TIGERCAT 830 FELLER BUNCHER OPERATOR'S MANUAL - PDF DOWNLOAD

OPERATOR'S MANUAL TIGERCAT 830 FELLER BUNCHER ISSUE 1.3, JUNE 2003

TABLE OF CONTENTS

SECTION INTRODUCTION .............................................................................................................. iii NON-APPROVED FIELD PRODUCT CHANGES ........................................................... iv SAFETY ............................................................................................................................ 1 USING HIGH SPEED DISC SAWS SAFELY .......................... APPENDIX TO SECTION 1 CONTROLS AND OPERATION ........................................................................................ 2 LUBRICATION AND MAINTENANCE ............................................................................... 3

830-OM00

Tigercat

830 Feller Buncher Available Literature Operator's Manual ............................... Part No. 14211A Service Manual .................................... Part No. 14212A Parts Catalog ....................................... Part No. 17866A Hydraulic Adapters Book ....................... Part No. 1472A Hydraulic Hose Assemblies Book ......... Part No. 3707A

®

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

Fax: (519) 442-1855

Tigercat 830 Feller Buncher

Introduction

ii

Tigercat 830 Feller Buncher

Introduction

Tigercat 830 Feller Buncher

INTRODUCTION An Operator's manual, Service manual and a Parts catalog are made available by Tigercat to assist the dealer, customer and operator in becoming familiar with the features of the 830 Feller Buncher serial number 8300111 to 8300189 or 830T0111 to 830T0189 if configured as a leveller.

The operator's manual will assist the operator with the techniques of proper and safe operation of the 830 Feller Buncher. There is also important information regarding the safe operation of the saw head. The service manual contains safety and servicing procedures and a preventive maintenance schedule to ensure optimum machine performance.

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

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

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

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

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

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

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

Tigercat Industries Inc.

830-D18

iii

Tigercat 830 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 830 Feller Buncher

SECTION 1 - SAFETY MARCH 2003

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

Read and understand all manuals for any attchment or accessories.

CONTENTS - SECTION 1 CAB EXITS .................................................................................................... 1.6 COOLING SYSTEM ..................................................................................... 1.13 EFFICIENT REACH (ER) BOOM SYSTEM PRECAUTIONS ...................... 1.14 EMERGENCY CAB EXITS ............................................................................ 1.6 ENGINE DOORS ......................................................................................... 1.15 EXHAUST FUMES ....................................................................................... 1.15 FELLING TREES ........................................................................................... 1.9 FIRE PREVENTION ..................................................................................... 1.17 FIRE PREVENTION GUIDELINES ........................................................... 1.16 WHAT ELSE TO DO BEFORE YOU EXPERIENCE A FIRE .................... 1.17 WHAT TO DO AFTER A FIRE ................................................................. 1.18 WHAT TO DO IN CASE OF A MACHINE FIRE ........................................ 1.17 FLUID LEAKS .............................................................................................. 1.13 HYDRAULIC PRESSURE HAZARD ............................................................ 1.13 LEVELLING UNDERCARRIAGE PRECAUTIONS ........................................ 1.8 LOOSE CLOTHING HAZARD ..................................................................... 1.13 PARKING THE MACHINE ........................................................................... 1.10 PROTECTIVE CLOTHING ............................................................................. 1.3 SAFETY INTERLOCK SWITCHES ON CAB DOORS ................................... 1.7 SAFETY PRECAUTIONS, GENERAL ........................................................... 1.3 SAFETY PRECAUTIONS, OPERATING ....................................................... 1.6 SAFETY PRECAUTIONS, SERVICING ....................................................... 1.10 SAFETY SYMBOLS ....................................................................................... 1.2 SIGNAL WORDS ........................................................................................... 1.2

Tigercat 830 Feller Buncher

Safety

SAFETY SYMBOLS

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

Understanding Signal Words

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

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

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

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

1.2

Tigercat 830 Feller Buncher

Safety

GENERAL SAFETY PRECAUTIONS

KEEP BACK 500 FEET

Remember that safety is a prime responsibility of all.

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

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

Follow all instructions from safety inspector and supervisors.

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

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

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

Do not let untrained persons operate the machine.

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.

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

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

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

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

Do not use the machine foot controls as steps.

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

1.3

Tigercat 830 Feller Buncher

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

GENERAL SAFETY PRECAUTIONS continued

Check all fluid levels.

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

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

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

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

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.

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

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

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

•

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

•

If these are found, Do Not Touch!!!

•

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

•

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

•

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

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

Machine should be washed completely at every major service.

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

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

NOTE:

Check windows and door guards for damage.

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

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

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

1.4

Tigercat 830 Feller Buncher

Safety WARNING WARNING

GENERAL SAFETY PRECAUTIONS continued

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

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

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

Wash hands after handling.

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

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

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

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

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

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

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

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

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

1.5

Tigercat 830 Feller Buncher

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

OPERATING SAFETY PRECAUTIONS

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

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

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

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

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

Sound the machine horn before starting the machine.

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

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

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

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

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

WARNING

1.6

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

Tigercat 830 Feller Buncher

Safety Secure loose items in the cab.

OPERATING SAFETY PRECAUTIONS continued

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

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

SWITCH

ACTUATOR ON DOOR

••

••

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

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

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

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

822-D02

INTERLOCK SWITCH (FRONT DOOR)

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

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

Close the front door and press the PILOT RESET switch.

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

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

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

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

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

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

Use only prearranged and approved signalling practices.

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

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

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

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

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

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

1.7

Tigercat 830 Feller Buncher

Safety

OPERATING SAFETY PRECAUTIONS continued

NORMAL WORKING RANGE OF BOOM SYSTEM

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

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

NEVER travel across a STEEP slope or side hill: •

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

•

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

•

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

•

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

FIG. 1 DO NOT OPERATE OVER THE REAR OF THE UNDERCARRIAGE

• 830-03 830-04A

TRACK GEARBOX AT REAR OF UNDERCARRIAGE

MACHINE MODELS EQUIPPED WITH OPTIONAL LEVELLING UNDERCARRIAGE To reduce the risk of rollover, the machine is equipped with a special levelling system. The design of this system enhances stability in the normal working range of the boom system. Fig. 1 shows the recommended working range of the boom. Operating the boom system outside of this range reduces the machine's stability, increasing the risk of rollover and substantially reduces the life of the levelling mechanism.

1.8

Tigercat 830 Feller Buncher

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

OPERATING SAFETY PRECAUTIONS continued

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

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

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

Always replace saw tooth retaining bolts when replacing saw teeth.

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

24°

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

Shut down machine immediately if vibration occurs during cutting.

Check that the saw discharge area is clear and undamaged.

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

Do not over load felling head.

20°

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

830-05 830-06

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

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

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

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

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

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

1.9

Tigercat 830 Feller Buncher

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

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

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.

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.

•

Do not park on a hillside or incline.

•

Lower felling attachment onto level ground.

•

Stop the engine.

•

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

1.10

Tigercat 830 Feller Buncher

Safety

SERVICING SAFETY PRECAUTIONS

Conduct maintenance inspections at least as frequently as recommended in section 3 of the OPERATOR'S MANUAL. When servicing or repairing equipment, shut the engine down. Turn Master Disconnect switch OFF. Install a “DO NOT START ENGINE” sign on the operator’s cab door and in the engine compartment when making repairs to the machine.

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

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

1.11

Tigercat 830 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.

QSC AND QSL9 ENGINES ONLY

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

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

830-D39

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.

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

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

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

•

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

IQAN DISPLAY DISCONNECT

ENGINE ANTI-STALL DISCONNECT PLUG

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

• DISCONNECT THE 42 PIN PLUG FROM THE XP MODULE

DISCONNECT THE TWO MULTI-PIN PLUGS FROM THE ENGINE CPU

••

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

QSC AND QSL9 ENGINES ONLY 830-D38

ENGINE CPU DISCONNECT - LEFT SIDE OF ENGINE

1.12

IQAN XP MODULE DISCONNECT

Tigercat 830 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

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

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

Never use your bare hand to check for fluid leaks.

Fluid leaks under pressure may not be visible.

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

Wear safety goggles for eye protection.

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.

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

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

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

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

1.13

Tigercat 830 Feller Buncher

Safety

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

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

STICK CYLINDERS FULLY EXTENDED

• TIP OF STICK BOOM FULLY SUPPORTED 830-07

ER. BOOM SYSTEM. FIG.1

HOIST CYLINDER FULLY RETRACTED

•

TIP OF STICK BOOM FULLY SUPPORTED 830-08

ER. BOOM SYSTEM. FIG.2

1.14

Tigercat 830 Feller Buncher

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

SERVICING SAFETY PRECAUTIONS continued

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

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

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.

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

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.

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.

WARNING

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

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

Dispose of fluids properly.

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

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

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

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

1.15

Tigercat 830 Feller Buncher

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

FIRE PREVENTION

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

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

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

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

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.

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

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.

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

2. Inspect the machine for any signs of fuel or hydraulic system leakage and check for worn or eroded fuel or hydraulic lines before starting up any equipment.

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

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

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

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

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

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

Visual inspection after blow off to ensure thorough cleanliness is vital. Engine exhaust systems provide numerous small pockets where saw dust, small wood chips and other flammable forest debris can gather. Even small accumulations close to hot exhaust components can ignite and smolder. If

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

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

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

1.16

Tigercat 830 Feller Buncher

Safety WHAT TO DO IN CASE OF A MACHINE FIRE

FIRE PREVENTION continued

•

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

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

•

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

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

•

Shut the engine off.

•

Activate the fire suppression system*

•

Radio or call for help (as appropriate).

•

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

•

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

•

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

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

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

•

•

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

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

•

Use the PASS method with most extinguishers.

•

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

•

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

•

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

•

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

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

•

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

•

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

•

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

•

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

•

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

Continued on page 18

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

1.17

Tigercat 830 Feller Buncher

Safety WHAT TO DO AFTER A FIRE

FIRE PREVENTION continued Continued from page 17

20229A

TYPICAL FIRE EXTINGUISHER ACCESS HOLE

•

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

•

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

•

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

•

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

1.18

•

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.

