) to select MORE...(screen shown below) or COMMENT.

Press INTERNAL (F2) to select INTERNAL.

6.25

Tigercat 822/L830 Feller Buncher

Electrical, gauges, alarms and computers

Press INFO SW (F2) to select INFO SW (software information).

Press INFO HW (F3) to select INFO HW (hardware information).

6.26

Tigercat 822/L830 Feller Buncher

Electrical, gauges, alarms and computers Cancel (F2) or ESC returns the character window to the previous window without saving any new setting.

3. SETTINGS MENU OPERATION The computer sound volume, display contrast, light, date, time and language can be adjusted in this menu.

A.

Reset Contrast RESET (F3) resets the character window’s contrast to the preset factory value which corresponds to 30.

CHANGE CONTRAST

B. CHANGE LIGHT (DISPLAY BRIGHTNESS)

630C-68

Press LCD (F1) to select LCD SETTINGS. 630C-27

Press LIGHT (F2) to select the function LCD LIGHT.

630C-27

Press CONTRAST (F1) to select the function LCD CONTRAST.

630C-73

Change to desired CONTRAST using UP/DN and press OK (F1) to save setting and return to previous menu.

Cancel (F2) or ESC returns the character window to the previous window without saving any new setting.

630C-74

Reset Light

Change to desired CONTRAST using UP/DN and press OK (F1) to save setting and return to previous menu.

RESET (F3) resets the character window’s light to the preset factory value which corresponds to 100.

6.27

Tigercat 822/L830 Feller Buncher

Electrical, gauges, alarms and computers

C. SOUND SETTINGS

CHANGE BUTTON SOUND

Adjusting BUZZER VOLUME and change BUTTON SOUND.

1014-D110

Press SOUND (F1) to select the function SOUND SETTINGS. 1014-D110

To shift to the tab SOUND, press MORE (F3).

Press SOUND (F1) to select the function SOUND SETTINGS. CHANGE ALARM VOLUME

630C-75

Press BUTTON (F2) to select the function to change the button sound.

630C-75

Press ALARM (F1) to select the function for setting the volume for the alarm signal.

Change to desired VOLUME using UP/DN. 630C-77

Change to desired BUTTON SOUND using UP/DN. There are Ten button beep levels.

0 implies that the button beep is turned OFF. 100 is the loudest. Thereafter, press OK (F1) to save setting and return to previous menu.

630C-76

Cancel (F2) or ESC returns the character window to the previous menu without saving any new setting.

There are Ten volume levels. 0 implies that sound is turned OFF. 100 is the loudest.

Thereafter, press OK (F1) to save setting and return to previous menu.

Reset the Volume RESET (F3) resets the alarm volume to the preset factory value which corresponds to 50.

Cancel (F2) or ESC returns the character window to the previous menu without saving any new setting.

Reset the Volume RESET (F3) resets the alarm volume to the preset factory value which corresponds to 50.

6.28

Tigercat 822/L830 Feller Buncher

Electrical, gauges, alarms and computers

D. DATE TIME SETTINGS

630C-68

To shift to the tab SET CLOCK, press MORE (F3).

1014-D110

Press SET CLOCK (F2) to select the function for setting the DATE and TIME.

630C-78

Browse using UP/DN and thereafter press SELECT (F1) to select alternative from list.

YEAR - MONTH - DAY - HOUR - MINUTE

630C-78A

Change to desired value using UP/DN and press OK (F1) to save setting and return to previous menu.

Cancel (F2) or ESC returns the character window to the previous menu without saving any new setting.

6.29

Tigercat 822/L830 Feller Buncher 4. MEASURE MENU OPERATION

Electrical, gauges, alarms and computers

Measurements can be viewed for the following channels:

INPUTS TYPE VOLTAGE VOLTAGE VOLTAGE VOLTAGE VOLTAGE VOLTAGE

IN IN IN IN IN IN

OUTPUTS TYPE CURRENT OUT CURRENT OUT CURRENT OUT

SCREEN MESSAGE Tilt_front_button Tilt_rear_button Tilt_left_button Tilt_right_button Wrist_Left_button Wrist_Right_button

ACTIVATING CONTROL/SENSOR/SWITCH Levelling tilt forward switch Levelling tilt back switch Levelling tilt left switch Levelling tilt right switch Wrist cw switch Wrist ccw switch

LOCATION Right joystick Right joystick Left joystick Left joystick Right joystick Left joystick

SCREEN MESSAGE Level_cyl_right Level_cyl_left Wrist_current

CONTROL ACTIVATED Right levelling cylinder solenoids (+extend/-retract) Left levelling cylinder solenoids (+extend/-retract) Wrist solenoids (+ccw/-cw)

LOCATION Levelling proportional manifold Levelling proportional manifold Levelling proportional manifold

CHANNELS

OUTPUTS

The definition ‘channels’ is a collective name for the inputs and outputs found on the different IQAN modules. There are also channels internally in the system, to handle for example, MDM messages and mathematical calculations. The channels are used to collect and/or send data. Input and output channels are described below.

CURRENT OUT (COUT)

INPUTS

PWM (Pulse Width Modulation) Out is a way of producing an analog signal level with a digital output that turns on and off many times a second.

By varying the ratio between on and off time (duty cycle) an output proportional to the system voltage can be obtained. PWMOUT maintains a constant output voltage, and the output current is governed by the resistance in the circuit.

VOLTAGE IN (VIN) The input signal at these inputs comes primarily from analog sensors, levers, and switches. These devices use a power/signal/ground system to provide an input value (VIN) between the high (+5V) and low (-5V) signals generated in the modules.

DIGITAL IN (DIN) An input that is typically on or off, such as a switch.

This input is often used to determine if an event has occurred, such as pushing a button or engaging a relay.

The COUT channel maintains a constant output current to control proportional solenoids. The voltage is regulated to maintain the constant current based on the resistance of the circuit.

PWM OUT (PWMOUT)

DIGITAL OUT (DOUT) A PWMOUT with 100% duty cycle is a Digital Out (DOUT). The outputs have a value of low or high.

These are mostly used to activate lamps, on/off valves or to pull relays.

FREQUENCY IN (FIN) Typical functions are speed measure or revolution measure. This input can count the number of signals per second to determine the speed of a rotating or reciprocating body.

6.30

Tigercat 822/L830 Feller Buncher Electrical, gauges, alarms and computers CURRENT OUT - TROUBLESHOOTING FOR OPEN CIRCUITS The COUT channel maintains a constant output current to control proportional solenoids. The voltage is regulated to maintain the constant current based on the resistance of the circuit.

It is important to note that currrent out readings displayed on the MDM display screen are measured at the current out (COUT) side of the connection to the IQAN module (rather than the current return (CRET) side).

When troubleshooting for problems with a function controlled by a CURRENT OUT signal the correct reading may appear on the screen even if there is no CURRENT RETURN signal (an open circuit).

In the case of an open circuit it will be necessary to use a diagnostic breakout harness to identify an open circuit locate it. Refer to ELECTRICAL KIT SERVICE AND DIAGNOSTICS in this section for more information about diagnostic breakout harnesses.

• CURRENT OUT VALUE MEASURED AT COUT

620C-34

630C-211

CURRENT OUT CONNECTIONS

DIAGNOSTIC BREAKOUT HARNESS

6.31

Tigercat 822/L830 Feller Buncher EXAMPLE ~ VIEW INPUT CHANNELS

Electrical, gauges, alarms and computers

Press SELECT (F1) to select VOLTAGE IN. Press INPUTS (F1) to select INPUTS.

Use UP/DOWN scroll buttons to select the input channel you wish to view

Press MV (F1) to select show the voltage value of the measurement.

Press SCALED (F1) to show the scaled value of the measurement.

Press scope (F3) to view a graph of the measurement over time.

Press ESCAPE button to return to previous screen.

6.32

Tigercat 822/L830 Feller Buncher Electrical, gauges, alarms and computers EXAMPLE ~ VIEW OUTPUT CHANNELS

Press SELECT (F1) to select CURRENT OUT.

Press OUTPUTS (F2) to select OUTPUTS.

Press scope (F3) to view a graph of the measurement over time.

Press ESCAPE button to return to previous screen.

Press UP/DOWN scroll button to move through the OUTPUTS display screens (CURRENT OUT, PWM OUT and DIGITAL OUT).

6.33

Tigercat 822/L830 Feller Buncher

Electrical, gauges, alarms and computers CURRENT/FINE CONTROL/STOPSLOPE/ STARTSLOPE/MAX CURRENT).

5. PROPERTIES MENU OPERATION A. ADJUST OUTPUTS

Press SELECT(F1) to select a parameter for adjustment

Press OUTPUTS(F2) to select OUTPUTS. Use UP/DOWN scroll buttons to select type of output you wish to adjust.

Use UP/DOWN scroll buttons adjust parameter setting.

Select OK (F1) to confirm new setting.

Press SELECT (F1) to select.

Use UP/DOWN scroll buttons to select the output you wish to adjust.

Press SELECT(+)(F1) or SELECT(-)(F2) to select adjustment of positive or negative output signal.

Use UP/DOWN scroll buttons to select the parameter you wish to adjust (MIN 6.34

Tigercat 822/L830 Feller Buncher ADJUSTABLE OUTPUTS TYPE

Electrical, gauges, alarms and computers

SCREEN MESSAGE (+) Level_cyl_right

(-) Level_cyl_right

(+) Level_cyl_left

CURRENT OUT (-) Level_cyl_left

(+) Wrist_current [ccw]

(-) Wrist_current [cw]

6.35

Parameter Factory Default MIN CURRENT 420 Ma MAX CURRENT 1200 Ma STARTSLOPE 0 ms STOPSLOPE 0 ms FINE CONTROL 0% MIN CURRENT 420 Ma MAX CURRENT 1200 Ma STARTSLOPE 0 ms STOPSLOPE 0 ms FINE CONTROL 0% MIN CURRENT 300 mA MAX CURRENT 700 mA STARTSLOPE 0 ms STOPSLOPE 0 ms FINE CONTROL 0% MIN CURRENT 300 mA MAX CURRENT 700 mA STARTSLOPE 0 ms STOPSLOPE 0 ms FINE CONTROL 0% MIN CURRENT 300 mA MAX CURRENT 700 mA STARTSLOPE 0 ms STOPSLOPE 0 ms FINE CONTROL 0% MIN CURRENT 300 mA MAX CURRENT 700 mA STARTSLOPE 0 ms STOPSLOPE 0 ms FINE CONTROL 0%

Tigercat 822/L830 Feller Buncher

Electrical, gauges, alarms and computers Use UP/DOWN scroll buttons to select the output you wish to adjust.

B. ADJUST FUNCTION PARAMETERS

Press OTHER(F3) to select other properties for adjustment.

Press SELECT(F1) to select a function parameter for adjustment

Use UP/DOWN scroll buttons to select type of output you wish to adjust.

Use UP/DOWN scroll buttons adjust parameter setting.

Press SELECT (F1) to select.

Select OK (F1) to confirm new setting.

6.36

Tigercat 822/L830 Feller Buncher

Electrical, gauges, alarms and computers

ADJUSTABLE FUNCTION PARAMETERS TYPE FUNCTION FUNCTION FUNCTION FUNCTION FUNCTION FUNCTION

PARAMETER PARAMETER PARAMETER PARAMETER PARAMETER PARAMETER

SCREEN MESSAGE For_tilt_speed Rear_tilt_speed Ramp_rate_leveller W rist_speed_R W rist_speed_L Ramp_rate_W rist

6.37

Factory Default 70% 55% 500 ms 100% 100% 250 ms

Min 0% 0% 0 ms 0% 0% 0 ms

Max 100% 100% 2000 ms 100% 100% 2000 ms

Tigercat 822/L830 Feller Buncher MAIN SYSTEM ERRORS

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

Likely causes are: • Power - Fuse (MDM or CLOCK) • Ground • LCD display settings too light to read • Faulty MDM module

Electrical, gauges, alarms and computers MODULE IS OFFLINE

The MODULE IS OFFLINE warning message indicates a loss of communication with or power to an IQAN module. The offline module is identified on the display screen.

When a module goes offline all machine functions controlled by that module cease and all alarms and warnings associated with that module are triggered. If the problem is with the CAN wires all modules beyond the problem module will also be affected.

NOTE: It is possible for an operator or service technician to disable this warning message. If the MODULE IS OFFLINE warning function is disabled for a module the first indication of a loss of communication or power to a module will be the loss of all machine functions controlled by the module and the triggering of all alarms and warnings associated with that module. This may cause problems in identifying the source of a control problem, as it will not be immediately obvious that a loss of communication or power to the module is the source of the problem.

To greatly reduce the time required to diagnose a MODULE IS OFFLINE warning, it is recommended that all available modules ALWAYS be set to ENABLED as shown. This screen is accessed through the INFORMATION MENU, which should normally be accessed by Tigercat service technicians only. Refer to INFORMATION CENTER~SYSTEM DIAGNOSTICS MENUS~DIAGNOSTICS MENU OPERATION inTHIS SECTION.

6.38

Tigercat 822/L830 Feller Buncher

Electrical, gauges, alarms and computers 2 1

••• XP MODULE OFFLINE ERROR Expect all machine functions controlled by this module to cease and all alarms and warnings associated with this module to be triggered.

XP MODULE 2. CHECK MODULE STATUS INDICATORS Status lights can also give an immediate indication of the nature of the error.

1. CHECK FOR OTHER ERROR/ALARM MESSAGES ON SCREEN

(1) Supply Voltage LED.

Press OK to acknowledge each error message. Note that module offline errors will be followed by other alarm messages (if any) associated with the module which is offline.

LED ON solid green light indicates supply voltage is ON. LED OFF indicates supply voltage is OFF.

The likely causes are:

(2) Arrow and Heart Status Indicator LEDs.

• Power - Fuse (XP MODULE)

LED for Heart and Arrow flash alternately (solid green) indicates Status is Correct.

• Ground • CAN wire connection

When Heart LED is off and LED for arrow flashes (green), this indicates the following errors: •

One flash indicates fault on inputs/outputs or that supply voltage is to low or to high.

•

Two flashes in a row indicates that the internal temperature of the unit is to high or to low.

•

Three flashes in a row indicates that the fault is related to the CAN-bus.

•

Four flashes in a row indicates an internal fault on the hardware of the unit.

XP Module Error code I/O and voltage errors Low/High temperature CAN error VREF error

6.39

Blink (Arrow only gre e n light)

Tigercat 822/L830 Feller Buncher FAULT CODES : ERROR MESSAGES A typical fault code error message is described below.

Note: When contacting Tigercat Customer service about any error message it is very important to write down and communicate the whole message (all text shown on the screen). This will greatly reduce troubleshooting time.

1

5

3

Electrical, gauges, alarms and computers COMMON ERROR MESSAGES ERROR: INPUT LOW Applies to : Voltage In if fault detection is in use.

Probable cause: Short circuit to ground.

ERROR :INPUT HIGH Applies to : Voltage In if fault detection is in use.