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

2

using high speed disc saws safely

Tigercat

®

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

Tigercat

®

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

Tigercat

®

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

Tigercat

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

®

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.

Tigercat

®

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.

Tigercat

®

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 830 Feller Buncher SECTION 2 - CONTROLS & OPERATION MARCH 2003

CONTENTS - SECTION 2 AIR CONDITIONER/HEATER CONTROLS .................................................... 2.13 CHECKING THE AIR CONDITIONING SYSTEM ........................................ 2.14 AIR INTAKE CLEAN-OUT COVER PLATE .................................................... 2.33 AIR INTAKE SEAL ........................................................................................ 2.33 AM/FM STEREO CASSETTE ....................................................................... 2.21 AUXILIARY POWER OUTLET ....................................................................... 2.16 BATTERY DISCONNECT - SWITCH ............................................................. 2.28 BOOM CONTROLS ER (EFFICIENT REACH) BOOM OPTION ................................................... 2.4 SPECIAL OPERATING INSTRUCTIONS ................................................ 2.42 MAIN BOOM ............................................................................................... 2.4 STICK BOOM .............................................................................................. 2.4 TILT FUNCTION, FELLING HEAD ................................................................ 2.4 BREATHER/VENT, HYDRAULIC TANK ........................................................ 2.29 BULB TEST SWITCH .................................................................................... 2.10 CARE OF THE MACHINE ............................................................................. 2.43 CIGARETTE LIGHTER .................................................................................. 2.16 CIRCUIT BREAKERS AND FUSES ................................................................ 2.5 CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR .................... 2.34 COOLING ASSEMBLY - OVERALL VIEW ................................................ 2.34 CLEANING LEXAN WINDOWS ..................................................................... 2.43 CONTROL PANEL ........................................................................................ 2.12 COOLANT LOW - WARNING LIGHTAND HORN ............................................. 2.9 COOLING ASSEMBLY - CLEANING ............................................................. 2.34 COOLING FAN - SWITCH ............................................................................. 2.16 DIMMER CONTROL, INSTRUMENT PANEL ................................................. 2.10 EFFICIENT REACH (ER) BOOM SYSTEM HORIZONTAL REACH MOTION CHARACTERISTICS ................................ 2.42 OPERATION OF THE BOOM ...................................................................... 2.4 EMERGENCY EXITS ESCAPE HATCH ....................................................................................... 2.22 ESCAPE HATCH REMOVAL/REPLACEMENT ......................................... 2.23 MAINTENANCE GUIDE ............................................................................. 2.22 SIDE DOOR .............................................................................................. 2.22 ENGINE AIR CLEANER ................................................................................ 2.32 FILTER RESTRICTION INDICATOR ........................................................... 2.32 ENGINE AIR CLEANER UNLOADER VALVE ............................................... 2.32 ENGINE AIR PRECLEANER ......................................................................... 2.32 ENGINE ANTI-STALL - SWITCH WITH LIGHT ............................................... 2.12 ENGINE COLD START SWITCH ................................................................... 2.12 ENGINE COOLANT TEMPERATURE - GAUGE AND HORN .......................... 2.8 ENGINE HOT WATER SHUT OFF VALVES ................................................. 2.21 ENGINE OIL PRESSURE - GAUGE ............................................................... 2.8 ENGINE POWER DOOR - SWITCH ................................................................ 2.7 ENGINE RPM ............................................................................................... 2.13 ENGINE SHUTDOWN OVERRIDE - SWITCH ............................................... 2.12

Tigercat 830 Feller Buncher

Controls and operation

FELLING HEAD OPERATING INSTRUCTIONS ............................................. 2.42 SAFETY PRECAUTIONS .......................................................................... 2.42 FILTER BYPASS, HYD. OIL - WARNING LIGHT ........................................... 2.10 FILTER, CHARGE PRESSURE, FAN DRIVE ................................................ 2.31 FILTER, FRESH AIR - A/C UNIT ................................................................... 2.21 FILTER, MEDIUM PRESSURE, PILOT SYSTEM .......................................... 2.30 FILTER, RE-CIRCULATING AIR - A/C UNIT ................................................... 2.20 FILTERS, HYDRAULIC OIL ........................................................................... 2.30 FIRE SUPPRESSION SYSTEM (OPTIONAL) AUTOMATIC OPERATION ......................................................................... 2.17 AVOIDING DAMAGE AND FALSE DISCHARGES DURING MACH ........... 2.19 COMPONENT LOCATIONS ....................................................................... 2.21 DISCHARGE OF THE SYSTEM ................................................................ 2.17 IN CASE OF FIRE ..................................................................................... 2.18 INSPECTION OF FIRE SUPPRESSION SYSTEM .................................... 2.18 MANUAL OPERATION .............................................................................. 2.17 FOOT PEDALS, LEFT AND RIGHT TRACK DRIVE ......................................... 2.5 FUEL LEVEL - GAUGE .................................................................................. 2.8 FUEL SHUT-OFF VALVE ............................................................................. 2.28 FUEL TANK .................................................................................................. 2.28 CAPACITY ................................................................................................ 2.28 FUSE, ALTERNATOR ..................................................................................... 2.6 FUSES AND CIRCUIT BREAKERS ................................................................ 2.5 GRAFFITI REMOVAL .................................................................................... 2.43 HAND FILL PUMP, HYDRAULIC OIL ............................................................ 2.31 FILLING HYDRAULIC TANK ...................................................................... 2.31 HORN, SAFETY ALERT - SWITCH ............................................................... 2.15 HOT WATER SHUT OFF VALVES (ENGINE) ............................................... 2.21 HOUR METER ................................................................................................ 2.7 HYDRAULIC OIL FILTERS ............................................................................ 2.30 HYDRAULIC OIL LEVEL SIGHT GAUGES .................................................... 2.30 HYDRAULIC OIL LOW - LIGHT AND HORN .................................................... 2.9 HYDRAULIC OIL TANK ................................................................................. 2.29 HYDRAULIC OIL TEMPERATURE GAUGE AND HORN ................................. 2.9 IGNITION KEY SWITCH ................................................................................ 2.13 INSTRUMENT PANEL ..................................................................................... 2.7 INTERIOR LIGHTS ........................................................................................ 2.21 JOYSTICKS, LEFT AND RIGHT HAND ........................................................... 2.4 JUMPER BAR - POSITIVE TERMINAL ......................................................... 2.28 KEY SWITCH ............................................................................................... 2.13 LIGHTS, SERVICE .......................................................................................... 2.7 LIGHTS, SERVICE - SWITCH ......................................................................... 2.7 LIGHTS, WORK - SWITCH ........................................................................... 2.10 MACHINE PREPARATION ............................................................................ 2.40 SYSTEM TEST AND WARM-UP ............................................................... 2.40

2.2

Tigercat 830 Feller Buncher

Controls and operation

OPERATING MACHINE ................................................................................ 2.36 PRE-START CHECKS ............................................................................... 2.36 RESTARTING, AFTER RUNNING OUT OF FUEL ...................................... 2.40 STARTING ENGINE .................................................................................. 2.39 STARTING IN COLD WEATHER ............................................................... 2.39 SYSTEM TEST AND WARM-UP ............................................................... 2.40 OPERATING TIPS WITH LOAD SENSING .................................................... 2.41 OPERATOR’S SEAT (SEATS INC.) ............................................................. 2.26 PILOT SYSTEM INTERLOCK SWITCH (FRONT DOOR) ............................... 2.15 PILOT SYSTEM "OFF "- PUSH BUTTON SWITCH ....................................... 2.15 PILOT SYSTEM "OFF" LIGHT ....................................................................... 2.10 PILOT SYSTEM "ON" LIGHT ........................................................................ 2.10 PILOT SYSTEM RESET - PUSH BUTTON SWITCH ..................................... 2.15 POWER ENGINE DOOR - SWITCH ................................................................ 2.7 POWER DOOR LATCH ............................................................................... 2.7 PRECLEANER, ENGINE AIR ........................................................................ 2.32 PUMP DRIVE GEARBOX OIL TEMP. - GAUGE ............................................. 2.7 RETURN FILTERS ~ HYDRAULIC OIL .......................................................... 2.30 SAW - SWITCH ............................................................................................ 2.16 SAW "ON" LIGHT ......................................................................................... 2.10 SEAT, OPERATOR'S (SEATS INC.) ............................................................ 2.26 SERVICE LIGHTS ........................................................................................... 2.7 STARTING ENGINE ...................................................................................... 2.39 STARTING IN COLD WEATHER ................................................................... 2.39 STEREO CASSETTE AM/FM RADIO ........................................................... 2.21 STOPPING ENGINE ..................................................................................... 2.42 SWING BRAKE - SWITCH WITH LIGHT ....................................................... 2.12 SYSTEM CIRCUIT BREAKERS AND FUSES ................................................. 2.5 TACHOMETER ............................................................................................... 2.8 THROTTLE SWITCH ..................................................................................... 2.13 TRACK DRIVE, LEFT AND RIGHT .................................................................. 2.5 TRACK, LOW/DRIVE - SWITCH WITH LIGHT ............................................... 2.15 TRAVELLING (BOOM RAISED) .................................................................... 2.41 VENT/BREATHER, HYDRAULIC TANK ........................................................ 2.29 VOLTMETER .................................................................................................. 2.8 WINDOWS - CLEANING ............................................................................... 2.43

2.3

Tigercat 830 Feller Buncher

Controls and operation 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.

CONTROLS - CAB

1 2

•

•

822-D04

822-D05

2. R.H. JOYSTICK CONTROL LEVER*

1. L.H. JOYSTICK CONTROL LEVER*

FOOT PEDAL

FOOT PEDAL

19749A R0

19748A R0

Stick Move the joystick back to move the stick IN.

Main boom Move the joystick back to raise the boom.

Move joystick forward to move stick OUT.

Move the joystick forward to lower the boom.

Swing Move the joystick right to swing the upper to the right.

Head Tilt Move the joystick right to tilt the felling head forward.

Move the joystick left to swing the upper to the left.

Move the joystick left to tilt the felling head back.