Probable cause: Short circuit to VBAT (battery side).

ERROR: OUTPUT LOW

2 4

•••• •

••

••

Applies to : Current Out if fault detection is in use.

Probable cause: Return current is lower than the set value.

ERROR: OUTPUT HIGH

822-D77

TYPICAL ERROR MESSAGE

1. TYPE OF ERROR

Applies to : Current Out if fault detection is in use.

Probable cause: Return current is higher than the set value.

Refers to the type of error being shown. There are several common error types including: •

ERROR: INPUT LOW

•

ERROR :INPUT HIGH

•

ERROR: OUTPUT LOW

•

ERROR: OUTPUT HIGH

2. MODULE ADDRESS The module address identifies the module from which an error signal is being received.

In this case XP-A0.

3. PIN NUMBER Refers to pin number for the error generating function. Pin numbers match those shown on pin diagrams and electrical schematics.

4. FUNCTION NAME This name is programmed by tigercat to identify the function.

5. DEFAULT ERROR VALUE This is a programmed default value, which the computer control system substitutes for actual readings in the event of a signal error. These values are chosen for safety reasons and to protect the machines components from damage in the event of a signal error from the control system.

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Tigercat 822/L830 Feller Buncher

Electrical, gauges, alarms and computers

Example 1: 1. ERROR: OUTPUT HIGH 2. XP-A0 IQAN module 3. Connector 1 : Pin 8 4. Right_cyl_base 5. Defaults to 0.0 mA in the event of an error Probable cause: Return current is higher than the set value.

Example 2: 1. ERROR: OUTPUT LOW 2. XP-A0 module 3. Connector 1 : Pin 9 4. Left_Cyl_base 5. Error value Probable cause: Return current is lower than the set value.

6.41

Tigercat 822/L830 Feller Buncher ELECTRICAL KIT - SERVICE AND DIAGNOSTICS

Electrical, gauges, alarms and computers

This kit includes a variety of electrical connectors, tools, cable, IQAN components, diagnostic breakout harnesses and service harnesses (Tigercat part number 20045B).

SELECTED ITEMS 1. DIAGNOSTIC BREAKOUT HARNESS DEUTSCH CONNECTOR - CURRENT (20036B) This harness is used to check current (amps) flow to a component with a Deutsch connector and verify outputs.

630C-211

2. DIAGNOSTIC BREAKOUT HARNESS DEUTSCH CONNECTOR - VOLTAGE (20037B) This harness is used to check voltage (volts) to a component with a Deutsch connector and verify inputs.

3. DIAGNOSTIC BREAKOUT HARNESS AMP CONNECTOR - CURRENT (20038B)

is tagged as “Modem” and the serial connector will have female sockets. Cable DG023 can be used in place of DG029 for most purposes however, to install an IQAN vmAC file cable DG029 must be used.

6. IQAN DATA CABLE FOR PC/LAPTOP (DG024 - NOT STANDARD IN THIS KIT) This cable is used to connect the IQAN MDM module RS232 port directly to COM1 serial port on the PC/Laptop. This cable is tagged as “PC”.

This harness is used to check current (amps) flow to a component with a Deutsch connector and verify outputs.

7. ID-TAG ‘0’ (AN068)

4. DIAGNOSTIC BREAKOUT HARNESS AMP CONNECTOR - VOLTAGE (20039B)

This is a replacement address tag. This tag is used for addressing the LX-A0 and XT2-A0 modules. Refer to ID-TAG in THIS SECTION for more detailed information.

This harness is used to check voltage (volts) to a component with an Amp connector and verify inputs.

8. ID-TAG ‘0T’ (AN071)

5. IQAN DATA CABLE FOR PDA (DG029)

This is a replacement address/terminating tag.

This tag is used for addressing the XP2-A0 module. Refer to ID-TAG in THIS SECTION for more detailed information.

This cable is used to connect the IQAN MDM module RS232 port to a PDA via a serial port adapter cable (for the PDA being used ). The serial port adapter cable is unique to each specific PDA model and is not available through Tigercat.

9. DEUTSCH 2 POLE SERVICE HARNESS (24860B)

It is very important that the correct IQAN data cable be used for connection to a PDA. Use of the incorrect cable may cause damage to the PDA. This cable is tagged as “Palm” and the serial connector will have female sockets.

Note: Some earlier versions of this kit supplied IQAN data cable for PDA (DG023) This cable

DIAGNOSTIC BREAKOUT HARNESS

This harness is used to bypass a wiring harness while troubleshooting electrical problems. This will identify or eliminate the wiring harness as a cause.

10. AMP 2 POLE SERVICE HARNESS (24859B) This harness is used to bypass a wiring harness while troubleshooting electrical problems. This will identify or eliminate the wiring harness as a cause.

WARNING Damage may occur to the PDA if the wrong data cable is used. Ensure the appropriate cable is selected when using a PDA; DO NOT USE AN ADAPTER TO MATCH UP SERIAL PORTS. 6.42

Tigercat 822/L830 Feller Buncher

630C-56

Electrical, gauges, alarms and computers

ELECTRICAL KIT - SERVICE AND DIAGNOSTICS - SELECTED ITEMS 6.43

Tigercat 822/L830 Feller Buncher IQAN SOFTWARE IQAN software can be downloaded from the Tigercat Dealer Website (click on Customer Service/ Warranty to find Machine Software).

All software required for both PC (laptop) and PDA use is included in this download. A user’s manual in PDF format is also included. Some of the software requires a software key (available from Tigercat).

Contact Tigercat Customer Service for more information about specific hardware requirements for PC (laptop) and PDA.

Electrical, gauges, alarms and computers NOTE: In the event of a battery failure in a PDA registration information may be lost. If this occurs it will be necessary to re-register the PDA for use.

Contact Tigercat Customer Service or your Tigercat District Manager for more information about registering a PDA.

DOWNLOADING APPLICATIONS FROM THE TIGERCAT DEALER WEBSITE Currently applications (IQAN programs) can be downloaded from the Tigercat dealer website in two formats: 1. An executable program can be downloaded.

This will automatically unzip and place the IQAN application file in the required file location. This is the preferred method for downloading as it keeps things simple for the user.

Note however that security settings on some user computers may not allow downloading of executable programs (EXE files). These users will need to use the second method of downloading files or approach their IT administrator to download executable files.

2. The application file itself can be downloaded.

The file must be placed in the required file location by the user in order to be used by the IQAN G3 software.

NOTE: The following downloading instructions apply to the Tigercat dealer website format at the time of printing. If you experience difficulty due to changes on the website contact Tigercat Customer Service for assistance.

APPLICATION PROGRAM UPDATES FOR PRODUCT SERVICE BULLETINS

DOWNLOADING APPLICATIONS AS EXE FILES

Machine program updates are also available on the Tigercat dealer website. These program updates are generally associated with specific Product Service Bulletins. Updating of programs should only be undertaken as part of a PSB or under instruction from Tigercat Customer Service.

The latest version of the application can be run on any machine provided that all applicable Product Service Bulletin updates have been completed.

PDA REGISTRATION In order to use a PDA (personal digital assistant) to perform maintenance procedures the PDA must be registered for authorized use of the software on Tigercat products. Each Tigercat product line has its own application code and must be registered separately for authorized use.

1. Click on the EXE to the right of the file you wish to download.

6.44

Tigercat 822/L830 Feller Buncher

Electrical, gauges, alarms and computers DOWNLOADING APPLICATIONS AS IDT FILES

2. Click on Open.

1. Click on the IDT to the right of the file you wish to download.

3. The correct folder location will automatically be chosen. Click Unzip.

2. Click on Save.

4. A pop up box will confirm the file has been successfully unzipped. Click on OK

3. The correct folder location must be manually chosen. C:\Program Files\ IQAN software\ G3 Second edition\Applications\To Palm.

4. Click on Save.

5. Click on Close.

6. The IQAN program file has now been downloaded to the correct folder.

5. The IQAN program file has now been downloaded to the correct folder.

6.45

Tigercat 822/L830 Feller Buncher

Electrical, gauges, alarms and computers

UPDATING THE IQAN APPLICATION A. UPDATING THE IQAN APPLICATION FROM A PDA (PERSONAL DIGITAL ASSISTANT) The following procedure instructs how to send a Tigercat IQAN application from a PDA (Personal Digital Assistant) device to the MDM module.

To perform this procedure you will require: • • •

PDA IQAN data cable for PDA PDA serial port adapter cable (for the PDA being used).

1. Park machine on level ground, lower all implements to the ground, set the park brake ON, and turn the key switch to OFF. 2. Locate the ‘round’ RS232 port connection on the back of the MDM. Do not disconnect the rectangular 6-pin connector.

PDA MAIN IQAN WINDOW

Note: This will require temporary removal of the MDM from its mounting location (4 screws).

5. Turn on power to the PDA, and start the IQANdevelop G3 program.

6. Turn the key switch to ‘RUN’. DO NOT START THE MACHINE.

3. Remove the rubber dust seal from the RS232 port and connect IQAN data cable for PDA.

WARNING Damage may occur to the PDA if the wrong data cable is used. Ensure the appropriate cable is selected when using a PDA; DO NOT USE AN ADAPTER TO MATCH UP SERIAL PORTS. IQAN DATA CABLE FOR PDA

PDA SERIAL PORT ADAPTER CABLE

IQAN - MDM PALM OS PDA

CONNECTING MDM TO PDA PDA DROP DOWN MENU DISPLAY

4. Connect the other end of the cable to the serial port adapter cable for the PDA being used.

7. Select the ‘IQAN’ box from the top left corner of the PDA screen. This will display a drop down menu showing ‘System / Options / Help’.

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Tigercat 822/L830 Feller Buncher

Electrical, gauges, alarms and computers

8. From the ‘System’ menu, select ‘Update application…’. Note: it will take a moment for the PDA to display available application programs.

18. Start the machine and verify correct operation of the new application.

19. Turn the key switch to ‘OFF’.

20. Turn off power on the PDA.

9. All IQAN application programs available for upload will be displayed.

21. Disconnect the IQAN data cable for PDA from both the MDM and the PDA serial port adapter cable.

10. Highlight the appropriate application program by selecting it on the PDA screen.

22. Reinstall the rubber dust seal on the MDM RS232 port. Reinstall the MDM into the mounting panel (4 screws).

PDA SEND APPLICATION DIALOG BOX 11. Select the ‘SEND’ box. This will display a dialog box titled ‘Send application’.

12. Set the ‘Factory default values’ to ‘Use values from application file’.

13. Set the ‘Adjustable values’ to ‘Use values from application file’.

14. Set the ‘Stored values’ to: For an MDM previously installed: ‘Leave values in master unchanged’.

For a new MDM (field replacement): ‘Reset all values to zero’.

15. Select the ‘SEND’ box. The MDM will display ‘! RECEIVING APPLICATION !’.

Important: The upload process should take less than one minute to complete.

During this time, do not perform any other functions on the PDA, or turn off power to the MDM. DO NOT START THE MACHINE. Should this occur, the upload will be halted and incomplete; starting from the beginning will be required.

16. Once the application is sent, turn off power to the MDM. 17. Select the ‘DONE’ box on the PDA. This will return the PDA display to the IQANdevelop G3 main screen.

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Tigercat 822/L830 Feller Buncher

Electrical, gauges, alarms and computers

B. UPDATING THE IQAN APPLICATION FROM A PC/LAPTOP The following procedure instructs how to send a Tigercat IQAN application from a personal computer (PC) or laptop to complete an upload of a Tigercat IQAN application.

code and select the ‘OK’ box. Note: contact the Tigercat Customer Service to acquire the correct application code.

To perform this procedure you will require: • • •

PC/Laptop IQAN data cable for PC/Laptop (no adapter cable required) Hardware key (Parker IQAN component available from Tigercat)

1. Park machine on level ground, lower all implements to the ground, set the park brake ON, and turn the key switch to OFF. 2. Locate the ‘round’ RS232 port connection on the back of the MDM. Do not disconnect the rectangular 6-pin connector.

9. Using the toolbar: select the ‘Send current application to IQAN system’ icon.

OR

Note: This will require temporary removal of the MDM from its mounting location (4 screws).

Using the drop-down menus: select ‘System’, ‘Send application…’.

3. Remove the rubber dust seal from the RS232 port and connect IQAN data cable for PC/Laptop.

4. Connect the other end of the cable to the COM1 serial port on the PC/Laptop.

5. Turn on power to the computer, and start the IQANdevelop G3 program.

6. Turn the key switch to ‘RUN’. DO NOT START THE MACHINE. 7. Open the new application in IQANdevelop G3 on the computer.

10. This will display another dialog box titled ‘Send application’.

11. Set the ‘Factory default values’ to ‘Use values from application file’.

12. Set the ‘Adjustable values’ to ‘Use values from application file’.

13. Set the ‘Stored values’ to: For an MDM previously installed: ‘Leave values in master unchanged’.

For a new MDM (field replacement): ‘Reset all values to zero’.

8. A dialog box titled ‘Enter application code’ will appear. Enter the correct application

6.48

Tigercat 822/L830 Feller Buncher

Electrical, gauges, alarms and computers 20. Disconnect the IQAN data cable for PC/ Laptop from both the MDM and the computer.

21. Reinstall the rubber dust seal on the MDM RS232 port. Reinstall the MDM into the mounting panel if previously removed.

14. Select the ‘SEND’ box. The MDM will display ‘! RECEIVING APPLICATION !’.

Note: In some cases a dialog box will appear titled ‘IQANdevelop: Confirmation’.

This dialog box states that the current application has a different description than the application loaded in the IQAN system.

Select the ‘Yes’ box to continue.

Important: The upload process should take less than one minute to complete.

During this time, do not perform any other functions on the computer, or turn off power to the MDM. DO NOT START THE MACHINE. Should this occur, the upload will be halted and incomplete; starting from the beginning will be required.

15. When the upload is complete, the computer display will return to the IQANdevelop G3 main screen.

16. Turn off power on the MDM. 17. Start the machine and verify correct operation of the new IQAN application.

18. Turn the key switch to ‘OFF’.

19. Turn off power on the computer.

6.49

Tigercat 822/L830 Feller Buncher GET APPLICATION (DOWNLOAD FROM MDM)

Electrical, gauges, alarms and computers 5. Turn on power to the PDA, and start the IQANdevelop G3 program.

A. GET APPLICATION USING A PDA (PERSONAL DIGITAL ASSISTANT) The following procedure instructs how to retrieve a Tigercat IQAN application with a PDA (Personal Digital Assistant) device from the MDM (Master Display Module).

To perform this procedure you will require: • • •

PDA IQAN data cable for PDA PDA serial port adapter cable (for the PDA being used).

1. Park machine on level ground, lower all implements to the ground, set the park brake ON, and turn the key switch to OFF. 2. Locate the ‘round’ RS232 port connection on the back of the MDM. Do not disconnect the rectangular 6-pin connector.

Note: This will require temporary removal of the MDM from its mounting location (4 screws).

PDA MAIN IQAN WINDOW 6. Turn the key switch to ‘RUN’. DO NOT START THE MACHINE.

3. Remove the rubber dust seal from the RS232 port and connect IQAN data cable for PDA.

WARNING Damage may occur to the PDA if the wrong data cable is used. Ensure the appropriate cable is selected when using a PDA; DO NOT USE AN ADAPTER TO MATCH UP SERIAL PORTS. IQAN DATA CABLE FOR PDA

PDA SERIAL PORT ADAPTER CABLE

IQAN - MDM PALM OS PDA

CONNECTING MDM TO PDA 4. Connect the other end of the cable to the serial port adapter cable for the PDA being used.

SELECTING AN EMPTY SLOT 7. Select an <empty slot> from the top right of the PDA screen. This is the location the application program will be downloaded to.

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Electrical, gauges, alarms and computers

8. In the IQANdevelop main screen, select the

7. Open the new application in IQANdevelop G3 on the computer.

icon.

9. This will display a new dialog box titled ‘Receiving…’, and the download process will begin.

10. Once the download process is complete, the PDA display will return to the main IQANdevelop G3 window. The downloaded application description will replace the <empty slot> in the top right corner of the PDA. Important: The download process should take less than one minute to complete. During this time, do not perform any other functions on the PDA, or turn off power to the MDM. DO NOT START THE MACHINE. Should this occur, the download will be halted and incomplete; starting from the beginning will be required.

8. A dialog box titled ‘Enter application code’ will appear. Enter the correct application code and select the ‘OK’ box. Note: contact the Tigercat Customer Service to acquire the correct application code.

B. GET APPLICATION USING A A PC/LAPTOP

9. Using the drop-down menus: select ‘System’, ‘Get application’

The following procedure instructs how to retrieve a Tigercat IQAN application with a personal computer (PC), or laptop from the MDM (Master Display Module).

To perform this procedure you will require: • • •

PC/Laptop IQAN data cable for PC/Laptop (no adapter cable required) Hardware key (Parker IQAN component available from Tigercat)

1. Park machine on level ground, lower all implements to the ground, set the park brake ON, and turn the key switch to OFF.

10. Choose a filename and the location you wish to save the file. Click on Save.

2. Locate the ‘round’ RS232 port connection on the back of the MDM. Do not disconnect the rectangular 6-pin connector.

Note: This will require temporary removal of the MDM from its mounting location (4 screws).

3. Remove the rubber dust seal from the RS232 port and connect IQAN data cable for PC/Laptop.

4. Connect the other end of the cable to the COM1 serial port on the PC/Laptop.

5. Turn on power to the computer, and start the IQANdevelop G3 program.

11. A pop-up box will confirm that the file is being downloaded.

6. Turn the key switch to ‘RUN’. DO NOT START THE MACHINE. 6.51

Tigercat 822/L830 Feller Buncher 12. When the download is complete, the computer display will return to the IQANdevelop G3 main screen.

13. Turn the key switch to ‘OFF’.

14. Turn off power on the computer.

15. Disconnect the IQAN data cable for PC/ Laptop from both the MDM and the computer.

Electrical, gauges, alarms and computers GRAPHING AND MEASUREMENT OF CHANNELS A. GRAPHING AND MEASUREMENT OF CHANNELS USING A PDA The following procedure instructs how to graph and measure channels with a PDA (Personal Digital Assistant) device from the MDM (Master Display Module).

1. Get application from the MDM. Refer to IQAN SOFTWARE ~GET APPLICATION procedure in THIS SECTION.

16. Reinstall the rubber dust seal on the MDM RS232 port. Reinstall the MDM into the mounting panel if previously removed.

2. Tap the channels icon.

3. Select the channel type in popup list and then a channel.

Highlight a channel by tapping on the channel’s name. (Used for graphing) Notice only one channel at a time can be graphed.

Check a channel by tapping on channel box. (Used for measure) You can measure more than one channel at a time.

4. To measure on channels tap the Measure button. The channel you have selected in channels window with checkboxes will show up. Tap the Start button to start measure. Tap the stop button to stop. (The button label changes from start to stop and vice versa). For each channel you will see the value and the status indicator. If the value is ok, OK will show. If not then you see “!!!”. By tapping on the channel you will see the channel name, channel unit, complete status message and pin

assignment at the bottom of screen.

You can change the scale (relates to the type of channel) by taping to top right corner.

6.52

Tigercat 822/L830 Feller Buncher

Electrical, gauges, alarms and computers

The Clear button is used to deselect all selected channels and return to channels window.

master cycle time. Measurement is typically carried out with a 100ms sample interval on Palm. That means the glitches and spikes on the signal may not be registered.

5. You can also graph a channel. This means you can measure graphically one channel

B. GRAPHING AND MEASUREMENT OF CHANNELS USING A PC/LAPTOP Procedure information to follow in next revision of the service manual.

Contact Tigercat service department for more information

at a time. In figure 3 highlight a channel and tap the graph button. This will take you to Figure 5. The scaling of the Y-axis is shown next to the axis. Tap the start button to start measure. After having measured, the total log time is displayed after channel name. The SMZ buttons allow you to manipulate the graph. With the S you can use your stylus pent to position a cursor on the graph and read out the corresponding value and time of the cursor at the bottomright corner. With the M you can move the graph and with the Z you can zoom in the graph. This is done by dragging your stylus pen on the screen. The drop down menu at the top right corner has five graph slot that are available to you for measurement.

Select an empty slot, unless you want to overwrite your current graph. The info button allows you to add a comment to

graph. The comment can hold 255 characters. The time is automatically captured when measurement starts.

Notice: Due to limited power of the processor of Palm, the measurement is not performed at full speed with respect to the 6.53

Tigercat 822/L830 Feller Buncher GET ERROR/EVENT LOG

Electrical, gauges, alarms and computers

A. GET ERROR/ EVENT LOG USING A PDA The following procedure instructs how to get an error/event log with a PDA (Personal Digital Assistant) device from the MDM (Master Display Module).

1. Get application from the MDM. Refer to IQAN SOFTWARE~GET APPLICATION procedure in THIS SECTION. 2. The error log is retrieved automatically when you get the application.

8. If you tap on one of the errors/events you will get the description and the time at the bottom of the screen.

PDA MAIN IQAN WINDOW 3. Tap the error log icon.

4. The error and event log will be retrieved automatically when you get the application.

5. Switch between viewing the error and event log with the two buttons in the topright corner.

6. If you tap on the Module/Name button you will alternate between showing “module:module name” and “module name” alone or “channel:channel name” and “channel name” alone.

7. If you tap on the Description/Time button you will alternate between showing the date/time and the error/event description.

The time format depends on your PDA formats settings.

6.54

Tigercat 822/L830 Feller Buncher

Electrical, gauges, alarms and computers

B. GET ERROR/ EVENT LOG USING A PC/LAPTOP The following procedure instructs how to get an error/event log using a PC/Laptop 1. Get application from the MDM. Refer to IQAN SOFTWARE~GET APPLICATION procedure in THIS SECTION.

4. When the transmission is complete the Events or Errors/alarms can be viewed by selecting one of the tabs at the top of the display.

2. Using the drop-down menus select System then Get error/event log.

5. Error/event logs can be copied or saved.

3. The receiving channels pop up box will appear.

6.55

Tigercat 822/L830 Feller Buncher

Electrical, gauges, alarms and computers

6.56

Tigercat 822/L830 Feller Buncher

SECTION 7 - ENGINE START AND STOP JUNE 2007

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 ............................................................................. 7.8 START CIRCUIT - RUN, PILOT RESET 'OFF', PILOT OFF .................... 7.11 START CIRCUIT - RUN, PILOT RESET SWITCH 'OFF' .......................... 7.10 START CIRCUIT - RUN, PILOT RESET SWITCH 'ON' ............................. 7.9 START CIRCUIT - RUN, PRESTART ........................................................ 7.6 START CIRCUIT - START ......................................................................... 7.7

Tigercat 822/L830 Feller Buncher

Engine start and stop

ENGINE START CIRCUIT For detailed engine information, refer to the Cummins engine manufacturer’s manual.

START RELAY

The Tigercat 822/L830 machines have two engine options: • •

•

Cummins QSC rated at 240 hp Cummins QSL9 rated at 280 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.

RELAY PANEL 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. Current then flows from the (ST) contact through RED wire (23A), a 5 amp fuse, RED wire (23B) and TAN wire (29) to energize the coil of the start relay.

420-04

To start engine; Turn battery disconnect switch to the ON position. Turn ignition key to the RUN position until the WAIT TO START warning lamp extinguishes, then to the START position and release it to the RUN position again after the engine starts.

CIRCUIT DESCRIPTION

Current also flows through TAN wire (29) to the IQAN computer. The IQAN computer then keeps the fan pump at zero displacement to reduce loading on the starting motor.

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 BAT contact of the key switch (ignition switch), the power door circuit, the engine computer and some of the cab circuits.

RED wire (6B) carries current to the coil of the alternator excite relay to energize the excite circuit. (This is only applicable for alternators with an external excite terminal).

When the key switch is first turned to the RUN position, current is supplied to the engine computer RUN SIGNAL connection through RED wire (106). The engine computer then supplies current to the grid heater relays through TAN wires (217) and (214), allowing current to flow from the batteries to the intake manifold grid heaters and also provides a ground for the WAIT TO START lamp, causing this lamp to light, for as long as the grid heaters are energized. The length of time that the grid heaters remain energized is determined by the engine computer based primarily on the temperature of the engine.

The engine computer also provides a ground for the STOP ENGINE, WARNING, and WATER IN FUEL lamps for a brief period of time to illuminate these lamps as a diagnostic measure to show the operator that these lamps are functional.

Current also flows from the RUN contact through RED wire (2), a 15 amp fuse and RED wire (6A) across the function lockout relay, through TAN wires (9A) and (9), across the start relay, through TAN wire (16) to energize the coil of the start solenoid relay and TAN wire (16B) to energize the coil on the pilot dump valve. The pilot dump valve will open the hydraulic pilot system to tank during start-up to reduce the load on the starting motor. Current also flows through TAN wire (9) to turn ON the pilot off warning light.

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

7.2

Tigercat 822/L830 Feller Buncher

Engine start and stop

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

The RUN SIGNAL on the engine computer also remains connected to the battery through RED wire (106) and the optional fire suppression system, allowing the engine to continue to run. If the key is switched off or the fire suppression system activated, power is removed from this circuit and the engine will shut off. The engine computer will also continue to cycle the grid heaters on and off by providing current to TAN wires (217) and (214) for a period of time after start-up to assist with warming up the engine.

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.

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, the drive brake release solenoid valve and turn ON the pilot on warning light.

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.

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 and drive motor brakes will also be applied. The pilot on warning light will turn OFF and the pilot off warning light will turn ON. For additional information on the PILOT SYSTEM refer to SECTION 5 in THIS SERVICE MANUAL.

7.3

Tigercat 822/L830 Feller Buncher

Engine start and stop

830-60

START CIRCUIT - AT REST 7.4

Tigercat 822/L830 Feller Buncher

Engine start and stop

830-60A

START CIRCUIT - AT REST BATTERY DISCONNECT SWITCH - ON

7.5

Tigercat 822/L830 Feller Buncher

Engine start and stop

830-60B

START CIRCUIT - RUN, PRESTART IGNITION KEY - RUN POSITION

7.6

Tigercat 822/L830 Feller Buncher

Engine start and stop

830-60C

START CIRCUIT - START IGNITION KEY - START POSITION

7.7

Tigercat 822/L830 Feller Buncher

Engine start and stop

830-60D

START CIRCUIT - RUN IGNITION KEY - RUN POSITION

7.8

Tigercat 822/L830 Feller Buncher

Engine start and stop

830-60E

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

7.9

Tigercat 822/L830 Feller Buncher

Engine start and stop

830-60F

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

7.10

Tigercat 822/L830 Feller Buncher

Engine start and stop

830-60G

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

7.11

Tigercat 822/L830 Feller Buncher

Engine start and stop

7.12

Tigercat 822/L830 Feller Buncher

SECTION 9 - ENGINE ANTI-STALL SEPTEMBER 2007

CONTENTS - SECTION 9 CONTROL MODULE IN CAB ........................................................... 9.2 CONTROL MODULE PIN CONNECTIONS ...................................... 9.4 ENGINE ANTI-STALL CURVE.......................................................... 9.4 ENGINE ANTI-STALL SWITCH ........................................................ 9.2 FAULT FINDING PROCEDURE ~ ANTI-STALL QUICK CHECK ..... 9.7 FAULT FINDING PROCEDURES, ADDITIONAL ............................. 9.8 HORSEPOWER LIMITING CONTROL GENERAL DESCRIPTION ............................................................ 9.2 SEE ALSO SECTION 4 LOAD SENSE; SET MARGIN PRESSURE ................ SEE SECTION 4 SCHEMATIC DIAGRAMS ENGINE ANTI-STALL CIRCUIT .................................................... 9.5 LOAD SENSING SYSTEM CIRCUIT DIAGRAM ........................... 9.6 SET PILOT PRESSURE ............................................. SEE SECTION 5 SPEED SENSOR, ADJUSTING ........................................................ 9.4 SPEED SENSOR ON ENGINE ......................................................... 9.2 VERIFY ANTI-STALL SETTING ................................. SEE SECTION 4

Tigercat 822/L830 Feller Buncher HORSEPOWER LIMITING CONTROL

Engine anti-stall

GENERAL DESCRIPTION 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.

•

ENGINE ANTI-STALL SOLENOID VALVE PILOT SUPPLY 'P1'PORT

••

• •

MARGIN PRESSURE ADJUSTING SCREW

MAIN PUMP

MAIN PUMP CONTROLLER (LS CONTROL) (QSC 8.3 ENGINE - 82210191 TO 82210600 ONLY)

ENGINE ANTI-STALL SOLENOID VALVE GAUGE TEST PORT ANTI-STALL SIGNAL PRESSURE

The anti-stall incorporates the following components:

•

•• ••

GAUGE TEST PORT 'L.S.'

The engine anti-stall system monitors the swing, main boom, stick boom, tilt, wrist and track drive functions. The anti-stall system also monitors the levelling system when the machine is configured as a leveller.

CONTROL MODULE

HORSEPOWER CALIBRATION DO NOT ADJUST

••

•

822-D75

WIRING HARNESS WITH 25 PIN CONNECTOR

••

GAUGE TEST PORT 'X1' ANTI-STALL SIGNAL PRESSURE

•• ••

••

••

MAIN PUMP

MODULE DISCONNECT PLUG

••

GAUGE TEST PORT 'L.S.'

••

• 822-D80

'LS' CONNECTION FROM MAIN VALVE

MARGIN PRESSURE ADJUSTING SCREW

MAIN PUMP CONTROLLER (LS CONTROL)

••

•

•

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.

830-071

•

CONTROL MODULE IN CAB A control module on the rear electrical panel.