Thumb switch, lower left - Accumulating Arms Push to open the arms.

Thumb switch, lower left - Clamp Arms Push to close the arms.

Thumb switch, lower right - Accumulating Arms Push to CLOSE the arms.

Thumb switch, lower right - Clamp Arms Push to OPEN the arms.

Thumb switch, upper left - Tilt left Push to tilt upper structure to the LEFT.

Thumb switch, upper left - Tilt forward Push to tilt upper structure FORWARD.

Thumb switch, upper right - Tilt right Push to tilt upper structure to the RIGHT.

Thumb switch, upper right - Tilt backward Push to tilt upper structure BACKWARD.

Trigger switch, Wrist Pull the trigger switch to rotate the wrist to the RIGHT.

Trigger switch - Wrist Pull the trigger switch to rotate the wrist to the LEFT. *ER BOOM OPTION* Operation of the ER boom system on this machine differs from a conventional feller buncher

2.4

Tigercat 830 Feller Buncher

Controls and operation

boom system with regard to the function of the two joystick controls. Pushing the left joystick control forward moves the head away from the machine, while pulling it back moves the head towards the machine. Pushing the right joystick control forward lowers the boom system, while pulling it back lifts the boom system.

4

5. SYSTEM CIRCUIT BREAKERS AND FUSES Each major circuit on the vehicle is protected against current overload by a circuit breaker.

The circuit breakers on this machine are arranged on two separate panels. The breakers on the smaller panel numbered 1 to 8 protect all

3

•

2 AMP FUSE

••

••

FOOT PEDALS

822-D06

3. RIGHT FOOT PEDAL - RIGHT TRACK DRIVE Depress the foot pedal with the toe to drive forward.

Depress the foot pedal with the heel to drive backward.

4. LEFT FOOT PEDAL - LEFT TRACK DRIVE Depress the foot pedal with the toe to drive forward.

Depress the foot pedal with the heel to drive backward.

NOTE: Use these drive pedals in conjunction with the TRACK LOW/DRIVE control switch. See THIS SECTION. Travelling Travel is accomplished by depressing both foot pedals simultaneously. Travel over distances should be done in the forward direction to reduce the wear on track components. Track drive gearboxes are considered to be at the rear of the machine. NOTE: Track component life is severly reduced by driving the machine backwards.

830-D01

SYSTEM CIRCUIT BREAKERS

of the external work and service lights, the power door and the cold start circuit. The breakers on the larger panel numbered 9 to 24 protect the rest of the machine operating circuits. A 2 amp fuse located at the top of the panel protects the engine anti-stall circuit.

Push breaker to reset. If the breaker does not immediately reset it may be necessary to wait a few seconds. If the breaker "blows" again, the circuit in question should be inspected for a possible short circuit.

822-D07

SYSTEM CIRCUIT BREAKERS 2.5

Tigercat 830 Feller Buncher

Controls and operation

There are also three 60 amp fuses, a 2 x 12 gauge fusible link and one 10 amp fuse that are "in-line".

2X12 GAUGE FUSIBLE LINK CONNECTION

• 822D10

822-D12

•• ••

•

FUSIBLE LINK, ENGINE COMP. The 2 x 12 gauge fusible link protects the engine fuel PULL and HOLD solenoids and also the power cover door motor circuit.

• ••

BATTERIES

ENGINE BELL HOUSING

10 AMP ALTERATOR FUSE

THREE 60 AMP FUSES

822-D09

MAIN SYSTEM FUSES, ENGINE COMP. The three 60 amp fuses are ahead of the system circuit breakers in terms of their location within the circuit and are there to prevent major damage to the electrical systems of the machine in the event of a short circuit in any of the three main battery feed lines.

• • ALTERATOR 822-D11

ALTERNATOR FUSE, ENGINE COMP.

The 10 amp in line fuse is in the alternator exciter wire is to protect the alternator.

2.6

Tigercat 830 Feller Buncher

Controls and operation POWER DOOR LATCH

•• • ••

1

••

2

RIGHT SIDE ACCESS DOOR OPEN 822-D19

••

2. SERVICE LIGHTS - SWITCH

4

This is a two position switch labelled ON - OFF. Use to turn ON the three service lights located in the engine compartment.

•

4. HOUR METER Powered through the engine oil pressure switch, this meter records the total number of hours the engine has run.

5

9

••

5. PUMP DRIVE GEARBOX OIL TEMP. - GAUGE

• •

Displays the current oil temperature registered in the pump drive gearbox. If the oil temperature rises above 115°C(240°F)* stop all operations, lower the felling head onto the ground, stop the engine and check the oil level in the gearbox, including over filling. Also check the condition of the oil, burnt oil could indicate worn gear teeth or bearings.

••

••

*NOTE: Pump drive gearbox oil temperature limit is based on use of the recommended synthetic gear oil for severe duty applications, which allows higher operating temperatures.

8

6

7

10

•

830-D06

POWER DOOR LATCH

INSTRUMENT PANEL

INSTRUMENT PANEL 1. POWER ENGINE DOOR - SWITCH This is a three position "momentary" switch labelled OPEN - CLOSE, spring return to center OFF position. Push and hold switch in OPEN position to OPEN door or push and hold in CLOSE position to CLOSE door. NOTE: Engine access door on right side of engine enclosure must be open to unlatch power door before opening/closing power door.

CAUTION Watch for personnel in area of power door before opening door 2.7

Tigercat 830 Feller Buncher

Controls and operation If pressure drops below 15 psi., the engine will shut down automatically. If the shutdown was caused by a fault other than low engine oil pressure or a fire suppression activation, the engine shutdown override switch may be held DOWN to restart the engine.

•• ••

1

NOTE: At low engine speeds the oil pressure will be low. This is not an abnormal condition but must be closely monitored.

2

7.

•• 4

Displays the current engine coolant temperature. Gauge should normally indicate between 87°C - 96°C (190°F and 205°F). If temperature rises beyond 99°C (210°F), stop working and with engine at FULL rpm activate the cooling system fan in REVERSE for about 10 seconds by pressing and holding the cooling fan purge switch. If the temperature does not drop quickly after the purge cycle, stop engine and determine cause. Do not continue to operate machine above recommended temperatures.

• 5

9

••

8

6

A RED warning light will come ON and a warning horn will sound if the coolant temperature goes above 102°C (215°F).

•

8. FUEL LEVEL - GAUGE Capacity when full:Standard fuel tank; 378 L/100 gal (US)

•

7

10

••

9. VOLTMETER Normal operating range with the engine running is 12 to 13.5 volts.

••

A reading in excess of 15 volts indicates a possible faulty voltage regulator.

••

830-D06

ENGINE COOLANT TEMPERATURE - GAUGE, WARNING LIGHT AND HORN

A reading of less than 12 Volts indicates a possible faulty battery or alternator.

INSTRUMENT PANEL

6. ENGINE OIL PRESSURE - GAUGE The oil pressure should be greatest after starting a cold engine. Check oil pressure as soon as engine starts. If gauge does not rise above the minimum oil pressure of 20 psi. within 5 seconds, stop engine and determine cause.

Engine should normally operate between 40 and 70 psi. when the engine is running at rated speed and operating temperature. If the gauge registers less than the above range with engine running at full throttle, check the engine oil level. With engine at IDLE, the gauge should read a minimum of 20 psi.

2.8

10. TACHOMETER This meter indicates the engine speed.

Refer to THROTTLE SWITCH in THIS SECTION for engine speeds.

Tigercat 830 Feller Buncher

Controls and operation • Malfunction of hydraulic fan drive system

10

11

13 14 12

••

18 19

•

Low hydraulic oil level in reservoir

Operating outside the recommended operating range will shorten hydraulic component life.

• • ••

12. COOLANT LOW WARNING LIGHT AND HORN

••

This light will come ON and a HORN behind the panel will sound when the coolant level drops below a safe operating level. The sensor (proximity switch) is located in the top of the radiator.

20

17

Malfunction of engine Anti-Stall system

A RED warning light will come ON and a warning alarm will sound when the hydraulic oil temperature goes above 96°C (205°F). This alarm must not be used to monitor the hydraulic oil. Operator must use the temperature gauge, together with the operating range chart in SECTION 3 to prevent damage to the hydraulic system.

••

•

•

If this light comes on when the engine is running, stop the engine immediately and correct the fault.

•• •• •

WARNING 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.

•

21 22

13. HYDRAULIC OIL LOW - LIGHT AND HORN

• INSTRUMENT PANEL 830-D07 11. HYDRAULIC OIL TEMPERATURE - GAUGE, WARNING LIGHT AND HORN Displays the current hydraulic oil temperature registered in the hydraulic reservoir.

If hydraulic oil temperature rises above the recommended range listed in the HYDRAULIC OIL OPERATING RANGE chart in SECTION 3 of THIS MANUAL, reduce load on engine and activate the cooling system fan in REVERSE for about 10 seconds by pressing and holding the cooling fan purge switch. If the temperature does not drop quickly after the purge cycle, stop engine and check for: •

Plugged oil cooler, radiator, A/C condenser or debris screen

•

Malfunction in a hydraulic circuit 2.9

This light will come ON when the oil level falls 10 gal.

US (38L) below the FULL mark. The light will stay on and a HORN will sound when the oil level falls 18 gal.

US (68L) below the FULL mark. When the light first comes on stop engine and look for signs of broken hoses or other leaks. Repair leaks and refill the tank to FULL mark on the sight gauge. Restart engine and inspect for leaks. When the horn sounds stop the engine immediately. Operating machine with low hydraulic oil can cause hydraulic pumps to fail.

Tigercat 830 Feller Buncher

Controls and operation pilot system not being reset, this will be indicated by the pilot off light being ON. In this case press the PILOT RESET switch* and turn the saw switch OFF and then ON. 18. PILOT "OFF" LIGHT (AMBER)

10

This light comes ON when the pilot system has been de-activated*.

••

19. PILOT "ON" LIGHT (GREEN) 11

••

• 13 14 12

This light comes ON when the pilot system is activated by the pilot reset switch*. *When the ignition key switch is in the RUN position, either the PILOT OFF or the PILOT ON will be lit. If neither are lit then the state of the SAFETY INTERLOCK SYSTEM is unknown and should be checked out immediately.

• • ••

••

For more information on the pilot shut off system see PILOT SYSTEM OFF SWITCH in THIS SECTION.

20

WARNING

17 18 19

Do not, under any circumstances allow the pilot system to be re-activated without an operator in the cab.

•• •• •

20. BULB TEST SWITCH This is a two position "momentary" switch.

Press and hold this switch in the ON position to test the bulbs in the 3 warning lights; Items 12, 13 and 14. Replace the bulb in any light that does not come ON. If the light does not come ON after inserting a new bulb, check the circuit breaker. Bulbs should be tested at the start of each shift.

•

21 22

• 830-D07

INSTRUMENT PANEL

21. WORK LIGHTS - SWITCH

14. FILTER BYPASS - WARNING LIGHT

This switch controls all work lights around the top and base of the cab, the R.H. side and the lights mounted on the stick boom. The circuit draws current directly from the battery and in addition to the individual circuit 15 amp circuit breakers is protected by one of three 60 amp fuses located near the batteries.

This light comes ON when an oil flow restriction in excess of 15 psi is encountered at the return filters manifold. When this occurs the filters require immediate service. Excessive pressure drop through the return filters can cause the filter bypass valve to open.

22. DIMMER CONTROL

If the light comes on during cold start-ups, the engine speed should be reduced to MINIMUM throttle to allow the filter bypasses to close.

Rotate this control to dim or brighten the back lights in the gauges mounted immediately above this control, except for the HOURS gauge.

17. SAW "ON" LIGHT This light is ON when the saw system is activated. It comes ON when the saw switch is turned to the ON position. It is possible that the light will not be on even though the saw switch is in the ON position due to the 2.10

Tigercat 830 Feller Buncher

Controls and operation

2.11

Tigercat 830 Feller Buncher 1

2

Controls and operation 3

4

••

•

•

6

•

••

••

822-D16

5

CONTROL PANEL

CONTROL PANEL

This is a two position switch labelled ON /OFF. The light in the switch will come ON when the switch is in the ON position.

1. ANTI-STALL - SWITCH WITH LIGHT This is a two position switch labelled ON /OFF. The light in the switch will come ON when the switch is in the ON position.

This switch turns on an electronic load control system which automatically prevents overloading of the engine when several high load functions are in use at the same time. It should be in the ON position during normal machine operation at FULL throttle and in OFF position when operating at less than FULL throttle.

IMPORTANT: It should be noted that this anti-stall system will only allow full main pump flow with the engine running at speeds above 1950 RPM. If BOOM, SWING or TRACK DRIVE functions slow down or stop, check to ensure that the engine throttle control is activating FULL throttle position on fuel injector pump.

If engine stalling occurs, check:

3. ENGINE SHUTDOWN OVERRIDE - SWITCH

CAUTION • Turning ON the swing brake while the boom is moving can damage the gearbox • NEVER operate the tracks with the swing brake ON as boom contact with the ground will damage the swing gearbox This is a two position "momentary" switch.

Press and hold this switch to override the engine safety shutdown system when starting the engine. Refer to STARTING ENGINE in THIS SECTION.

(a) The ANTI-STALL switch is in the ON position. (b) The 2 amp fuse located on the larger circuit breaker panel in cab.

4. COLD START SWITCH

(c) Malfunction of the anti-stall system.

NOTE: Under heavy track load it may still be possible to stall the engine with the anti-stall functioning properly.

2. SWING BRAKE - SWITCH WITH LIGHT

Placing this switch in the ON position will apply the swing brake and prevent the upper structure from turning. The brake is also engaged whenever the pilot system is shut off, but as an added safety precaution, the brake should always be applied with this switch when leaving the cab. The swing brake is a spring apply, hydraulic release, multi disc brake.

2.12

Tigercat 830 Feller Buncher

Controls and operation

The SISU engine cold start system uses an intake manifold diesel fuel flame burner to preheat the intake air.

MINIMUM 1000 to 1200 RPM (No Load) FULL ....... 2150 to 2200 RPM max. (No Load) The above values are with the hydraulic and engine oil at normal operating temperatures and no functions activated and without pilot system engaged. Check engine speed regularly with a calibrated hand tachometer.

WARNING Do not, under any circumstances use Ether to assist with starting the engine.

WARNING: Under no circumstances allow the full throttle engine speed to vary from the recommended settings; particularly faster, this could cause serious damage to the pumps.

This is a two position "momentary" switch.

With the ignition key in the RUN position, press and hold this switch DOWN to activate the cold start system. For a complete procedure, refer to STARTING IN COLD WEATHER in THIS SECTION.

Under no circumstances allow the no load minimum throttle speed to vary below the recommended minimum setting.

5. IGNITION KEY SWITCH

of the If engine stalls, press the bottom throttle switch for 3 seconds to return the fuel rack to the IDLE position.

This is a three-position switch labelled OFF/ RUN/START. OFF Position - All electrical power through the ignition switch is turned “OFF”

7. AIR CONDITIONER/HEATER

RUN Position - Connects the battery to all functions. Used for normal machine operation.

START Position - Connects the battery to the start relay to start the engine. NOTE: The PILOT SYSTEM must be OFF to start the engine. To deactivate the pilot system push the large pilot off switch button DOWN (item 9).

6. THROTTLE SWITCH This is a three position "momentary" switch, spring return to center OFF position..

For FULL engine speed press and hold the top of the rocker switch, release when the desired increase in RPM level is reached.

For MINIMUM engine speed press and hold the bottom of the rocker switch, release when the desired decrease in RPM level is reached.

NOTE: All harvesting operations should be performed at full throttle. Anti-stall system will not function correctly below full throttle.

Maintaining Correct Engine RPM. It is most important that the RPM. of the engine be correct at all times: Sisu Engine

2.13

Tigercat 830 Feller Buncher

Controls and operation

7 8 C

B

9

10

11

12

13

14

6

A

••

••

••

• ••

••

••

•

••

••

••

CONTROL PANEL authorized A/C technicians. The system The three controls on this panel are used to should be charged with R134a refrigerant only. adjust the heating and air conditioning PAG (polyalkylene glycol) oil should be temperature for operator comfort in the operator’s present in the system and must be used on cab.

‘O’ rings and fittings during assembly.

A. A/C SWITCH The compressor and charge valves are This is a two position switch labelled accessed on the top left side of the engine.

ON - OFF. Placing this switch in the ON A/C SYSTEM TOTAL CAPACITIES position will turn ON the A/C compressor for cooling.

R134a REFRIGERANT PAG OIL (polyalkylene glycol) B. FAN SPEED - OFF/LOW/MED/HIGH

822-D17

3 LBS. 0 OZ.

This is a rotary, four position switch for controlling the speed of the blower fan.

7 OZ.

The receiver dryer is mounted to the back of the engine compartment.

C. HEAT/COOL - VARIABLE This is a variable, rotary dial to adjust the amount of heated air for the cab by controlling the flow of engine coolant through the heater core. Make sure this control is set to the MAX COLD position when using the air conditioning. See NOTE below.

NOTE: To maximize the efficiency of the air conditioning, the heat/cool control must be rotated to the MAX COLD position and the two hot water shut off valves on the engine should be turned to the OFF position. Also refer to HOT WATER SHUT OFF VALVE, in THIS SECTION. CHECKING THE AIR CONDITIONING SYSTEM Any service work must be performed by

2.14

Use checklist to maintain system between service intervals. a. Check and adjust compressor drive belt tension. b. Check re-circulating and fresh air filters (items 17 and 18). Clean as required. c. Check the condenser core for dirt and debris. Clean as required. Refer to CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR in THIS SECTION. d. Check the evaporator and the inside of the A/C housing for dirt and debris. Clean as

Tigercat 830 Feller Buncher

Controls and operation 10. TRACK, LOW/DRIVE - SWITCH WITH LIGHT

IMPORTANT

This is a two position switch labelled LOW and DRIVE.

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.

IMPORTANT: This switch when in DRIVE provides infinitely variable travel speeds/torque ranges, unlike similar travel range controls on some types of construction equipment.

CAUTION

LOW: Placing the switch in the LOW position will provide the slowest travel speed but with increased torque or driving force.

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

It is recommended that during all harvesting functions and when travelling down slopes that the range switch be placed in the LOW position to maximize drive motor life. Low position is indicated by a light on the Track Low/drive switch.

• Always use personal protective equipment to guard against flying debris. required. e. Run air conditioning system for 3 - 5 minutes. f. Check to see that compressor clutch will engage.

8. PILOT SYSTEM RESET - PUSH BUTTON SWITCH This is a push ON spring return switch. With the engine running and the front door closed, push this switch to activate the pilot system. The pilot ON light will be ON and the pilot OFF light will be OFF. NOTE: The front door must be closed to ACTIVATE the pilot system. The side door exit WILL NOT DEACTIVATE the pilot system when opened.

9. PILOT SYSTEM OFF - PUSH BUTTON SWITCH SWITCH

ACTUATOR ON DOOR

•

DRIVE: When this switch is in the DRIVE position the travel speed (and torque) ranges of the drive system become infinitely variable and will automatically adjust to any point between the HIGH and LOW speed/torque set points, relative to the terrain or load conditions.

It should be noted that the available torque when travelling at maximum speed is only half of that in LOW. The DRIVE position will provide a faster travel speed range but with a lower driving force.

However, when the machine encounters tougher terrain conditions, e.g. stumps, soft ground or slopes etc., the drive system will automatically adjust* to a slower travel speed/ higher torque range. *This amount of adjustment can be anywhere from a slight reduction in speed to all the way down to LOW, this will be dependant on the terrain conditions encountered.

•

INTERLOCK SWITCH (FRONT DOOR) This is a push OFF spring return switch. This switch shuts off the pilot system deactivating all operating functions as well as applying the track drive brake and swing brake. The pilot OFF light will be ON and the pilot ON light will be OFF.