WARNING Before welding anywhere on machine, disconnected the 25 pin connector from the control module and the two multi-pin plugs from the engine CPU to prevent damage to the electrical system.

SPEED SENSOR

••

105-2

•

SPEED SENSOR ON ENGINE

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

9.2

Tigercat 822/L830 Feller Buncher

Engine anti-stall

ANTI-STALL SWITCH

••

822-D79

•

ANTI-STALL SWITCH

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: Cummins QSC Engine Cummins QSL9 Engine

2000 RPM 1650 RPM

To compensate the engine anti-stall valve will signal the main pump to de-stroke 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 engine anti-stall system can be turned OFF when required for maintenance work. The engine may then be used at less than full throttle.

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

9.3

Tigercat 822/L830 Feller Buncher CONTROL MODULE PIN CONNECTIONS Refer to Engine anti-stall circuit diagram; •

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

•

Pin 13 is connected to ground.

•

Cummins QSL 9 - Pins 8 and 17 jump wire connected to each other.

•

Cummins QSC - Pins 6, 8 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.

Engine anti-stall The system control module constantly monitors the engine speed and any drop in RPM from the rated 2000 RPM (Cummines QSC Engine) or 1650 RPM (Cummins QSL9 Engine) 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.

ADJUSTING SPEED SENSOR 1. Stop engine.

2. Loosen locknut on speed sensor.

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.

NOTE: THIS GRAPHIC OF THE ANTI-STALL CURVE IS ONLY A PICTORIAL REPRESENTATION FOR EXPLANATION PURPOSES. IT SHOULD NOT BE USED TO IDENTIFY OR DETERMINE ACTUAL VALUES AS THEY CAN VARY FROM ONE MACHINE TO ANOTHER.

870B-21A

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

Tigercat 822/L830 Feller Buncher

822-33

Engine anti-stall

ENGINE ANTI-STALL CIRCUIT

9.5

Tigercat 822/L830 Feller Buncher

822-37

Engine anti-stall

LOAD SENSING SYSTEM CIRCUIT DIAGRAM 9.6

Tigercat 822/L830 Feller Buncher FAULT FINDING ~ ANTI-STALL QUICK CHECK

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

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.

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

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

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

A. WHEN DOES THE PROBLEM OCCUR ?

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.

•

Occurs only with the system ON.

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

•

Expected Results: All functions should operate normally.

•

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.

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

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

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

4. Fully activate MAIN BOOM UP function.

• •

9.7

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

Tigercat 822/L830 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:

•

SWING SPEED AND SWING PRESSURE SETTINGS.

•

MAIN SYSTEM (L.S.) PRESSURE SETTINGS.

•

CLAMP VALVE MAIN RELIEF.

Refer to the 822/L830 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.

Cummins QSC Engine 2000 RPM Cummins QSL9 Engine 1650 RPM

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.

9.8

Tigercat 822/L830 Feller Buncher

Engine anti-stall 2. Measure resistance of solenoid coil.

• The resistance should be 6.6 ±2 ohms.

7. Activate the SWING function fully.

Hold a CLAMP function over relief.

H. SPEED SENSOR OUTPUT

• Measure the engine speed.

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

8. Activate the SWING function fully.

Bottom the TILT cylinder.

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

Hold a CLAMP function over relief.

• Measure the engine speed.

3. Measure the AC voltage across 12 and 14 on connector.

• The speed sensor output should be greater than 0.5 VAC.

• The engine speed should always be above "rated speed" of 2000 RPM (Cummines QSC Engine) or 1650 RPM (Cummins QSL9 Engine). 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 12 and 14 on connector • The resistance should be: 130 to 140 ohms at 72° (22°C)

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

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

3. Check for continuity from pin 14 to 13 and 12 to 13. (Pin 13 is connected to ground) J. SPEED SENSOR COIL

E. ELECTRICAL POWER TO ANTI-STALL CONTROL MODULE.

1. Remove connector from anti-stall speed sensor.

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

2. Measure resistance of speed sensor coil between terminals on sensor.

• The resistance should be: 130 to 140 ohms at 72° (22°C)

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.

9.9

Tigercat 822/L830 Feller Buncher

Engine anti-stall

9.10

Tigercat 822/L830 Feller Buncher SECTION 10- OIL COOLER AND COOLING FAN JUNE 2007

CONTENTS - SECTION 10 COOLING FAN .......................................................................................... 10.10 COOLING FAN CIRCUIT DESCRIPTION ................................................. 10.14 COOLING FAN CIRCUIT DIAGRAM ......................................................... 10.15 FAN DRIVE MOTOR INSTALLATION ....................................................... 10.11 FAN MOTOR .............................................................................................. 10.11 FAN PUMP (CLAMPS/FAN PUMP) ........................................................... 10.10 FAN SPEED ADJUSTMENT ...................................................................... 10.18 HYDRAULIC SCHEMATIC FAN CIRCUIT ......................................................................................... 10.17 OIL COOLER CIRCUIT ............................................................................ 10.9 HYDRAULIC TANK ...................................................................................... 10.5 MAIN CONTROL VALVE ........................................................ SEE SECTION 4 MAIN PUMP ............................................................................ SEE SECTION 4 OIL COOLER ............................................................................................... 10.2 OIL COOLER BYPASS/ RETURN MANIFOLD............................................ 10.4 OIL COOLER CIRCUIT DESCRIPTION ...................................................... 10.6 OIL COOLER CIRCUIT DIAGRAM .............................................................. 10.7 RETURN MANIFOLD/RETURN FILTERS ................................................... 10.5

Tigercat 822/L830 Feller Buncher

Oil Cooler and Cooling Fan

OIL COOLER

A/C CONDENSER

The hydraulic oil cooler/radiator/charge air cooler (CAC) cooling assembly is mounted to the rear of the fan. The A/C condenser core is mounted to the rear of the oil cooler/radiator/charge air cooler (CAC) cooling assembly. A debris screen is used to protect the cooling assembly. The hydraulically driven fan draws air through the screen, through the A/C condenser, the oil cooler/radiator/CAC cooling assembly and finally blows the air across the engine. The air is expelled to atmosphere through fan and exaust access door and the perforated panels that make up the engine enclosure.

OIL COOLER/ RADIATOR/CAC ASSEMBLY

••

• •• SLIDE DEBRIS SCREEN OUT AND REMOVE

The complete cooling assembly is rubber isolation mounted to reduce the transmission of noise and to isolate the components from vibration.

COOLING ASSEMBLY LH830-09

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, hydraulic oil cooler/radiator/ charge air cooler (CAC) cooling 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.

•• NUTS A/C CONDENSER

•• HINGES

• •

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

LH830-10

10.2

SWING OUT A/C CONDENSER

Tigercat 822/L830 Feller Buncher

Oil Cooler and Cooling Fan

OIL COOLER A/C CONDENSER

RADIATOR

DEBRIS SCREEN

COOLING FAN SHROUD FINGER GUARD

•

•

•

SURGE TANK

•

•

FAN DRIVE MOTOR

•

••

•• •

• CHARGE AIR COOLER

822C-01

COOLING ASSEMBLY - OVERALL VIEW

10.3

NOTE: REGULARLY CHECK FOR DEBRIS BETWEEN A/C CONDENSER, OIL COOLER AND RADIATOR

Tigercat 822/L830 Feller Buncher

Oil Cooler and Cooling Fan

OIL COOLER BYPASS/ RETURN MANIFOLD The oil cooler bypass return manifold collects oil from the main control valve and fan return oil and routes it through the oil cooler. The oil cooler bypass return manifold incorporates an oil 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 passes through the oil cooler bypass valve returning to tank bypassing the oil cooler. Thus 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.

Note that the saw return oil and ER boom counterbalance valve return (if equipped) are plumbed into the cooler return side of the bypass valve.

10.4

Tigercat 822/L830 Feller Buncher

HYDRAULIC TANK

5 - HYDRAULIC RETURN FILTERS

RETURN MANIFOLD

• •• 422-07

• •• ••

Oil Cooler and Cooling Fan

••

• 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 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.

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. On machines equipped with a pressurized hydraulic tank (82210191 TO 82210345, 82210347 to 82210350, 82210611 to 82210999, 830*0191 to 830*0343, 830*0611 to 830*0999), the air space in the top of the hydraulic tank is vented to atmosphere via a check valve and spinon filter. On machines equipped with a nonpressurized hydraulic tank (82210346, 82210351 to 82210610, 830*0344 to 830*0610) the air space in the top of the tank is vented to atmosphere via a spin on filter only.

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. 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.

10.5

Tigercat 822/L830 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.

10.6

Tigercat 822/L830 Feller Buncher

822-39

Oil Cooler and Cooling Fan

OIL COOLER CIRCUIT 10.7

Tigercat 822/L830 Feller Buncher

Oil Cooler and Cooling Fan

10.8

Oil Cooler and Cooling Fan

HYDRAULIC SCHEMATIC OIL COOER CIRCUIT

Tigercat 822/L830 Feller Buncher

822-50

10.9

Tigercat 822/L830 Feller Buncher 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.

Oil Cooler and Cooling Fan 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

SAW PUMP

•

AP179

•

• 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.

822-D73

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.

10.10

PUMP ASSEMBLY

•

INPUT DRIVE SHAFT (CONNECTED TO SAW PUMP)

Tigercat 822/L830 Feller Buncher

Oil Cooler and Cooling Fan

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.

DANGER PRESSURE PORT 'B' PRESSURE PORT 'A'

CAUTION Ensure that ALL hydraulic connections at fan motor are tight and leak free. leaking oil will be blown into engine area

TANK LINE

•• •

The fan motor is equipped with an integral loop flushing valve which provides additional cooling to the cooling fan circuit.

ASSEMBLY NOTE (822*00191 to 822*0470, 830*00191 to 830*0470 only): Before re-installing a fan drive motor, pack spline area of fan hub and motor shaft with EP Moly-Graph grease. See Fig. 630B-10.

H822-02

FAN MOTOR

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 (822*00191 TO 822*0470, 830*00191 TO 830*0470 ONLY) 10.11

Tigercat 822/L830 Feller Buncher

Oil Cooler and Cooling Fan

FAN CONTROL VALVES

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.

The fan direction is controlled by two solenoid operated fan pilot valves and a pilot operated fan control valve.

DIN CONNECTOR

VALVE BODY

•

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.

1

•

3

• 1

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.

•

CONTROL VALVE CARTRIDGE

SOLENOID

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.

FAN PILOT VALVE

AT022

SAW PUMP PRESSURE COMPENSATOR

CLAMPS AND SAW PUMP FAN DRIVE PUMP (PISTON PUMP) (DOUBLE GEAR PUMP)

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

•• ••

•• ••

• •

•• •• ••

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

822-D70

•• COOLING FAN CONTROL VALVE

HYDRAULIC PUMPS 10.12

•• PILOT SUPPLY VALVE

Tigercat 822/L830 Feller Buncher

Oil Cooler and Cooling Fan

FAN CONTROL VALVE The fan control valve consists of one open center spool section, an inlet section and an outlet section.

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.

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.

FAN CONTROL VALVE SCHEMATIC

822-19

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.

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.

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 10.13

PILOT END CAP

Tigercat 822/L830 Feller Buncher

•

COOLING FAN CIRCUIT DESCRIPTION

ACCUMULATORS (FAN CONTROL) ONE SHOWN, ONE HIDDEN BEHIND PUMPS FAN PILOT VALVE 'REV'

FAN PILOT VALVE 'FWD'

822-D74

Oil Cooler and Cooling Fan

••

•

FAN CONTROL ACCUMULATORS

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.

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.

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.

10.14

Tigercat 822/L830 Feller Buncher

Oil Cooler and Cooling Fan

COOLING FAN CIRCUIT 822-40

10.15

Tigercat 822/L830 Feller Buncher

Oil Cooler and Cooling Fan

10.16

Oil Cooler and Cooling Fan

HYDRAULIC SCHEMATIC FAN CIRCUIT

Tigercat 822/L830 Feller Buncher

822-51

10.17

Tigercat 822/L830 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 adjustment 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 10.18

Tigercat 822/L830 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

10.19

SPOOL STOP ADJUSTING SCREW 'FORWARD'

• •

GAUGE TEST PORT

FAN CONTROL VALVE

REVERSE PORT RELIEF VALVE

MAIN RELIEF VALVE

Tigercat 822/L830 Feller Buncher

Oil Cooler and Cooling Fan

10.20

Tigercat 822/L830 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 HYDRAULIC SCHEMATIC TRACK DRIVE CIRCUIT .......................................................................... 11.9 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 ....................................................... 11.13 PRESSURE SETTINGS, DRIVE SYSTEM BEGIN OF REGULATION, SET, FOR DRIVE MOTOR .......................... 11.12 BRAKE RELEASE PRESSURE ADJUSTMENT ON DRIVE MOT .......... 11.11 CROSSOVER RELIEF VALVES, FOR DRIVE MOTOR ......................... 11.10 RIGHT TRACK SPEED ADJUSTMENT .................................................... 11.16 SCHEMATIC DIAGRAMS DRIVE CIRCUIT ....................................................................................... 11.8 DRIVE MOTOR .................................................................... 11.3, 11.5, 11.6 SET BRAKE RELEASE PRESSURE ON DRIVE MOT .............................. 11.11 SET STRAIGHT TRAVEL .......................................................................... 11.16 TRACK COMPONENTS BOTTOM ROLLER RETAINING BOLTS ................................................ 11.19 MEASURING TRACK SAG .................................................................... 11.17 TRACK SAG ADJUSTMENT .............................................................. 11.18 OPERATING THE MACHINE ................................................................. 11.17 TORQUING UNDERCARRIAGE BOLTS ............................................... 11.18 TRACK SHOE RETAINING BOLTS ....................................................... 11.18 WEAR LIMITS BOTTOM ROLLER WEAR ................................................................. 11.20 BUSHING WEAR, OUTSIDE DIAMETER .......................................... 11.20 IDLER WEAR ...................................................................................... 11.21 PIN AND BUSHING WEAR ................................................................ 11.20 TRACK LINK WEAR ........................................................................... 11.19 TRACK SHOE GROUSER HEIGHT WEAR ....................................... 11.19 TRACK SLIDE WEAR ......................................................................... 11.21 TRACK DRIVE ASSEMBLY ......................................................................... 11.2 TRACK SPEED SET-UP PROCEDURE HIGH FORWARD (MOTOR MINIMUM DISPLACEMENT ...................... 11.15 HIGH REVERSE (VALVE FLOW SETTING) .......................................... 11.16 LOW FORWARD (VALVE FLOW SETTING) ......................................... 11.14 SET MOTOR MAXIMUM DISPLACEMENT ........................................... 11.13 SET STRAIGHT TRAVEL ....................................................................... 11.16 SUMMARY OF PROCEDURE ................................................................ 11.16 TRACK TIMING CHART ............................................................................ 11.15

JULY 2007

Tigercat 822/L830 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/L830 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.

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.