822-D02

NOTE: The operator should be aware that this automatic speed/torque range adjustment will cause the machine to gradually slow down over a period of 1 to 2 seconds, due in part to the infinitely variable displacement drive motors used. It is not necessary to place the range switch in the LOW position.

11. HORN, SAFETY ALERT - SWITCH This is a two position "momentary" switch.

Press and hold this switch to sound the safety alert horn.

Always use this horn prior to starting the

The pilot system can be REACTIVATED when the PILOT RESET button (item 8) is pressed with the front door closed.

2.15

Tigercat 830 Feller Buncher

Controls and operation

7 8 C

B

9

10

11

12

13

14

15

A

••

••

••

• ••

••

•

822-D17

••

••

••

••

CONTROL PANEL

engine and to alert other personnel in the area of your presence.

position the hydraulically driven cooling fan will be turning and drawing cool air through the debris screen and cooling assembly. The air is expelled to atmosphere through the perforated panels that make up the engine enclosure.

12. SAW - SWITCH This is a two position switch labelled ON/OFF. Use this switch to turn the saw ON. A lockout button is incorporated into the switch to prevent the switch from being turned ON accidentally. To turn the switch ON, push and hold the lockout button UP and place the switch in the ON position.

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

Place throttle in FULL position before turning saw ON.

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.

NOTE: If the engine has been turned off or the pilot shut off system tripped (Front Door opened) with the saw switch left in the ON position, the saw will not start up when the engine is restarted or the front door closed. In this case press the PILOT RESET button and turn the saw switch OFF and then ON.

14. AUXILIARY POWER OUTLET A 12 volt outlet with a 15 amp capacity for portable devices such as cell phones.

15. CIGARETTE LIGHTER

13. COOLING FAN - SWITCH

Cigar/Cigarette lighter.

This is a two position "momentary" switch.

Press and hold this switch in the CLEAN (PURGE) position to run the cooling fan in reverse. With this switch in the "normal"

NOTE: Items 14 and 15 share the same 15 amp circuit breaker.

16. AMEREX FIRE SUPPRESSION SYSTEM (OPTIONAL) The machine leaves the factory with the AMEREX fire suppression system fully activated.

The system is not certified for use and certification must be performed by a local AMEREX approved dealer.

NOTE: A pre-delivery inspection of the fire 2.16

Tigercat 830 Feller Buncher

Controls and operation AUTOMATIC OPERATION There are 4 thermostats mounted in the engine and hydraulic enclosures which are wired to a control panel. The thermostats are automatic heat detection devices and are set to “close” at 177°C (350°F). When a thermostat closes it sends an electrical signal to the control panel.

16

••

MANUAL OPERATION The fire suppression system can also be activated manually using the manual actuation switch.

• FIRE SUPPRESSION SYSTEM suppression system must be carried out to ensure the system is fully operational. This involves performing all daily and weekly inspection steps. Refer to INSPECTION OF THE AMEREX FIRE SUPPRESSION SYSTEM AND PORTABLE EXTINGUISHERS in THIS SECTION.

822-D19

••

The fire suppression system installed on this machine uses a dry chemical powder which is stored in a 50 lbs. pressurized cylinder. It is discharged through 8 nozzles strategically placed in the engine compartment and hydraulic areas.

SYSTEM CONTROL PANEL To manually operate the system:

376-24A

2. Pressing red FIRE button.

An electrical signal is sent to the control panel from the manual actuation switch.

DISCHARGE OF THE SYSTEM When an electrical signal (automatic or manual) is received by the control panel it sends a discharge signal to the electrical

The control panel mounted in the cab provides continuous monitoring of the system. It also, automatically actuates the suppression system when signalled by the thermostats.

RED FIRE BUTTON

•

ELECTRICAL ACTUATOR

•

PRESSURE GAUGE

••

822-D19

•

MANUAL ACTUATION SWITCH

actuator located on top of the pressurized cylinder. When activated the electrical actuator extends a control shaft which mechanically opens the agent cylinder valve. This releases the dry chemical in the discharge area protected by the system. At the same time the control panel will also automatically shut down the engine.

PRESSURIZED CYLINDER

•• 822-D20

"PUSH TO TEST" BUTTON

1. Pull locking pin.

The discharge is triggered either automatically by the fire detection thermostats or manually by the operator.

•

•• •

Please read the owners manual applicable to the system installed on this machine for additional information on operation, service and AMEREX warranty requirements.

DISCHARGE HOSE

SHUTDOWN RESET" BUTTON

"SYSTEM OK" LIGHT

PRESSURIZED CYLINDER CHECK GAUGE DAILY 2.17

Tigercat 830 Feller Buncher

Controls and operation

The automatic engine shutdown feature will either shutdown the engine immediately the fire suppression system is discharged (none levelling machines) OR will delay the shutdown for a period of between 10 to 15 seconds for levelling machines. The time delay period is a factory setting. This delay feature allows the operator to lower the load or move the machine to a safer location before the engine shuts down. The operator can extend the delay by pressing the SHUTDOWN RESET button on the control panel to repeat the preset delay period. This button can be pressed repeatedly until the operator has brought the machine to a safe stop. The SHUTDOWN RESET button does not delay the discharge of the fire suppression system.

IN CASE OF FIRE: If a fire starts in any space protected by the system, DO NOT wait for the system to operate automatically. Instead, operate the system manually:

Do not restart the machine until it has been serviced and cleaned. Do not return the machine to service until the source of the fire has been located and neutralized. The fire suppression system must be recharged by Amerex Factory Certified Personnel before returning the machine to service.

Before cleaning up after a discharge, read the AMEREX manual. If water mixes with the dry chemical it becomes corrosive and can

CAUTION Wear protective clothing and masks when cleaning up after a discharge seriously damage wiring connections.

Dry chemical must be vaccummed or blown off with compressed air.

INSPECTION OF THE AMEREX FIRE SUPPRESSION SYSTEM AND PORTABLE EXTINGUISHERS:

1. Pull locking pin.

2. Push red FIRE button.

DAILY:

The system will activate the discharge system and the automatic engine shutdown system.

There will be a cloud of dry chemical dispersed in the discharge area. The engine will automatically shutdown either immediately or

•

Check the pressure gauge on the agent cylinder and all portable extinguishers.

DISCHARGE HOSE

ELECTRICAL ACTUATOR

•

RED FIRE BUTTON

PRESSURE GAUGE

• ••

••

PRESSURIZED CYLINDER

• •• 822-D19

MANUAL ACTUATION SWITCH 822-D20

will be delayed for 10 to 15 seconds if the machine is a leveller.

IMPORTANT: Stop the engine before discharging the system. This will keep the dry chemical in the engine area.

•

Get away from the machine. Take a portable fire extinguisher along if possible or obtain one from another location.

•

PRESSURIZED CYLINDER CHECK GAUGE DAILY Proper pressurization is indicated when the pointer is in the green zone.

Verify that the green “SYSTEM OK” light on the system control panel is illuminated.

WEEKLY:

Stand by with a portable fire extinguisher and watch for any flashbacks after the system has discharged.

2.18

Inspect all parts for damage, rust, corrosion or dirt. Replace any damaged

Tigercat 830 Feller Buncher

Controls and operation SHUTDOWN RESET" BUTTON

"SYSTEM OK" LIGHT

PRESSURE GAUGE

••

••

••

"PUSH TO TEST" BUTTON

•• 376-24A

SYSTEM CONTROL PANEL access is unobstructed.

Please read the owners manual applicable to the system installed on this machine for additional information on operation, service and AMEREX warranty requirements.

BI-YEARLY 822-D21

PORTABLE FIRE EXTINGUISHER CHECK CHARGE GAUGE DAILY

•

parts immediately.

•

All components are in place and unobstructed.

•

All chemical delivery hoses and nozzles are in connected and tight.

•

Check fire suppression electrical network.

•

Ensure thermostats are clean.

•

Operate the machine and depress the “Push to TEST” button to confirm the automatic engine shutdown feature is

378-19A

AVOIDING DAMAGE AND FALSE DISCHARGES DURING MACHINE SERVICE: Pay attention to the location of the components of the fire suppression system.

TYPICAL THERMOSTAT working.

•

Check the system owners manual for correct re-certification intervals. These are required for insurance policy.

Check the manual actuation switch to ensure that all tamper indicators are in place, operating instructions are visible and

2.19

Tigercat 830 Feller Buncher

Controls and operation

Take care not to damage heat sensors or wiring, this includes hitting, cutting, bending, denting, etc. Damage to heat sensors due to shock could cause an accidental discharge of the system. Cut, pinched, or kinked wiring could cause false signals and lead to burnt wiring or an accidental discharge of the system.

In addition thermostats are sensitive to heat from welding torches, steam cleaning or other outside sources which may create a false discharge of the system. Cutting the wiring anywhere along the electrical circuits especially the detection circuits, will cause a false discharge.

If any of the components are damaged replace them immediately.

It is also important to take care around the chemical cylinder. The chemical cylinder is pressurized and can explode if struck with sufficient force. Pressurized cylinders are extremely hazardous.

822-03

Failure to follow the system manufacturers instructions and guidelines may result in serious bodily injury, death, and property damage.

17. FILTER, RE-CIRCULATING AIR - A/C UNIT Air in the cab is drawn into the A/C-HEATER unit via this filter and re-circulated. The filter should be inspected and cleaned on a regular

2.20

COMPONENT LOCATIONS

Tigercat 830 Feller Buncher

Controls and operation MAX COLD position. During times when cab heating is not required close the hot water shut off valve (A) on the left side of the engine and hot water shut off valve (B) located beside the main boom, this will prevent hot water from seeping through the A/C unit and thereby reducing the effectiveness of the cooling

basis. The A/C will not cool efficiently if these filters become dirty or plugged.

18. FILTER, FRESH AIR - A/C UNIT Outside air is continuously drawn into the cab air conditioning unit through this filter and mixed with interior air from the cab. The filter 17

A

••

••

822-D22

LOCATED ON THE LEFT SIDE OF THE ENGINE

RE-CIRCULATING AIR FILTER

409-08

HOT WATER SHUT OFF VALVE

is located on the right side of cab and can be serviced from the outside by removing the two fasteners holding the hinged cover. The filter should be inspected on a regular basis and

B

•• 18

••

LOCATED BESIDE THE MAIN BOOM

HOT WATER SHUT OFF VALVE system.