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.

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.

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 822-34

TRACK SPROCKET

PLANETARY TRACK DRIVE GEARBOX

•

MOTOR SCHEMATIC DIAGRAM

•

LOWER FRAME

•

TRACK DRIVE MOTOR (AQ019 SHOWN)

• ••

BRAKE ASSEMBLY

BK004-822

TRACK DRIVE MOTOR AND GEARBOX ASSEMBLY 11.3

Tigercat 822/L830 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/L830 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.

822-34

MOTOR SCHEMATIC DIAGRAM

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 Continued on page 6

11.5

Tigercat 822/L830 Feller Buncher

Track drive

Continued from page 5

the supply oil entering the drive speed change valve at 2000 psi. maximum.

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;

For 822 AQ019, MAXIMUM DISPLACEMENT = 105cc/rev.

MINIMUM DISPLACEMENT = app. 50cc/rev.

822-34

For L830 AQ047, MAXIMUM DISPLACEMENT = 135cc/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.

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

Tigercat 822/L830 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/L830 Feller Buncher

822-41

Track drive

TRACK DRIVE CIRCUIT DIAGRAM WITH AQ019 MOTOR 11.8

Track drive

HYDRAULIC SCHEMATIC TRACK DRIVE CIRCUIT

Tigercat 822/L830 Feller Buncher

822-52

11.9

Tigercat 822/L830 Feller Buncher DRIVE SYSTEM PRESSURE SETTINGS FOR DRIVE MOTOR

Track drive 5.

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.

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.

LINDE MAIN VALVE MANIFOLD

HIGH PRESSURE LIMITING CONTROL

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. 9. Activate LEFT track drive foot pedal in both FORWARD and REVERSE directions to ensure that the track does not move.

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.

•• ••

•

Start engine and set throttle speed to above 1500 RPM.

•

12. Set throttle switch to FULL

L.S. GAUGE TEST PORT

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.

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

•

'P' GAUGE TEST CONN.

L.S. GAUGE TEST CONN.

'B' SIDE REVERSE CROSSOVER RELIEF VALVE

'A' SIDE FORWARD CROSSOVER RELIEF VALVE

EARLIER DESIGN

LINDE MAIN VALVE MANIFOLD

103-17A

...

•

•

MAIN VALVE MANIFOLD

••

••

••

L.S. PRESSURE LIMIT, SET AT 300 BAR(4300 PSI) WITH GAUGE ON 'P' TEST PORT • 4MM ALLEN KEY • 13MM WRENCH SYSTEM RELIEF VALVE NON-ADJUSTABLE

•• •• 860C-035

822-D60

DRIVE MOTOR - LEFT SIDE SHOWN 'B' SIDE REVERSE CROSSOVER RELIEF VALVE

'A' SIDE FORWARD CROSSOVER RELIEF VALVE

5mm ALLEN KEY 17mm WRENCH

5mm ALLEN KEY 17mm WRENCH

LATER DESIGN

LINDE 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.

••

•

822-D62

DRIVE MOTOR - RIGHT SIDE SHOWN 11.10

Tigercat 822/L830 Feller Buncher

Track drive

14. With the aid of an assistant; While holding the LEFT drive foot pedal in the FORWARD position 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.

5.

15. Repeat step (14) for the LEFT REVERSE crossover relief valve.

8. Place DRIVE/LOW switch to DRIVE position.

16. Repeat steps (4) through (15) for RIGHT track drive motor.

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.

Start engine and set throttle to FULL

...

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.

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.

18. Re-connect brake line(s) to both gearboxes.

19. Remove pressure gauge and wipe up any spills.

BRAKE RELEASE PRESSURE ADJUSTING SCREW

20. Replace both LEFT and RIGHT drive motor inspection covers.

•• ••

SET BRAKE RELEASE PRESSURE ADJUSTMENT ON DRIVE MOTOR

5mm ALLEN KEY 17mm WRENCH

Pressure setting: 500 psi. (cracking pressure) Place felling head securely on the ground before performing any service work.

• PRESSURE REGULATOR VALVE BLOCK

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.

822-D62

BEGIN OF REGULATION ADJUSTING SCREW 6mm WRENCH 13mm WRENCH

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.

Continued on page 12

• GAUGE TEST PORT 'Y1'

•• 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).

11.11

Tigercat 822/L830 Feller Buncher

Track drive

SET BEGIN OF REGULATION (DRIVE SPEED CHANGE VALVE)

6.

1. Ensure hydraulic oil is at operating temperature.

7. From inside the cab close and latch the front door and press the PILOT RESET switch to activate the pilot system.

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.

LINDE MAIN VALVE MANIFOLD

HIGH PRESSURE LIMITING CONTROL

••

••

L.S. GAUGE TEST PORT

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

10. Activate LEFT track drive foot pedal in both FORWARD and REVERSE directions to ensure that the track does not move.

EARLIER DESIGN

•

L.S. GAUGE TEST CONN.

MAIN VALVE MANIFOLD

••

••

L.S. PRESSURE LIMIT, SET AT 300 BAR(4300 PSI) WITH GAUGE ON 'P' TEST PORT • 4MM ALLEN KEY • 13MM WRENCH SYSTEM RELIEF VALVE NON-ADJUSTABLE

•• •• 860C-035

9. Place DRIVE/LOW switch to DRIVE position.

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.

LINDE MAIN VALVE MANIFOLD

'P' GAUGE TEST CONN.

••

8. Place ANTI-STALL switch to OFF position.

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.

'P' GAUGE TEST PORT

103-17A

...

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.

•• •

Start engine and set throttle to FULL

LATER DESIGN

LINDE 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.

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.

11.12

Tigercat 822/L830 Feller Buncher TRACK SPEED SET-UP PROCEDURE

Track drive WARNING

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/L830 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

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

11.13

••

RIGHT TRACK DRIVE MOTOR

Tigercat 822/L830 Feller Buncher 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.

Track drive 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

...

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

••

RETURN MANIFOLD

••

••

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.

11.14

Tigercat 822/L830 Feller Buncher

Track drive

HIGH FORWARD (motor minimum displacement)

TRACK TIMING CHART

18. Turn ‘DRIVE/LOW’ switch to ‘DRIVE’ 19. Set throttle switch to FULL

GEARBOX RPM

...

10 23.48 24.52 26.09 26.61 11 21.34 22.29 23.72 24.19 12 19.57 20.43 21.74 22.17 13 18.06 18.86 20.07 20.47 14 16.77 17.52 18.63 19.01 15 15.65 16.35 17.39 17.74 16 14.67 15.33 16.30 16.63 17 13.81 14.42 15.35 15.65 18 13.04 13.62 14.49 14.78 LOWER 19 12.36 12.91 13.73 14.00 TRACTIVE 20 11.74 12.26 13.04 13.30 EFFORT 21 11.18 11.68 12.42 12.67 22 10.67 11.15 11.86 12.09 23 10.21 10.66 11.34 11.57 24 9.78 10.22 10.87 11.09 25 9.39 9.81 10.43 10.64 26 9.03 9.43 10.03 10.23 27 8.70 9.08 9.66 9.86 8.39 8.76 9.32 9.50 DESIRED 28 HIGH 29 8.10 8.46 9.00 9.18 30 7.83 8.17 8.70 8.87 DO NOT 31 7.57 7.91 8.42 8.58 EXCEED 32 7.34 7.66 8.15 8.32 33 7.11 7.43 7.91 8.06 34 6.91 7.21 7.67 7.83 35 6.71 7.01 7.45 7.60 36 6.52 6.81 7.25 7.39 37 6.35 6.63 7.05 7.19 38 6.18 6.45 6.86 7.00 39 6.02 6.29 6.69 6.82 40 5.87 6.13 6.52 6.65 *45 LINK TRACK NOT APPLICABLE TO 860/870/L870

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.

822 TRACK CHART.XLS

NOTE: Levelling machines equipped with track drive gearbox BK065 have a speed range of 9 to 25 rpm.

•• •• MAXIMUM DISPLACEMENT ADJUSTMENT STOP 822-D60

NUMBER OF TRACK LINKS 47 50 51 TRACK REVOLUTION TIME (SECONDS)

DESIRED LOW

20. With an assistant depressing ‘LEFT’ TRACK drive pedal ‘FORWARD’, record track drive sprocket speed.

MINIMUM DISPLACEMENT ADJUSTMENT STOP

45

LEFT TRACK DRIVE MOTOR IMPORTANT: DO NOT exceed the recommended track speed specified above, over speeding will damage the drive motor.

11.15

Tigercat 822/L830 Feller Buncher HIGH REVERSE (valve flow setting)

Track drive SUMMARY 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.

11.16

Tigercat 822/L830 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.

11.17

Tigercat 822/L830 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 11.18

Tigercat 822/L830 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.

SINGLE GROUSER

Only bolts with grade '12.9' or '170' designation forged in the head are approved.

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" UNF (D6) TORQUE-TURN ............ 220LBF-FT. + 1/3 TURN. CHECKING TORQUE ....................... 450 LBF-FT.

TRIPLE GROUSER

Track shoe bolts ~ M20 (F8) BERC-1

TORQUE-TURN ............ 260LBF-FT. + 1/3 TURN.

GROUSER WEAR (HEIGHT)

CHECKING TORQUE ............... 563-648 LBF-FT.

WEAR LIMITS

Track shoe bolts ~ M24 (FH400)

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)

TORQUE-TURN ............ 340LBF-FT. + 1/3 TURN. CHECKING TORQUE ..................... 1040 LBF-FT. BOTTOM ROLLER RETAINING BOLTS 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.

NOTE: Allowable wear for soft ground conditions is 100%. Allowable wear for rocky ground conditions is 75%.

When checking the torque values at the first 100 hours and every 125 hours thereafter use the torque value(s) shown below.

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. BERC-2

Bottom roller bolts ~ 3/4" UNC TORQUE ......................................... 310 LBF-FT. Bottom roller bolts ~ 7/8" UNC TORQUE ......................................... 475 LBF-FT. 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" (121.5mm) 50% wear ................................ 4.60" (116.8mm) 75% wear ................................ 4.48" (113.8mm) 100% wear .............................. 4.34" (110.2mm)

11.19

Tigercat 822/L830 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.

11.20

Tigercat 822/L830 Feller Buncher

Track drive

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.

1/8"

845-33A

SUGGESTED MEASURING GAUGE

BERC-7

MEASURING IDLER WEAR

WEAR LIMITS New idler dimension ...................... 0.85"(22.0mm) 100% wear .................................... 1.18"(30.0mm)

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.

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.

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.

Since the checking area is not immediately 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 'A'

'A'

845-32

TRACK SLIDE WEAR

CHAIN LINK

CHECK THIS DIMENSION

•

• •

CHAIN LINK BUSHING

•

TRACK GUIDE TRACK SLIDE

845-33

SECTION A - A 11.21

Tigercat 822/L830 Feller Buncher

Track drive

11.22

Tigercat 822/L830 Feller Buncher

SECTION 12 - BOOM FUNCTIONS JULY 2007

CONTENTS - SECTION 12 ADJUST OIL FLOW TO CYLINDERS (CYLINDER CYCLE TIMES ................ 12.8 BOOM CONTROL VALVE ............................................................................ 12.3 SEE ALSO SECTION 4 BOOM SYSTEM DESCRIPTION 'CONVENTIONAL' BOOM .......................................................................... 12.2 'ER' BOOM SYSTEM ................................................................................ 12.2 CIRCUIT DIAGRAM 'CONVENTIONAL' BOOM SYSTEM .......................................................... 12.4 'ER' BOOM SYSTEM ................................................................................ 12.5 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/L830 Feller Buncher BOOM SYSTEM DESCRIPTION

Boom functions 'ER' BOOM SYSTEM The 'ER' Boom Valve, located on the upper frame at the base of the main boom, connects one of the STICK cylinders with the HOIST boom cylinders circuit in such a way that allows the boom system to be controlled by movement of a single joystick lever.

CONVENTIONAL BOOM One "hoist" cylinder is used to raise and lower the main boom.

Two identical cylinders are used side by side in the "stick" position.

The "head tilt" function uses one cylinder.

860-01.AI

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).

PUSH LEFT JOYSTICK FORWARD TO MOVE FELLING HEAD AWAY FROM MACHINE Simply pushing the LEFT joystick FORWARD moves the boom straight out of pulling back on the joystick moves the head towards the machine. The right joystick moves the boom system UP or DOWN. 860-01.AI

PULL LEFT JOYSTICK BACK TO MOVE FELLING HEAD IN TOWARDS THE MACHINE 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/L830 Feller Buncher CONTROL VALVE MANIFOLD

Boom functions

TILT 'BACK' PORT STICK 'IN' 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

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.

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.

For adjusting procedure refer to TILT CYLINDER (ROD END) FLOW ADJUSTMENT in THIS SECTION.

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.

To adjust the relief valves, Refer to SET MAIN BOOM, STICK AND TILT PORT RELIEF VALVES in THIS SECTION.

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.

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

870B-D16

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.

TILT 'BACK' PILOT END CAP

For a full description of the pilot system including the joystick handles, Refer to SECTION 5 in THIS MANUAL.

ADJUSTING SCREW

FLOW CONTROL ADJUSTING SCREW - TILT 12.3

Tigercat 822/L830 Feller Buncher

822-35

Boom functions

'CONVENTIONAL' BOOM SYSTEM CIRCUIT DIAGRAM 12.4

Tigercat 822/L830 Feller Buncher

822-42

Boom functions

'ER' BOOM SYSTEM CIRCUIT DIAGRAM 12.5

Tigercat 822/L830 Feller Buncher

Boom functions SET MAIN BOOM, STICK AND TILT PORT RELIEF VALVES

WARNING

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.

1. With hydraulic oil at operating temperature, LINDE MAIN VALVE MANIFOLD

•• ••

•

•• L.S. GAUGE TEST PORT

'P' GAUGE TEST PORT

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.

LS PRESSURE ADJUSTMENT P2

EARLIER DESIGN

• 103-17A

LINDE MAIN VALVE MANIFOLD

'P' GAUGE TEST CONN.

L.S. GAUGE TEST CONN.

MAIN VALVE MANIFOLD

••

••

STICK CYLINDERS FULLY EXTENDED

•• LS PRESSURE ADJUSTMENT P2 SYSTEM RELIEF VALVE NON-ADJUSTABLE

••

•

•

TIP OF STICK BOOM FULLY SUPPORTED 830-07

HIGH PRESSURE LIMITING CONTROL

860C-035

LATER DESIGN

LINDE MAIN VALVE MANIFOLD

SERVICE POSITION FIG.1

2. Connect a 0-5000 psi pressure gauge on 'P' test port of Linde main valve manifold.

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.

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.

12.6

Tigercat 822/L830 Feller Buncher SPOOL TRAVEL STOP • 19mm WRENCH • 6mm ALLEN KEY

•

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.

PILOT END CAP

•

ADJUSTING SCREW • 5mm ALLEN KEY

•

WARNING

•

LOCKNUT • 17mm WRENCH

When adjusting the port relief valves, the boom will fall if the relief adjusting screw is unscrewed (counterclockwise) out too

•

PORT RELIEF VALVE

MAIN VALVE BODY

90744-3

Boom functions

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.

•

MAIN VALVE PORT RELIEF VALVE

6. Turn port relief valve adjusting screws for functions being set fully IN (clockwise). Do not overtighten or breakage will result.

9. Slowly raise setting (clockwise) until hissing noise stops or until engine stops lugging.

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.

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.

10. Tighten locknut on adjusting screw taking care NOT to turn the adjusting screw at the same time.

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/L830 Feller Buncher

Boom functions 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.

11. Check the setting again by ensuring that the hissing noise is still absent after tightening the locknut.

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.

18. Stop engine, remove all gauges and reinstall plugs and caps.

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.

13. Slowly raise setting (clockwise) until hissing noise stops or until engine stops lugging.

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.

1. Ensure hydraulic oil is at operating temperature.

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

14. Tighten locknut on adjusting screw taking care NOT to turn the adjusting screw at the same time.

3. From inside the cab close and latch the front door and press the PILOT RESET switch to activate the pilot system.

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.

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.

CONTROL VALVE MANIFOLD

TILT 'BACK' PORT STICK 'IN' RELIEF PORT RELIEF

MAIN BOOM CYLINDER(S); 5. Fully retract cylinder(s).

6. Place MAIN BOOM joystick lever in 'FULL UP' position and fully ** extend cylinders. Record cycle time from stop to stop.

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/L830 Feller Buncher

Boom functions

7. Place MAIN BOOM joystick lever in 'FULL DOWN' position and fully ** retract cylinders.

Record cycle time from stop to stop.

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.

STICK BOOM CYLINDER; 8. Repeat steps (5), (6) and (7) using STICK BOOM joystick lever.

TILT CYLINDER; NOTE: Before the TILT cylinder cycle times can be recorded, the rod end flow control adjusting screw must first be set correctly.

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.

See TILT CYLINDER (ROD END) FLOW ADJUSTMENT in THIS SECTION. 9. Repeat steps (5), (6) and (7) using TILT joystick lever.

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.

** 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.

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.

BOOM FUNCTIONS MAIN BOOM UP MAIN BOOM DOWN BOOM OUT BOOM IN TILT FORWARD TILT BACK TELESCOPIC STICK OUT TELESCOPIC STICK IN

CYCLE TIMES - 822, H822, L830, LH830 ER BOOM TIME W/STD TILT TIME W/4-LINK 5 sec.

5 sec.

8 sec.

8 sec.

4.5 sec.

4.5 sec.

4.5 sec.

4.5 sec.

3.8 sec.

4.0 sec.

3.8 sec.

4.0 sec.

4 sec. n/a 4 sec. n/a

BOOM FUNCTIONS MAIN BOOM UP MAIN BOOM DOWN STICK BOOM OUT STICK BOOM IN TILT FORWARD TILT BACK TELESCOPIC STICK OUT TELESCOPIC STICK IN

CONVENTIONAL BOOM TIME WITH HEAD TIME NO HEAD 7.0 sec.

5.4 sec.

8.9 sec.

16.0 sec.

6.1 sec.

5.3 sec.

5.9 sec.

10.9 sec.

4.0 sec.

3.8 sec.

3.8 sec.

3.8 sec. n/a n/a n/a n/a

12.9

TIME NO HEAD 5 sec.

12 sec.

4.5 sec.

4.5 sec.

3.8 sec.

3.8 sec.

4 sec.

4 sec.

Tigercat 822/L830 Feller Buncher

Boom functions

TILT CYLINDER (ROD END) FLOW AND SPEED ADJUSTMENT

•

When correctly set, this restriction will prevent cylinder damage.

1. Ensure hydraulic oil is at operating temperature.

LINDE MAIN VALVE MANIFOLD

• •

This adjusting screw restricts the flow of oil leaving the rod end of the TILT cylinder when tilting FORWARD.

TOP OF CONTROL VALVE MANIFOLD

HIGH PRESSURE LIMITING CONTROL

870B-D16

TILT 'BACK' PILOT END CAP ADJUSTING SCREW

FLOW CONTROL ADJUSTING SCREW - TILT

•• ••

•

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.

• L.S. GAUGE TEST PORT

'P' GAUGE TEST PORT LS PRESSURE ADJUSTMENT P2

• 103-17A

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.

EARLIER DESIGN

LINDE MAIN VALVE MANIFOLD

'P' GAUGE TEST CONN.

L.S. GAUGE TEST CONN.

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.

MAIN VALVE MANIFOLD

••

••

•• LS PRESSURE ADJUSTMENT P2 SYSTEM RELIEF VALVE NON-ADJUSTABLE

• •• 860C-035

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.

LATER DESIGN

LINDE MAIN VALVE MANIFOLD

8. Tighten locknut on restriction adjustment screw taking care NOT to turn the adjusting screw at the same time.

2. Connect a 0-5,000 psi pressure gauge on 'P' test port of Linde main valve manifold.

9. Check the pressures again after tightening the locknut.

3. Start engine and place throttle control in FULL.

10. Stop engine and remove gauge.

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/L830 Feller Buncher

SECTION 13 - LEVELLING JULY 2007

CONTENTS - SECTION 13 CIRCUIT DESCRIPTION ............................................................................. 13.9 CIRCUIT DIAGRAM ..................................................................................... 13.8 CONTROL VALVE DESCRIPTION ......................................................................................... 13.3 SPOOL SECTIONS .................................................................................. 13.4 COUNTERBALANCE VALVE SCHEMATIC DIAGRAM ........................................................................... 13.6 COUNTERBALANCE VALVE ...................................................................... 13.6 OPERATING DESCRIPTION ................................................................... 13.6 PRESSURE SETTINGS ......................................................................... 13.12 CYLINDER PIN WEAR ADJUSTMENT ..................................................... 13.13 HYDRAULIC SCHEMATIC LEVELLING CIRCUIT ...................................... 13.7 IQAN COMPUTER CONTROL SYSTEM LEVELLING CONTROL ADJUSTMENT ................................................. 13.10 LEVELLING CIRCUIT DESCRIPTION ......................................................... 13.9 LEVELLING SYSTEM DESCRIPTION ........................................................ 13.2 LOAD SENSING. .......................................................... SEE ALSO SECTION 9 LUBRICATING CYLINDERS AND PINS. ................................ SEE SECTION 3 UNDERCARRIAGE ASSEMBLY, LEVELLING ............................................ 13.2

Tigercat 822/L830 Feller Buncher LEVELLING SYSTEM DESCRIPTION

Levelling

The levelling function is operated by switches on the joysticks. The joystick switches provide input signals for the IQAN computer control system.

The computer control system then transmits output signals to the XP module and out to the electro-hydraulic spool actuators on the levelling control valve. The levelling control valve then directs oil to the two levelling cylinders.

IDLER SPROCKET

860C-013

NOTE: All tilt directions (left, right, forward and backward) in this section refer to direction of tilt when the operator is facing the front of the machine (toward the idler).

For operating instructions refer to JOYSTICKS in the OPERATOR'S MANUAL for THIS MACHINE.

For additional information regarding SAFETY and OPERATING INSTRUCTIONS, Refer to SECTION 1 of THIS MANUAL and SECTION 2 in the OPERATOR'S MANUAL.

Two levelling cylinders are used to operate the levelling function. Operating both cylinders in the same direction tilts the leveller forward and backward. Operating the cylinders in opposite directions tilts the leveller left and right. Each cylinder is equipped with a counterbalance valve for crossline relief and load holding.

ROTARY MANIFOLD LH LEVELLING CYLINDER

UNDERCARRIAGE

LEVELLING ASSEMBLY IDLER ASSEMBLY RH LEVELLING CYLINDER

•

•

•

•

• •

• •

•

• • •

DRIVE MOTOR

TRACK GUARDS 860-70

LOWER ROLLERS

•

INSPECTION COVERS

• •

TRACK GUARDS

TRACK DRIVE GEARBOX DRIVE SPROCKET

LEVELLING UNDERCARRIAGE ASSEMBLY

13.2

•

TRACK ASSEMBLY

Tigercat 822/L830 Feller Buncher

Levelling

LEVELLING CONTROL VALVE

PORT CONNECTIONS:

The levelling control valve is located in the hydraulic pump compartment. Hydraulic oil for the levelling function is supplied by the main pump.

The 'B' ports (bottom ports) are connected to the base end of the cylinders and the 'A' ports (top ports) are connected to the rod end of the cylinders.

The spool sections of the levelling control valve are equipped with proportional, electro-hydraulic spool actuators. The actuators are spring centered to the neutral position, and are shifted by sending a variable volt signal (from the Iqan XP module) to the appropriate solenoid.

ELECTROHYDRAULIC SPOOL ACTUATORS

• B

A

PORT RELIEF VALVES

••

• ••

B

••

The levelling control valve is equipped with port reliefs on each side of all spool sections. Their function is to protect the valve and the function from pressure peaks in the system. The port reliefs also act as anti-cavitation valves, which means they allow oil to flow from the tank gallery in the valve to the service ports in the event of underpressure.

RETURN PORT

PILOT PRESSURE

A

••

•

•

LOAD SENSE PORT

•

Port reliefs cannot be adjusted. Port reliefs installed in each section are specifically designed for use in that section and should not be interchanged with port reliefs from other valve sections .

PORT RELIEF VALVES

••

••

•• INLET PORT

860C093

LEVELLING CONTROL VALVE (AT238)

830-D55

HYDRAULIC PUMP COMPARTMENT 13.3

Tigercat 822/L830 Feller Buncher

860C-160

Levelling

LEVELLING VALVE SCHEMATIC

SPOOL SECTIONS The valve spool sections are equipped with proportional, electro-hydraulic spool actuators. The actuators are spring centered to the neutral position. The actuators are shifted by a variable voltage signal sent to the appropriate solenoid.

Each section has a pilot restrictor installed in the ‘A’ and ‘B’ side to create a ‘ramping’ effect and result in smooth, gentle function operation.

Pressure Compensation The primary purpose of pressure compensation is to maintain a constant flow rate to functions (ie: maintain the same speed of movement), regardless of pressure variations in the system.

The pressure compensator also contains a loadhold check valve. An orifice is installed immediately down stream of the pressure compensator to smoothly regulate the response of the compensator.

860C-162

LEVELLING VALVE

The port reliefs also act as anti-cavitation valves, which means they allow oil to flow from the tank gallery in the valve to the service ports in the event of underpressure. Port reliefs cannot be adjusted. Port reliefs installed in each section are specifically designed for use in that section and should not be interchanged with port reliefs from other valve sections . Refer to REPLACING PORT RELIEF in THIS SECTION.

Port Reliefs The levelling valve is equipped with port reliefs on each side of the spool sections. The function of the port relief is to protect the valve and the function from pressure peaks in the system.

13.4

Tigercat 822/L830 Feller Buncher

Levelling

••

PORT RELIEF

AIR BLEED SCREW

•

END CAP

•

SPRING ASSEMBLY HOUSING

24V PROPORTIONAL ELECTRO-HYDRAULIC SPOOL ACTUATORS AIR BLEED SCREW

••

•• •• ••

••

PRESSURE COMPENSATOR

• END CAP

SPOOL SECTION EXPLODED VIEW

860C-143

PORT RELIEF ‘B’ SIDE

PORT RELIEF ‘A’ SIDE

24V PROPORTIONAL ELECTRO-HYDRAULIC SPOOL ACTUATORS

•

•

•

•

•

• SPOOL PRESSURE COMPENSATOR 1018-30

SPOOL CROSS SECTION 13.5

Tigercat 822/L830 Feller Buncher COUNTERBALANCE VALVES

Levelling

A counterbalance valve is mounted on each of the two levelling cylinders. Each counterbalance valve consists of a two cavity 90 degree cross piloted steel body and two adjustable pilot operated counterbalance valves.

The purpose of each counterbalance valve is to provide load holding and more precise control of levelling stability by minimizing creep.

OPERATING DESCRIPTION To tilt left; oil flows proportionally from both the RH and LH levelling sections of the levelling control valve to both the RH and LH levelling cylinders. Oil enters the RH cylinder base end and the LH cylinder rod end via the cylinder counterbalance valves mounted directly to the cylinders.

COUNTERBALANCE VALVE SCHEMATIC

830-28

'2A' RELIEF VALVE ADJUSTING SCREW

To tilt right; oil flows proportionally from both the RH and LH levelling sections of the levelling control valve to both the RH and LH levelling cylinders. Oil enters the RH cylinder rod end and the LH cylinder base end via the cylinder counterbalance valves mounted directly to the cylinders.

'VR' PORT

'2B' RELIEF VALVE ADJUSTING SCREW

•

•• ••

To tilt forward; oil flows proportionally from both the RH and LH levelling sections of the levelling control valve to both the RH and LH levelling cylinders. Oil enters the LH cylinder base end and the RH cylinder base end via the cylinder counterbalance valves mounted directly to the cylinders.

830-D28

DRAIN PORT

•

'CR' PORT

•

••

'VC' PORT

LEVELLING CROSSLINE RELIEF VALVE

DANGER Extreme care and attention must be exercised when making adjustments to the levelling hydraulic and electrical circuits.

Ensure that all personnel not directly associated with the servicing are well clear of the machine.

The whole upper frame/cab/engine compartment, boom and attachment can tilt unexpectedly from side to side or forward and backwards during servicing, creating "pinch points" between the upper frame and track assembly and the ground.

To tilt back; oil flows proportionally from both the RH and LH levelling sections of the levelling control valve to both the RH and LH levelling cylinders. Oil enters the LH cylinder rod end and the RH cylinder rod end via the cylinder counterbalance valves mounted directly to the cylinders.

Load control is provided by internal pilot operated relief valves which balance the pressure of hydraulic fluid in the cylinders. Oil entering the counterbalance valves provides pilot pressure to operate the relief valve in the opposite line which allows return oil from the cylinders to pass back to the levelling control valve. In addition there is a second internal pilot line which operates the relief valve from the return line to reduce pressure in the cylinders when necessary.

DANGER

23526A R0

13.6

TO AVOID PERSONAL INJURY OR DEATH USE SUPPORT BRACE AS SHOWN WHEN SERVICING.

Levelling

HYDRAULIC SCHEMATIC LEVELLING CIRCUIT

Tigercat 822/L830 Feller Buncher

830-100

13.7

Tigercat 822/L830 Feller Buncher

830-98

Levelling

LEVELLING CIRCUIT DIAGRAM 13.8

Tigercat 822/L830 Feller Buncher

Levelling 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

LEVELLING CIRCUIT DESCRIPTION

DANGER

Hydraulic oil for the levelling function is supplied by the main pump.

Extreme care and attention must be exercised when making adjustments to the levelling hydraulic and electrical circuits.

Ensure that all personnel not directly associated with the servicing are well clear of the machine.