822-D24

20. INTERIOR LIGHTS (2 OR 3 PLACES) The switch is activated by sliding the light lens.

822-D23

FRESH AIR FILTER

21. AM/FM STEREO CASSETTE

cleaned/replaced when dirty or when wet.

NEVER operate air conditioning without a filter installed.

19. HOT WATER SHUT OFF VALVES (ENGINE) To maximize the efficiency of the air conditioning, the heat control (C) on the A/C heater control panel must be rotated to the

2.21

Tigercat 830 Feller Buncher

Controls and operation 20

••

are two retaining knobs on the inside to allow removal of the hatch. These knobs should only be HAND TIGHTENED, to allow them to be unscrewed in case of an emergency.

22

For more information refer to ESCAPE HATCH AND SIDE DOOR EMERGENCY EXIT

•

21

••

23

•• 822-D25

•

• ••

•• •

••

RETAINING KNOB AND CLAMP BRACKET

INTERIOR LIGHTS, EMERGENCY EXITS

With dual front mounted speakers. See unit manufacturer’s manual for operation.

•

23

22. SIDE DOOR EMERGENCY EXIT This side door serves as one of two emergency exit routes from the cab. Opening the side door WILL NOT DE-ACTIVATE the 21

••

••

822-D26

ESCAPE HATCH, EMERGENCY EXIT

MAINTENANCE GUIDE in THIS SECTION. SIDE DOOR AND ESCAPE HATCH EMERGENCY EXIT MAINTENANCE GUIDE

822-D27

AM/FM STEREO CASSETTE

pilot system, for this reason only use this door in an emergency. In the event that it cannot be used, use the emergency escape hatch in the roof of the cab.

23. ESCAPE HATCH, EMERGENCY EXIT This is a third cab exit for use if the side exit and the front door exit become blocked. There

22

••

822-D29

SIDE DOOR EMERGENCY EXIT 2.22

Tigercat 830 Feller Buncher

Controls and operation

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.

3. Engage clamp bracket in slot of cab roof bracket and re-tighten the hand knobs hand tight.

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

NOTE: If the hand knobs become loose when operating the machine, the nylon inserts in the studs should be replaced.

It is also important that snow, debris and particularly ice not be allowed to build up in these areas. Check frequently and remove any accumulation immediately.

ESCAPE HATCH REMOVAL: 1. Unscrew both of the retaining knobs and remove the two clamp brackets.

REMOVE BOTH CLAMP BRACKETS

CHECKING PROCEDURE FOR SIDE DOOR: 1. Open side door twice, once using the interior latch handle and once using the exterior handle.

2. Check for proper operation of both handles, latches and hinges. Adjust and/or lubricate

••

822-D31 822-D29

INTERIOR

822-D28

EXTERIOR

any part of the mechanism that requires attention.

CHECKING PROCEDURE FOR ESCAPE HATCH:

ESCAPE HATCH REPLACEMENT:

1. Partially unscrew both the interior retaining knobs four complete revolutions.

2. Disengage clamp brackets from slot on cab UNSCREW RETAINING KNOB FOUR COMPLETE TURNS

CLAMP BRACKET

NOTE: Do not apply silicone sealant between Escape Hatch and Cab Roof Silicone in these areas can bond the escape hatch to the cab, preventing their removal.

1. Clean all mating surfaces on both the escape hatch and cab roof, remove any silicone residue that may have been used to seal the joint.

••

2. Ensure that the escape hatch gasket is in good condition and replace if damaged.

••

822-D30

ESCAPE HATCH REMOVAL

2. Push open from the inside the escape hatch or if hatch has become bonded to cab roof uses a pry bar taking care not to damage the sealing surface of the roof.

CHECK ESCAPE HATCH

roof attachment bracket, the escape hatch should move without using excessive force.

2.23

Tigercat 830 Feller Buncher

Controls and operation

3. Replace the nylon inserts in each stud, leaving approx. 1/8" protruding at each end. These are to prevent the hand knobs from coming loose under vibration.

NYLON INSERT

•

SKY LIGHT

•• CAB

••

NYLON STUD REPLACEMENT 4. Apply an anti-seize compound to stud threads on the escape hatch and engage hand knob threads 3 revolutions with washer and clamp bracket in place as illustrated.

822-01

5. Apply a thin film of dielectric grease around perimeter of escape hatch on ‘C’ channel.

6. Apply a thin film of dielectric grease to top surface of foam seal on cab roof to prevent foam seal from sticking to escape hatch over time.

7. Install escape hatch on roof and engage clamp bracket in slot of cab roof bracket and re-tighten the hand knobs hand tight.

WARNING Heat from sun exposure can cause the exit seals to bond to the cab's painted surfaces.

Careless use of glues or sealants to repair leaks also bond the exit panel.

Failure to follow these proper maintenance procedures can result in the exit being unusable in an emergency

2.24

Tigercat 830 Feller Buncher

Controls and operation

2.25

Tigercat 830 Feller Buncher

Controls and operation

OPERATOR’S SEAT (SEATS INC.)

RIDE ADJUSTMENT After adjusting height, the ride adjustment should be made by pulling or pushing the air ride control valve.

ADJUSTMENTS HEIGHT ADJUSTMENT PROCEDURES The SPRING-ASSISTED height adjustment is controlled by the height adjustment lever located on the front left side of the seat chassis.

The four height settings: top, bottom and two inbetween, provide a total height adjustment of 3”.

4-WAY ADJUSTABLE LUMBAR To position lumbar mechanism vertically, move vertical adjustment knob up or down. For fore-andaft displacement, rotate horizontal adjustment knob.

To Raise Firmly lift up on the height adjustment lever.

When the lever releases, hold it up while partially lifting the operator’s body weight from the seat.

When the seat is at the desired height, FIRMLY PUSH DOWN on the lever until the seat locks (a click should be heard).

BACK ANGLE ADJUSTMENT Rotate back angle adjustment knob to place seat at the desired angle.

FORE/AFT SLIDE Move and hold fore/aft slide lever. Roll seat forward or backward to the desired position relative to the foot pedal controls.

To Lower Firmly lift up on the height adjustment lever.

When the lever releases, partially apply operator body weight to the seat until the seat is at the desired height. FIRMLY PUSH DOWN on the lever.

Hold lever down until the seat locks into position (a click should be heard).

4-WAY 4-WAY LUMBAR LUMBAR HORIZONTAL HORIZONTAL ADJUSTMENT ADJUSTMENT

•• ••

WARNING The seat belt supplied with this seat must be used at all times when operating this machine.

•• ARMREST ADJUSTMENT

SEAT ADJUSTMENTS

332-6 4-WAY LUMBAR VERTICAL ADJUSTMENT

ARMREST ADJUSTMENT Each armrest has 2 adjustments to place it in the required position. Loosen adjustment locking wing bolts to reposition armrest height and fore/aft position.

•

4-WAY LUMBAR HORIZONTAL ADJUSTMENT

PROBLEMS AND CORRECTIVE ACTION

BACK ANGLE ADJUSTMENT KNOB

•• RIDE ADJUSTMENT KNOB 332-1B

RIDES TOO STIFF/SEAT TENDS TO PUSH OR THROW OPERATOR FORWARD The air ride control valve has over pressurized the seat air suspension. This typically happens because the operator is trying to use the air suspension to adjust the ride height rather than using height adjustment lever to raise the seat.

Refer to height adjustment.

•

•

•• ••

VIEW FROM RIGHT REAR OF SEAT

HEIGHT ADJUSTMENT LEVER FORE/AFT SLIDE LEVER

2.26

Tigercat 830 Feller Buncher

Controls and operation

RIDES TOO SOFT OR BOTTOMS OUT AND PINCHES OPERATOR The air ride control valve has under pressurized the seat air suspension ride adjustment Insufficient pressure exaggerates the knee-action movement of the seat. This usually happens because the operator is trying to lower the seat by decreasing the amount of air pressure instead of using the Height Adjustment lever. Refer to height adjustment.

SEAT TOO HIGH/SEAT TOO LOW There are several things which can cause improper seat height. Refer to the HEIGHT ADJUSTMENT and adjust seat to the desired position. If the proper height cannot be reached using one of the four height adjustment settings, it may be necessary to install the seat on a higher base.

OPERATOR’S LEGS FALLING ASLEEP The seat is adjusted too high, and the air ride control valve has under pressurized the seat air suspension ride adjustment, resulting in the operator sitting in a “bucket”. Refer to height adjustment and RIDE ADJUSTMENT.

2.27

Tigercat 830 Feller Buncher

Controls and operation

ENGINE COMPARTMENT

3. FUEL TANK Located at the rear left corner behind the operators cab. The engine fuel supply line has a shut-off valve located at the base of the tank and to the left of the main Linde control valve.

Use this valve to shut off the fuel supply when working on the engine. The fuel tank has a capacity of 100 gal. U.S. (378 l).

1. BATTERY DISCONNECT - SWITCH This manually operated switch located on the negative side of the battery completely disconnects all electrical circuits on the machine from the battery except for the fire suppression and service light circuits.

3 1

••

••

822-D34 822-D32

BATTERY DISCONNECT SWITCH

FUEL SHUT-OFF VALVE

The filler cap incorporates a fine mesh strainer.

The fuel level sender is adjacent to the fuel filler cap in the right side tank.

2. JUMPER BAR - POSITIVE TERMINAL This terminal allows for the use of jumper cables without removal of the battery terminal insulators. The negative connection can be made anywhere on the upper frame, close to the battery on bare metal.

••

2

•• FUEL FILLER CAP

FUEL LEVEL SENDER

•• 822-D48

822-D33

JUMPER BAR

2.28

FUEL FILLER CAP AND FUEL LEVEL SENDER

Tigercat 830 Feller Buncher

Controls and operation

4. HYDRAULIC OIL TANK

AIR VENT FILTER

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).

•

••

••

•• CHECK VALVE 10 PSI.

••

••

• ••

VENT, HYDRAULIC TANK 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.

WATER ABSORBING ELEMENT (COLOUR BLUE)

••

SERVICE NOTE:

4

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

••

HYDRAULIC OIL TANK

The spin on return filter group, is located above the tank. A drip tray with an attached drain hose is built into the top of the tank to prevent spills when servicing the filters.

5. VENT/BREATHER, HYDRAULIC TANK The air space in the top of the hydraulic tank is vented to atmosphere via a check valve and spin-on filter. The check valve will open or

••

••

AIR VENT FILTER

AIR VENT VALVE

822-D35

TOP OF HYDRAULIC TANK

822-D41

• ••

DRIP TRAY

422-07

AIR VENT VALVE

RETURN MANIFOLD

FILTER GROUP

HYDRAULIC TANK PRESSURE GAUGE

CONNECTION TO PRESSURE GAUGE

SOME COMPONENTS REMOVED FOR CLARITY

HYDRAULIC OIL TANK

"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.

2.29

Tigercat 830 Feller Buncher

Controls and operation

6. OIL LEVEL SIGHT GAUGES

7. RETURN FILTERS ~ HYDRAULIC OIL

Two sight gauges are used to indicate the level of the hydraulic oil in the tank with HIGH and LOW level limits. These gauges are accessible through the rear left side door.

••

The majority of return oil entering the tank passes through 6 spin on hydraulic oil filters, one of the filters is a water absorbing filter (colour blue) which is in place to assist with removing 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.

FIRST SIGHT GAUGE

SECOND SIGHT GAUGE

HYDRAULIC TANK PRESSURE GAUGE

••

•

•• ••

TEMPERATURE GAUGE

•• ••

•• •• •

••

LOW LEVEL SENDING UNIT, FOR WARNING LIGHT

422-07

RETURN MANIFOLD

5 - HYDRAULIC RETURN FILTERS

•• •

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.

LOW LEVEL SENDING UNIT, FOR WARNING BUZZER

HYDRAULIC OIL LEVEL SIGHT GAUGES Incorporated into the first sight gauge (highest) is a low level sending unit which signals a LOW HYDRAULIC OIL light in the cab to come ON when the oil level reaches the LOW mark. A second sight gauge is used to detect a further loss of oil. Incorporated into this gauge is a sending unit and a temperature gauge. If the level of oil reaches the bottom of this gauge, the sending unit will signal a buzzer in the cab to sound.

422-05

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

FILTER SERVICE NOTE The filters should be checked/changed when the FILTER BYPASS warning light in the cab comes ON.

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

8. MEDIUM PRESSURE PILOT FILTER There is a medium pressure pilot filter mounted to the base of the charge/pilot/filter manifold. The filter receives hydraulic oil from the charge pump. The charge pump is a gear pump driven from the power take-off of the main pump and supplies pilot oil via the filter and the charge/pilot/filter manifold to the pilot system.

2.30

Mounted on top of the manifold is 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 50 psi builds up inside the filter, the indicator will show RED, indicating a clogged filter.

Tigercat 830 Feller Buncher

••

Controls and operation

CLOG INDICATOR SIGHT GLASS

•

FILTER CLOG INDICATOR

FEMALE QUICK DISCONNECT PUMP DRIVE GEARBOX OIL LEVEL GAUGE

••

PILOT FILTER

FAN DRIVE CHARGE PRESSURE FILTER

•

•

SUCTION TUBE

• 822-D46

••

HAND FILL PUMP

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.

830-D08

PILOT FILTER AND FAN CHARGE PRESSURE FILTERS

To add oil to the tank; Depressurize tank, thoroughly clean outside surface of the suction tube and remove the plug. Connect the quick disconnect to the return manifold port, insert end of suction tube into supply drum and operate the pump. The oil is pumped directly into the hydraulic tank via the filters. The pump should always be operated at a medium speed with steady motion. Pumping too fast may cause oil to bypass oil filter.

This condition could happen during cold startups, but as the oil warms up the indicator will move into tthe 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.

9. CHARGE PRESSURE FILTER ~ FAN DRIVE The fan drive circuit contains a single element, Tigercat hydraulic filter with a restriction indicator sending unit (not used) and a 50 psi third port bypass valve. When a restriction is encountered, the bypass valve in the filter head opens and diverts oil back to tank via the third port to prevent unfiltered oil from entering the fan drive charge circuit.

IMPORTANT: 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.

RETURN MANIFOLD

NOTE: A plugged filter will result in a slower fan speed or stopped.

•

•• ••

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

RETURN MANIFOLD PORT

CONNECT THE QUICK DISCONNECT TO THE RETURN MANIFOLD PORT

10. 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

822-D40

2.31

FILLING HYDRAULIC TANK

Tigercat 830 Feller Buncher

Controls and operation

11. ENGINE AIR PRECLEANER

EXHAUST SYSTEM

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.

PRECLEANER TO TURBO CHARGER

•• ••

••

AIR CLEANER

• AIR CLEANER UNLOADER VALVE

••

AIR CLEANER AIR CLEANER UNLOADER VALVE

354-15

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

DISCHARGE PORT AREA

13. FILTER RESTRICTION INDICATOR

218-21B

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.

PRECLEANER

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

FILTER RESTRICTION INDICATOR

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

Refer to AIR CLEANER MAINTENANCE in SECTION 3 of THIS MANUAL.

•

822-D42

FILTER RESTRICTION INDICATOR

Refer to AIR CLEANER MAINTENANCE, OVER SERVICING and IMPROPER SERVICING in SECTION 3 of THIS MANUAL.

2.32

Tigercat 830 Feller Buncher

Controls and operation

14. AIR INTAKE CLEAN-OUT COVER PLATE The precleaner receives air via an air intake grill on the left side of the power door and through a passage way fabricated into the power door. Regularly inspect both sides of the intake grill and remove any accummulation of debris. Refer to AIR INTAKE CLEAN-OUT COVER PLATE in SECTION 3 of THIS MANUAL. CLEAN OUT COVER

•

421-15A

AIR INTAKE CLEAN-OUT COVER

15. 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.

•

CHECK CONDITION OF SEAL

•• 822-D58

PRECLEANER

AIR INTAKE SEAL

2.33

Tigercat 830 Feller Buncher

Controls and operation A/C CONDENSER OIL COOLER

RADIATOR COOLING FAN

•

SHROUD

••

••

FINGER GUARD SURGE TANK FAN DRIVE MOTOR

••

••

••

•

••

DEBRIS SCREEN

•

822-04

COOLING ASSEMBLY - OVERALL VIEW

CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR

NOTE: REGULARLY CHECK FOR DEBRIS BETWEEN A/C CONDENSER, OIL COOLER AND RADIATOR

PROCEDURE: 1. Shut down as per instructions in OPERATING MACHINE SECTION.

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

The hydraulic driven fan draws air through the screen, through the A/C condenser, the oil cooler and engine radiator and finally blows the air across the engine.

2. Open rear right side engine door.

3. Unlatch the hinged oil cooler A/C condenser unit and swing open about 20 degrees. The debris screen can now be pulled out.

The A/C condenser core, the oil cooler and the engine radiator assembly should be checked every 8 hours (every shift) for accumulation of twigs, leaves, pine needles and dust. All of the engine enclosure doors should also be kept clean.

OIL COOLER A/C CONDENSER UNIT

LATCH

• • 822-D45

LATCH, OIL COOLER - A/C CONDENSER UNIT

2.34

Tigercat 830 Feller Buncher

Controls and operation

•• SLIDE DEBRIS SCREEN OUT AND REMOVE

422-04 DEBRIS SCREEN 4. Remove two wing nuts (right side) and carefully swing out the A/C condenser (on hinges) to expose the oil cooler assembly. Remove any accumulated debris from between the oil cooler A/C /condenser and radiator.

OIL COOLER

RADIATOR

A/C CONDENSER

• •• ••

410-24

HINGED A/C CONDENSER & OIL COOLER 5.

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

This cooling assembly must be checked daily and may have to be thoroughly cleaned on a weekly or monthly basis, depending on operating conditions. 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.

Pay particular attention to cleaning in the corners of the cooler as these areas usually plug deeply. Reversing the fan at least once per hour will help reduce the dust accumulation in the cores.

2.35

Tigercat 830 Feller Buncher

Controls and operation

OPERATING MACHINE

5. Check the engine oil level. The level of the oil must be between the ADD and the FULL marks on the dipstick.

Ensure that the appropriate lubrication and maintenance schedule has been performed prior to operating the machine. (Section 3 in this manual).

Also refer to the Diesel engine manufacturers operator’s manual supplied with the machine.

ENGINE OIL DIPSTICK

•

Any personnel who are to operate this machine must be fully trained in safety and operating procedures by a competent person.

ENGINE THROTTLE CONTROL

BEFORE YOU BEGIN: PRE-START CHECKS

••

1. Ensure ignition key switch and saw switch are in the OFF position.

2. Check fire extinguisher is sufficiently charged.

LEFT SIDE OF ENGINE 822-D49

PRESSURE GAUGE

6.

CHECK ENGINE OIL LEVEL

Check air cleaner unloader valve.

EXHAUST SYSTEM

••

PRECLEANER TO TURBO CHARGER

•• 822-D21

•

PORTABLE FIRE EXTINGUISHER CHECK CHARGE GAUGE

•

AIR CLEANER

3. Check fuel level.(Turn ignition key switch to RUN position to check this, then to OFF)

•• AIR CLEANER UNLOADER VALVE

FUEL LEVEL GAUGE

• •

354-15 830-D06

INSTRUMENT PANEL

7. Check air intake pre-cleaner and top seal.

4. Check hydraulic oil level, the level should be up to within 2" (5 cm) of the HIGH mark on the upper sight gauge.

••

AIR CLEANER

AIR INTAKE AREA

UPPER SIGHT GAUGE

DISCHARGE PORT AREA

• TOP SEAL 218-21B

822-D50

422-05A

CHECK HYDRAULIC OIL LEVEL 2.36

UNDER SIDE OF PRECLEANER

CHECK AIR INTAKE PRE-CLEANER

Tigercat 830 Feller Buncher

Controls and operation

8. Check fuel line water separator and drain any accumulated water into a bowl and clean up any spilled fuel.

WARNING 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.