The whole upper frame/cab/engine compartment, boom and attachment can tilt unexpectedly from side to side or forward and backwards during servicing, creating "pinch points" between the upper frame and track assembly and the ground.

The levelling hydraulic system is integrated into the load sensing system or "main hydraulic system". Two valve sections on the levelling control valve supply oil to the rod and base ends of the two levelling cylinders.

The pilot manifold supplies lower pressure pilot oil to the pilot end caps of the two valve sections on the levelling control valve.

Two switches on the left joystick and two switches on the right hand joystick operate the levelling functions. Note that the joystick switch positions shown in this manual are factory installed and do not reflect changes or modifications made after shipment. Verify all functions before operating this machine.

DANGER

When the operator presses the level left, level right, level forward or level back switch a signal (VOLTAGE IN - Tilt_front_button, Tilt_rear_button, Tilt_left_button or Tilt_right_button) is sent to the IQAN computer control system. The computer control system generates two signals (CURRENT OUT - Right_cyl_base and CURRENT OUT - Left _cyl_base) which are sent out to the corresponding solenoids on the levelling control valve activating the LEVEL LEFT, LEVEL RIGHT, LEVEL FORWARD or LEVEL BACK function.

23526A R0

During levelling, the two levelling cylinders are in operation at the same time and in synchronization with each other in order to provide a level platform.

They oppose each other when tilting LEFT/RIGHT and work together when tilting FORWARD/BACK. The left levelling cylinder retracts while the right cylinder extends to tilt LEFT. To tilt RIGHT, the right levelling cylinder retracts while the left cylinder extends. Both cylinders extend at the same time to tilt FORWARD or retract at the same time to tilt BACK. Each cylinder is equipped with a counterbalance valve for pressure relief and load holding.

13.9

TO AVOID PERSONAL INJURY OR DEATH USE SUPPORT BRACE AS SHOWN WHEN SERVICING.

Tigercat 822/L830 Feller Buncher

Levelling

IQAN COMPUTER CONTROL SYSTEM LEVELLING CONTROL ADJUSTMENT Function Parameter For_tilt_speed [%] Back_tilt_speed [%] ramp_rate_leveller [ms}

Factory Description Minimum Maximum Default Levelling Cylinder Extension Speed (Forward) 0% 100% 100% Levelling Cylinder Retraction Speed (Back) 0% 100% 100% Levelling Cylinder Ramp Rate Adjustment 0 ms 2000 ms 500 ms

ADJUSTING EXTENSION (FORWARD) LEVELLING SPEED USING IQAN CONTROL SYSTEM

5. Use the SCROLL UP/DOWN buttons to scroll though the function parameters to the For_tilt_speed function.

NOTE: Both forward and back levelling speed should be adjusted to the same level to prevent tilting forward and back when levelling side to side.

6. Press SELECT (F1).

1. Press ESCAPE button to display one of the 5 menus (MODE, INFORMATION, SETTINGS , MEASURE and PROPERTIES).

2. `Use the SCROLL UP/DOWN buttons to scroll though the menus to the PROPERTIES menu.

7. Use the SCROLL UP/DOWN button to adjust the setting.

3. Press OTHER (F3) to select FUNCTION PARAMETERS. Press OK (F1) to accept the new setting.

Note: CANCEL (F2) will take you back to the previous screen without changing the setting.

RESET (F3) will restore the parameter to the factory setting.

4. Press SELECT (F1).

13.10

Tigercat 822/L830 Feller Buncher

Levelling

ADJUSTING RETRACTION (BACK) LEVELLING SPEED USING IQAN CONTROL SYSTEM

DANGER Extreme care and attention must be exercised when making adjustments to the levelling hydraulic and electrical circuits.

Ensure that all personnel not directly associated with the servicing are well clear of the machine.

The whole upper frame/cab/engine compartment, boom and attachment can tilt unexpectedly from side to side or forward and backwards during servicing, creating "pinch points" between the upper frame and track assembly and the ground.

NOTE: Both forward and back levelling speed should be adjusted to the same level to prevent tilting forward and back when levelling side to side.

8. Repeat steps 1 through 7 selecting Rear_tilt_speed in step 5.

DANGER ADJUSTING LEVELLING RAMP RATE USING IQAN CONTROL SYSTEM The levelling ramp rate controls the speed at which levelling function stops and starts adjustment controls the speed.

The ramp rate on screen is measured in milliseconds (ms), which represents the time it takes to go from stop to maximum cylinder speed.

Reducing ramp rate will make levelling start and stop quicker and more jerky. Increasing ramp rate will make levelling start and stop slower and smoother.

9. Repeat steps 1 through 7 select ramp_rate_levell in step 5.

13.11

23526A R0

TO AVOID PERSONAL INJURY OR DEATH USE SUPPORT BRACE AS SHOWN WHEN SERVICING.

Tigercat 822/L830 Feller Buncher SETTING COUNTERBALANCE VALVE PRESSURES DANGER Extreme care and attention must be exercised when making adjustments to the levelling hydraulic and electrical circuits.

Ensure that all personnel not directly associated with the servicing are well clear of the machine.

The whole upper frame/cab/engine compartment, boom and attachment can tilt unexpectedly from side to side or forward and backwards during servicing, creating "pinch points" between the upper frame and track assembly and the ground.

Levelling NOTE: Each valve is factory set and should require no further adjustment.

If adjustment is required counterbalance valves must be set manually per the following instructions.

1. Park machine on level ground, lower the felling head to the ground, engage the swing brake and stop engine. Turn battery disconnect switch off. Block the upper frame to prevent tilting of the cab during this procedure.

2. Access the levelling counterbalance relief valves located on the levelling cylinders.

'2A' RELIEF VALVE ADJUSTING SCREW

DANGER

'VR' PORT

••

• •

23526A R0

WARNING Always use extreme caution when servicing the levelling cylinders. Always adjust counterbalance relief valves fully clockwise to release pressure before servicing or removing levelling cylinders.

Counterbalance valves are designed to maintain hydraulic pressure in the levelling cylinders in the event of hydraulic hose failure. Therefore if pressure is not released prior to cylinder removal, very high pressure levels can be trapped in the levelling cylinders even after they have been completely removed from the machine.

830-D28

DRAIN PORT

••

'CR' PORT

TO AVOID PERSONAL INJURY OR DEATH USE SUPPORT BRACE AS SHOWN WHEN SERVICING.

'2B' RELIEF VALVE ADJUSTING SCREW

•

••

'VC' PORT

LEVELLING CROSSLINE RELIEF VALVE

3. Loosen locknut on a '2A' counterbalance relief valve and turn the adjusting screw all the way IN (turning clockwise).

4. Turn the adjusting screw OUT 5 1/2 turns (turning counter clockwise). Tighten locknut on adjusting screw taking care not to turn the adjusting screw itself. This will set the relief valve at approximately 5600 psi.

5. Repeat steps 3 and 4 for the '2B' counterbalance relief valve.

6. Repeat steps 3 to 5 for the counterbalance valve on the other cylinder (total of 4 reliefs, 2 on each counterbalance valve).

LUBRICATING CYLINDERS AND PINS Refer to LUBRICATION SCHEDULE AND DIAGRAM in SECTION 3 of THIS MANUAL.

13.12

Tigercat 822/L830 Feller Buncher LEVELLER CYLINDER PIN WEAR ADJUSTMENT

Levelling SHIMS

1. Park machine on level ground, lower the felling head to the ground, engage the swing brake and stop engine.

RETAINING CAP RING

• •• ••

2. Block the levelling cylinders with the cylinder support braces to prevent tilting of the cab during this procedure.

END BOLT (M30)

DANGER Extreme care and attention must be exercised when making adjustments to the levelling hydraulic and electrical circuits.

Ensure that all personnel not directly associated with the servicing are well clear of the machine.

The whole upper frame/cab/engine compartment, boom and attachment can tilt unexpectedly from side to side or forward and backwards during servicing, creating "pinch points" between the upper frame and track assembly and the ground.

DANGER

SUPPORT BRACE

••

••

BOLTS (M20) 6-PLACES

CYLINDER PIN 5. Engage swing brake and stop engine.

830-077

6. Check for gaps between spherical bearing and collars with a feeler gauge.

If the gap is less than 0.005" no adjustment is required.

If the gap is 0.005" or greater adjustment is required proceed to step 7.

7. Remove the six M20 bolts from the retaining cap ring and remove the retaining cap.

8. Remove the shim pack.

9. Loosen the pin end bolt (M30) from the shim end of the pin.

23526A R0

TO AVOID PERSONAL INJURY OR DEATH USE SUPPORT BRACE AS SHOWN WHEN SERVICING.

DO NOT LOOSEN M30 BOLT FROM OTHER END OF THE PIN. 10. Remove one thin shim (.005") from the shim pack.

11. Replace the shim pack and retaining cap ring. Tighten the six M20 bolts to 275 ft-lbs.

3. Start the engine.

12. Tighten both pin both pin end bolts(M30) to 450 ft-lbs.

4. Take the machine load off the levelling cylinder to be checked.

13. Repeat step 6 to recheck the gap.

Do this by pressing the felling head into the ground until the leveling cylinder can be freely rotated by hand.

14. Repeat the procedure for the other levelling cylinder.

Do not operate the levelling function with the support braces in place.

13.13

Tigercat 822/L830 Feller Buncher

Levelling

13.14

Tigercat 822/L830 Feller Buncher

SECTION 15 - SWING JUNE 2007

CONTENTS - SECTION 15 ADJUST OIL FLOW TO SWING MOTOR(SWING MOTOR SPEED) ......... 15.7 CIRCUIT DIAGRAM ..................................................................................... 15.3 LUBRICATION GEARBOX LOWER BEARINGS ........................................ 15.5 SCHEMATIC DIAGRAMS HYDRAULIC SCHEMATIC ....................................................................... 15.4 SET SWING MOTOR SPEED ..................................................................... 15.7 SWING BEARING WEAR LIMITS ............................................................. 15.10 SWING DRIVE SWING HYDRAULICS ............................................................................. 15.2 SET CROSSLINE RELIEF VALVES ...................................................... 15.6 SWING DRIVE GEARBOX LUBRICATION OF LOWER BEARING .................................................... 15.5 SUN GEAR INSTALLATION ..................................................................... 15.9 SWING MOTOR REMOVAL FROM GEARBOX .......................................... 15.8

Tigercat 822/L830 Feller Buncher MOTOR

R.H. ROTATION

CROSSLINE RELIEF VALVES

•• •••

•

L.H. ROTATION

SWING BRAKE

Swing 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'

• ••

FLUSHING PORT 'U'

• •

••

• •

GEARBOX

CONNECTOR/ ORIFICE 0.062" DIA

• 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 swing.

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.

WARNING

GEARBOX FLUSHING OIL SUPPLY FROM OIL COOLER BYPASS/ RETURN MANIFOLD

•

• CROSS LINE RELIEF VALVES

PRESSURE LINES FROM MAIN CONTROL VALVE

830-16

Never drive machine with swing brake applied. If felling head makes contact with an immoveable object, forces could damage swing drive gearbox.

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/L830 Feller Buncher

Swing

SWING DRIVE CIRCUIT 822.43

15.3

Swing

822-55

HYDRAULIC SCHEMATIC SWING CIRCUIT

Tigercat 822/L830 Feller Buncher

15.4

Tigercat 822/L830 Feller Buncher

Swing

LUBRICATION OF SWING DRIVE GEARBOX

STICK CYLINDERS FULLY EXTENDED

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'.

TIP OF STICK BOOM FULLY SUPPORTED 830-07

PARKING BOOM. FIG.5

HOIST CYLINDER FULLY RETRACTED

LOWER BEARING LUBRICATION

•

Ensure that the boom is properly parked for service (see fig. 5 & fig. 6) and engine is shut off before performing this procedures.

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

LUBE FITTINGS

••

••

TIP OF STICK BOOM FULLY SUPPORTED 830-08

PARKING BOOM. FIG.6

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.

845B-D33

EARLY MACHINES LUBRICATE GEARBOX LOWER BEARINGS On earlier machines to gain access to the lube fitting, remove the hoist cylinder cover. To gain access to the lube fitting, remove the cover plate directly below the gearbox.

LUBE FITTINGS

• ••

LH830-31

LATER MACHINES LUBRICATE GEARBOX LOWER BEARINGS On later machines lube fittings are remotely mounted for easy access.

15.5

Tigercat 822/L830 Feller Buncher

Swing

SET CROSSLINE RELIEF VALVES 1. Ensure that the hydraulic oil is at operating temperature.

CROSSLINE RELIEF VALVES L.H. ROTATION

2. Install a 0-5000 psi pressure gauge in the 'L.S.' test port on the back of the main valve manifold.

•

LINDE MAIN VALVE MANIFOLD

HIGH PRESSURE LIMITING CONTROL

•

ADJUSTING SCREWS 111-6

••

••

••

'P' GAUGE TEST PORT

EARLIER DESIGN

••

LINDE MAIN VALVE MANIFOLD L.S. GAUGE TEST CONN.

MAIN VALVE MANIFOLD

••

••

•• LS PRESSURE ADJUSTMENT P2 SYSTEM RELIEF VALVE NON-ADJUSTABLE

•• • 860C-035

• •• •• • CROSSLINE RELIEF

7. Stop engine, remove gauge and reinstall plug.

LS PRESSURE ADJUSTMENT P2

'P' GAUGE TEST CONN.

R.H. ROTATION

6. Retighten locknut on each adjusting screw taking care not to disturb adjusting screw and recheck pressure setting before removing pressure gauge.

L.S. GAUGE TEST PORT

103-17A

•••

LATER DESIGN

LINDE 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 3000 psi. for each direction.

If pressure gauge is installed in 'P' test port, reading on gauge would be 3300 psi.

15.6

Tigercat 822/L830 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 15.7

MAIN BOOM

FLOW ADJUSTING SCREW FOR SWING RIGHT

TANK PORT 'T3'

•

Tigercat 822/L830 Feller Buncher

•

SWING DRIVE MOTOR M16 HEX. HD. RETAINING BOLTS TORQUE TO 150 LBF/FT (205 NM) SWING BRAKE ASSY.

CROSS LINE RELIEF HOUSING

•

Swing 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).

15.8

Tigercat 822/L830 Feller Buncher M12 HEX. HD. RETAINING BOLTS

BRAKE HOUSING

SUN 'O' RING GEAR

Swing

MOTOR MOTOR MOUNTING SURFACE

• •

•

• 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).

15.9

Tigercat 822/L830 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.

••

15.10

NOTE: MAGNETIC BASE OF DIAL INDICATOR MUST BE MOUNTED TO BEARING MOUNTING FLANGE AS SHOWN AND NOT TO UNDERCARRIAGE CROSS FRAME.

Tigercat 822/L830 Feller Buncher SECTION 17 - SAW DRIVE JULY 2007

CONTENTS - SECTION 17 CIRCUIT DESCRIPTION ............................................................................. 17.6 CIRCUIT DIAGRAM ..................................................................................... 17.7 CONTROL VALVES SAW PILOT VALVE .................................................................................. 17.4 FELLING HEAD ....................... SEE ORIGINAL MANUFACTURERS MANUAL HYDRAULIC SCHEMATIC CIRCUIT ......................................................... 17.10 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/L830 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.

822-17

The pump is mounted and driven off the end of the main pump attached to the bell housing of the engine.

SAW PUMP SCHEMATIC

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

CLAMPS AND SAW PUMP FAN DRIVE PUMP (PISTON PUMP) (DOUBLE GEAR PUMP)

PILOT FILTER

•• ••

••

• •

•• ••

••

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

PILOT SUPPLY VALVE 822-D70

HYDRAULIC PUMPS

17.2

Tigercat 822/L830 Feller Buncher

•

Saw drive

SAW PUMP PRESSURE COMPENSATOR VALVE

INPUT SHAFT CONNECTION TO MAIN PUMP

•

AP098

SAW PUMP ~ SIDE VIEW

17.3

Tigercat 822/L830 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/L830 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/L830 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/L830 Feller Buncher

822-44

Saw drive

SAW CIRCUIT 17.7

Tigercat 822/L830 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

•

OPEN

CLAMPS ACCUMULATOR

CLOSE

MID INLET SECTION

SAW PUMP

CLOSE

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/L830 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/L830 Feller Buncher

822-56

Saw drive

HYDRAULIC SCHEMATIC CIRCUIT 17.10

Tigercat 822/L830 Feller Buncher

SECTION 18 - CLAMPS JULY 2007

CONTENTS - SECTION 18 CIRCUIT DESCRIPTION ............................................................................. 18.6 CIRCUIT DIAGRAM ..................................................................................... 18.7 CONTROL VALVE ....................................................................................... 18.4 HYDRAULIC SCHEMATIC CIRCUIT ......................................................... 18.10 PRESSURE SETTINGS .............................................................................. 18.8 AIR IN PILOT END CAPS ......................................................................... 18.8 PUMP CLAMPS/FAN ................................................................................... 18.3

Tigercat 822/L830 Feller Buncher

Clamps

18.2

Tigercat 822/L830 Feller Buncher

Clamps

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.

CLAMPS/FAN PUMP

•

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.

SAW PUMP

•

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.

PUMP ASSEMBLY

822-D73

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.

THRUST PLATES DRIVE GEAR ON INPUT SHAFT

THRUST PLATES DRIVE GEAR ON INPUT SHAFT

CONNECTING SHAFT

• • •

•

• • •

•

•

AP179

•

•

INPUT DRIVE SHAFT (CONNECTED TO SAW PUMP)

GEAR HOUSINGS

PORT PLATE, REAR

CLAMPS/FAN PUMP

OUTLET DRIVEN (IDLER) GEAR

DRIVE GEAR

•

•

INLET GEAR1

18.3

TYPICAL GEAR PUMP

Tigercat 822/L830 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 ) 18.4

END INLET SECTION (SAW)

Tigercat 822/L830 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. Holding this function will cause hydraulic oil to flow over reliefs creating excess heat and wasting power.

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/L830 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/L830 Feller Buncher

822-45

Clamps

CLAMP AND ACCUMULATING ARMS CIRCUIT DIAGRAM 18.7

Tigercat 822/L830 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/L830 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. Reset main relief.

14. Set throttle to FULL.

20. Stop engine and remove pressure gauge.

18.9

Tigercat 822/L830 Feller Buncher

822-56

Clamps

HYDRAULIC SCHEMATIC CIRCUIT 18.10

Tigercat 822/L830 Feller Buncher

SECTION 19 - WRIST JULY 2007

CONTENTS - SECTION 19 ENGINE ANTI-STALL .................................................................................. 19.3 LEVELLING MACHINES - IQAN CONTROL ADJUSTING WRIST RAMP RATES ....................................................... 19.14 CIRCUIT DIAGRAM ................................................................................ 19.11 HYDRAULIC SCHEMATIC CIRCUIT ........................................................ 19.9 PROPORTIONAL PILOT VALVES ........................................................... 19.8 WRIST DESCRIPTION ........................................................................... 19.10 TIGERCAT OPTIONAL 110° WRIST .................................................. 19.10 TIGERCAT OPTIONAL 340° WRIST .................................................. 19.10 TIGERCAT STANDARD 30° WRIST .................................................. 19.10 LOAD SENSING .......................................................................................... 19.3 MAIN CONTROL VALVE ............................................................................. 19.3 SET WRIST PORT RELIEF VALVES ..................................................... 19.12 WRIST CYCLE TIMES ................................................... SEE SAW MANUAL NON-LEVELLING MACHINES - PILOT CONTROL CIRCUIT DIAGRAM .................................................................................. 19.7 HYDRAULIC SCHEMATIC CIRCUIT ........................................................ 19.5 PILOT MANIFOLD .................................................................................... 19.4 WRIST DESCRIPTION ............................................................................. 19.6 TIGERCAT OPTIONAL 110° WRIST .................................................... 19.6 TIGERCAT OPTIONAL 340° WRIST .................................................... 19.6 TIGERCAT STANDARD 30° WRIST .................................................... 19.6

Tigercat 822/L830 Feller Buncher

Wrist

19.2

Tigercat 822/L830 Feller Buncher

Wrist

MAIN CONTROL VALVE

LOAD SENSING\ENGINE ANTI-STALL

The wrist spool section has port relief valves with anticavitation features.

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.

These protect the circuit from abnormally high pressures induced by the load.

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.

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.

For a full description of the engine anti-stall, Refer to SECTION 9 in THIS MANUAL.

To adjust the relief valves, Refer to SET WRIST PORT RELIEF VALVES in THIS SECTION.

For a full description of the pilot system including the joystick handles, Refer to SECTION 5 in THIS MANUAL.

To adjust oil flow (wrist cycle times) refer to TIGERCAT SAW OPERATING AND SERVICE MANUAL for detailed information.

The IQAN computer controls the speed at which the spools are shifted to reduce harsh starts and stops. The IQAN computer can also be used to reduce the operating speed wrist if required.

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

••

••

•

•

••

••

••

WRIST RIGHT (CW) PORT RELIEF LH DRIVE 822-D63

RH DRIVE

TILT

MAIN BOOM

STICK

MAIN CONTROL VALVE 19.3

SWING

Tigercat 822/L830 Feller Buncher 'P2' PORT TO ACCUMULATOR 'T' TANK PORT 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

Wrist

•• ••

•• •• •• •• • •• • •• •• •

•

'IN' INLET PORT 'T' TANK CONNECTION 822-D68

•• PILOT MANIFOLD

PILOT MANIFOLD (NON-LEVELLING MACHINES - 822) 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.

The manifold distributes oil to the wrist circuit ports listed below: • * Wrist CCW • * Wrist CW

(5) solenoid valve (6) solenoid valve

* NOTE: Wrist function uses this pilot manifold for 822 machines only.

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

19.4

Tigercat 822/L830 Feller Buncher

822-58

Wrist

HYDRAULIC SCHEMATIC CIRCUIT (NON-LEVELLING MACHINES - 822 ONLY) 19.5

Tigercat 822/L830 Feller Buncher WRIST DESCRIPTION (NON-LEVELLING MACHINES - 822)

Wrist

TIGERCAT STANDARD 30° WRIST One cylinder is used to rotate the wrist through 30° of rotation, 15° each side of the vertical position.

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.

This cylinder receives oil from the main pump via the wrist spool section on the main hydraulic valve.

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 at each end of the wrist section of the main hydraulic valve and move the cylinder.

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.

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 MANUALTIGERCAT SAWS for more detailed information.

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.

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. Refer to SECTION 18 of THIS MANUAL for information about the operation of attachment clamp and accumulating arms.

These cylinders receive oil through a wrist 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 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.

19.6

Tigercat 822/L830 Feller Buncher

822-46

Wrist

WRIST CIRCUIT (NON-LEVELLING MACHINES - 822 ONLY) 19.7

Tigercat 822/L830 Feller Buncher

Wrist

** WRIST CW

** WRIST CCW

830-079

PROPORTIONAL PILOT VALVES

PROPORTIONAL PILOT VALVES (LEVELLING MACHINES - L830) The proportional pilot valves are located in the valve compartment at the rear left corner of the upper frame.

The proportional pilot valves are cartridge style pilot operated spool type reducing relieving valves which can be infinitely adjusted across a prescribed range using a variable electric input from the IQAN computer control system.

Oil is supplied to the proportional pilot valves from the pilot manifold.

Two proportional pilot valves control the position of the spool valves to which they are hydraulically connected. When a solenoid valve is energized, by a trigger switch on a joystick via the IQAN computer control system, its spool is shifted and pilot oil is directed to one end of a spool valve.

When the solenoid is de-energized, a spring forces the spool back to the neutral position, blocking the pressure side and opening the pilot line back to tank. There are no adjustments on the solenoid valves. ** NOTE: Wrist function uses these proportional pilot valves for L830 machines only.

Refer to ADJUSTING WRIST RAMP RATES in THIS SECTION. Refer also to SECTION 6 of THIS MANUAL for more information abou the IQAN computer control system.

19.8

Tigercat 822/L830 Feller Buncher

830-99

Wrist

HYDRAULIC SCHEMATIC CIRCUIT (LEVELLING MACHINES L830 ONLY) 19.9

Tigercat 822/L830 Feller Buncher WRIST DESCRIPTION (LEVELLING MACHINES - L830) 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 wrist function is controlled by the IQAN computer control system through the wrist proportional pilot valves which direct pilot oil to the wrist section of the main hydraulic valve and moves the wrist cylinder.

The wrist cylinder extends or retracts to provide a counter-clockwise or 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 MANUALTIGERCAT SAWS for more detailed information.

These cylinders receive oil through a wrist 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 wrist function is controlled by the IQAN computer control system through the wrist proportional pilot valves which direct pilot oil to the wrist section of the main hydraulic valve and moves the wrist 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 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 wrist function is controlled by the IQAN computer control system through the wrist proportional pilot valves which direct pilot oil to the wrist section of the main hydraulic valve and moves the wrist cylinder.

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 provide a clockwise or counter-clockwise rotation of the felling head.

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. Refer to SECTION 18 of THIS MANUAL for information about the operation of attachment clamp and accumulating arms.

NOTE: All wrist rotation directions (cw and ccw) in this section refer to direction of wrist rotation as viewed from the operator's seat.

The wrist cylinders work together one extending and the other retracting to provide a clockwise or counter-clockwise rotation of the felling head.

19.10

Tigercat 822/L830 Feller Buncher

830-97

Wrist

WRIST CIRCUIT (LEVELLING MACHINES L830 ONLY) 19.11

Tigercat 822/L830 Feller Buncher

Wrist

SET WRIST PORT RELIEF VALVES 'P' GAUGE TEST CONN.

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.

• •

•• LS PRESSURE ADJUSTMENT P2

HIGH PRESSURE LIMITING CONTROL SYSTEM RELIEF VALVE NON-ADJUSTABLE

••

• ••

••

••

••

LATER DESIGN

LINDE MAIN VALVE MANIFOLD L.S. GAUGE TEST PORT

860C-035

2. Connect a 0-5000 psi pressure gauge on 'LS' test port of Linde main valve manifold.

'P' GAUGE TEST PORT

3. Start engine and place throttle control in FULL position.

LS PRESSURE ADJUSTMENT P2

EARLIER DESIGN

•• 103-17A

MAIN VALVE MANIFOLD

••

1. With hydraulic oil at operating temperature, LINDE MAIN VALVE MANIFOLD

L.S. GAUGE TEST CONN.

4. Turn anti-stall switch OFF.

LINDE MAIN VALVE MANIFOLD 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

••

•

•

•

•

••

••

WRIST RIGHT (CW) PORT RELIEF LH DRIVE 822-D63

RH DRIVE

TILT

MAIN BOOM

STICK

MAIN CONTROL VALVE

19.12

SWING

Tigercat 822/L830 Feller Buncher

Wrist

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.

WARNING The felling head will be rotated side to side during this procedure. Operator must ensure that no one is near the felling head during this procedure.

The swing brake should be applied at all times during this procedure.

SPOOL TRAVEL STOP • 19mm WRENCH • 6mm ALLEN KEY

•

For detailed instructions regarding adjustment of wrist cycle times (flow adjustment) refer to WRIST CYCLE TIMES for wrist type in use in the OPERATING AND SERVICE MANUALTIGERCAT SAWS or ATTACHMENT MANUFACTURER'S MANUALS.

PILOT END CAP

IMPORTANT In particular, for the 340° wrist additional flow control valves are located on the wrist distribution manifold. These flow control valves are used to set back pressure on the return gallery and should be used together with the main control valve adjustments described in the OPERATING AND SERVICE MANUAL-TIGERCAT SAWS. The flow control valves MUST be adjusted IN to provide sufficient backpressure to prevent cavitation damage.

• •

LOCKNUT • 17mm WRENCH

•

PORT RELIEF VALVE

90744-3

Before adjusting flow controls on the main valve it is important to read and understand the information in the OPERATING AND SERVICE MANUAL-TIGERCAT SAWS or ATTACHMENT MANUFACTURER'S MANUALS regarding the attachment and wrist type in order to avoid damage to components and ensure efficient and long term operation.

•

ADJUSTING SCREW • 5mm ALLEN KEY

MAIN VALVE BODY

WRIST CYCLE TIMES

•

It is important to check back pressure in the wrist motors each time wrist rotation speed is adjusted. Rotation speed adjustments may create pressures in the hydraulic system which result in cavitation in the wrist motors. If this is found to be the case further adjustments are required to prevent component damage and ensure efficient and long term operation.

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.

9. Tighten locknut on adjusting screw taking care NOT to turn the adjusting screw at the same time.

10. Check the setting again.

11. Stop engine, remove all gauges and reinstall plugs and caps.

19.13

Tigercat 822/L830 Feller Buncher

Wrist

ADJUSTING WRIST RAMP RATES (IQAN CONTROL ONLY LEVELLING MACHINES - L830) Adjusting the wrist ramp rate controls how quickly the wrist starts and stops rotating.

1. Press ESCAPE button to display one of the 5 menus (MODE, INFORMATION, SETTINGS , MEASURE and PROPERTIES).

2. Use the SCROLL UP/DOWN buttons to scroll though the menus to the PROPERTIES menu.

6. Press SELECT (F1).

7. Use the SCROLL UP/DOWN buttons to adjust the wrist ramp rate.

8. Press OK (F1) to set the ramp rate at the new value.

9. Press CANCEL (F2) to return the the last screen without making any changes.

10. Press RESET(F3) to reset ramp rate to factory default setting.

3. Press OTHER (F3) to select FUNCTION PARAMETERS.

4. Press SELECT (F1).

5. Use the SCROLL UP/DOWN buttons to scroll though the function parameters to the Ramp_rate_Wrist function.

19.14