WATER SEPARATOR BOWL

DRAIN TAP

• 822-D53

CHECK ENGINE COOLANT LEVEL 11. Check the engine coolant level.

822-D54

•

FUEL LINE WATER SEPARATOR

12. Check pump drive gearbox oil level at sight gauge, the level should at the "OK" mark.

9. Check fuel line water separators on side of engine and drain any accumulated water.

PUMP DRIVE GEARBOX OIL LEVEL GAUGE

WATER SEPARATOR BOWL

DRAIN TAP

• •• ••

PUMP DRIVE GEARBOX DRAIN/ FILL HOSE

• •

822-D52

ENGINE FUEL LINE WATER SEPARATORS

••

830-D09

PUMP DRIVE GEARBOX OIL LEVEL GAUGE 13. Clean radiator, A/C condenser and oil cooler.

10. Check tension and condition of engine belts.

OIL COOLER

RADIATOR

A/C CONDENSER

•• • •

822-D51

CHECK CONDITION OF ENGINE BELTS

410-24

CLEAN RADIATOR, A/C CONDENSER AND OIL COOLER. 14. Check all exits.

2.37

Tigercat 830 Feller Buncher

Controls and operation

15. Check condition of track shoes.

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

CRACKING

BENT

WARN HOLES

STRESS CRACK AROUND HUB

EDGE WEAR

EDGE WEAR SAW-26

BROKEN EDGE

CHECK DISC FOR CRACKS

830-02 CHECK CONDITION OF TRACK SHOES 16. Check track chain tension.

STRESS CRACK

SAG DIMENSION; 4" TO 6" FOR NORMAL OPERATIONS 853ILL8

SAW-27

MEASURING SAG DIMENSION

CHECK DISC FOR CRACKS

21. Never start or use a machine if the disc saw has missing teeth, missing teeth fasteners or a bent or damaged disc.

17. Check and tighten all of the fasteners retaining the disc saw teeth to the proper torque level.

SAW-24 MISSING TEETH/DAMAGED BLADE 22. Check that the saw housing is clear and undamaged.

CHECK/TIGHTEN TOOTH FASTENERS 18. Replace all worn disc saw teeth or rotate worn teeth to align fresh cutting tips.

SAW-P03

19. Replace the tooth fastener whenever replacing a saw tooth.

SAW-25

CHECK FOR DAMAGE TO SAW HOUSING 23. Shut down the machine immediately if you feel a vibration when the cutting disc is running.

24. Be sure that all doors and access panels are securely fastened.

SAW-23

REPLACE OR ROTATE WORN TEETH 2.38

Tigercat 830 Feller Buncher

Controls and operation

STARTING ENGINE

STARTING IN COLD WEATHER Cold temperatures require the use of the engine block heater.

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

WARNING

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

Do not, under any circumstances use Ether to assist with starting the engine. An explosion may result.

3. Turn the ignition key switch to RUN. 4. Depress and hold throttle switch to ensure idle speed is reduced to minimum and release.

IMPORTANT

5. Hold down engine shut down override switch.

6. Turn ignition key switch to the START position to crank engine and then to RUN.

Cold start-ups can result in pump failure, refer to "HYDRAULIC OIL CHART" for recommended oil viscosities and temperature ranges.

7. Release engine shutdown override once oil pressure has developed.

8. If for some reason the engine stalls while operating the machine, Turn the ignition key switch to the OFF position AND REPEAT STEPS (2) through (7).

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

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

3. Turn the ignition key switch to RUN.

IMPORTANT

4. Set throttle switch to just above IDLE.

After engine has started, keep engine speed low until engine oil pressure registers on gauge.

If it does not register within 10 seconds, stop engine and investigate cause.

5. Press and hold the cold start switch in the ON position for 20 to 25 seconds.

6. While holding the cold start switch in the ON position, crank engine until all cylinders are firing. Leave the cold start switch on for 30 seconds after the engine is running on all cylinders.

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

IMPORTANT

CAUTION

To prevent damage to starter, do not engage starter motor for more than 15 to 20 seconds.

Wait 2 minutes between each attempt to start the engine. If engine fails to start, refer to engine manufacturer operator's manual.

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

9. Adjust throttle to LOW IDLE. NOTE: If the engine does not start after three attempts, check the fuel supply system.

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

7. If the engine fails to start in 10 seconds, stop cranking, leave the cold start switch in the ON position for about 15 more seconds and then try to start the engine again.

8. Once the engine is running evenly and the engine oil pressure is at NORMAL, move the throttle control to the LOW IDLE position and allow to run for approx. 5 minutes or until the engine coolant temperature gauge begins to register.

9. Before applying any load to the engine proceed with MACHINE PREPARATION. 2.39

Tigercat 830 Feller Buncher

Controls and operation

RESTARTING AN ENGINE THAT HAS RUN OUT OF FUEL

MACHINE PREPARATION SYSTEM TEST AND WARM-UP

If the engine runs out of fuel, the fuel line must be primed: 1. Refill fuel tank completely.

Before commencing harvesting operations, follow steps (a) through (o) to accomplish the following;

2

•

Warm up the hydraulic system.

•

Test all systems for proper operation.

•

Inspect for hydraulic oil leaks.

Bleed the system according to engine manual procedures using button primer pump on fuel filter mounting head.

3. Crank engine until it starts. If it fails to start after 20 seconds, stop and wait for 2 minutes before trying again.

CAUTION If any system fails to respond to the controls, stop the warm-up procedure and call a mechanic, otherwise serious damage to pumps and other components could result.

NOTE: Do not use ether to restart an engine that has run out of fuel.

Assuming machine was parked on level ground at last shutdown: (a) Start engine. (b) Ensure gauges and warning lights are indicating normal operating conditions. (c) Check that all personnel are clear of the machine. (d) Press Pilot reset button (e) Raise throttle control to the MID position. (f) Slowly raise and lower the stick boom and the main boom, check for proper operation.

With the felling head raised slightly off the ground: (g) Operate the accumulator and clamp arms and check for proper operation. (h) Tilt the felling head forward and back and check that it is operating correctly. (i) Swing the upper to the left and right. (j) When cold weather conditions exist, continue the process of warming up the hydraulic system by repeating steps (f) through (i) several times. As the hydraulic system warms up, engine speed can be increased gradually to the HIGH IDLE position. If the FILTER BYPASS warning lights come on decrease engine speed immediately and continue warming the system. (k) Turn the saw on. (l) Observe all boom operations. If any operations are not operating as they should, take the necessary steps to correct the problem.

2.40

After completion of the warm-up and system testing, rest the felling head on the ground and turn the saw OFF.

Tigercat 830 Feller Buncher

Controls and operation OPERATING TIPS WITH LOAD SENSING

(m) Set the swing brake to the ON position. (n) Move the throttle control to LOW IDLE.

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 or pedal 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.

WARNING Ensure that the saw blade has stopped rotating before leaving the cab. (o) Leave the cab and visually check hose connections and cylinders for leaks. Check under the machine for oil leaks.

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.

WARNING

Refer to SET MARGIN PRESSURE in SECTION 4 of the SERVICE MANUAL

Never use your bare hand to check for fluid leaks.

Fluid leaks under pressure may not be visible.

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

Wear safety goggles for eye protection.

TRAVELLING (BOOM RAISED) 1. Select the appropriate drive range.

Place the track switch in the LOW or DRIVE position.

When in LOW the machine moves slower but with increased drive force. All harvesting should be done in LOW. When in DRIVE the machine moves faster but with less drive force. Travelling over longer distances (and not harvesting) should be done in DRIVE to allow for faster travel speeds when the terrain permits. Also, DO NOT travel continuously for more than 10 minutes, take 5 minute breaks, this will help prevent the track drive gearboxes from over heating.

For a more detailed description of drive range refer to TRACK, LOW/DRIVE SWITCH in THIS SECTION. 2. Place swing brake switch in OFF position.

3. Move throttle control to the HIGH idle position.

4. Operate the drive foot pedals to maneuver the machine.

2.41

Tigercat 830 Feller Buncher

Controls and operation

SPECIAL OPERATING INSTRUCTIONS FOR EFFICIENT REACH (ER) BOOM SYSTEM NORMAL HORIZONTAL REACH MOTION PERFORMANCE CAN BE EXPECTED IN THIS AREA

FELLING HEAD OPERATING INSTRUCTIONS AND SAFETY PRECAUTIONS

OPERATING THE MAIN BOOM IN THIS ZONE WITH A FULL LOAD WILL NOT ALLOW THE HORIZONTAL REACH MOTION TO PERFORM AS IT SHOULD WITHOUT ASSISTANCE FROM THE RIGHT JOYSTICK (TEXT)

1. All tree harvesting should be carried out in LOW driving range. Refer to TRACK, LOW/ DRIVE SWITCH in THIS SECTION. 2. See appendix to SECTION 1 - USING HIGH SPEED DISC SAWS SAFELY. 3. See felling head manufacturer’s manual for proper operation of the felling head.

••

•

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

830-01A

HORIZONTAL REACH MOTION CHARACTERISTICS This boom system is designed to minimize heat generation and fuel consumption during horizontal boom motion. To obtain maximum benefit from the system, the machine should be operated using mainly horizontal reaching motions as much as possible, lifting and lowering the boom only as much as necessary for positioning until the head is full.

Due to the nature of this efficient reach boom system, there will be certain conditions in which the weight of the head plus its carried load will be too great for the system to provide its intended horizontal reaching motion. This most notably occurs when the machine is operating on a hill with the head raised higher than the tracks and tucked in close to the cab. If such a situation occurs, the right joystick control should be pushed forward slightly while operating the left joystick to get the system moving. To help prevent this situation, the head should be kept as close to the ground as possible and slightly extended when climbing hills.

1. Stop the cutting disc before you leave the cutting area. Only then should you travel to the shut down area.

2. Find a parking spot on a clear and level area a least 50 feet from any other equipment.

3. Lower the cutting head until it rests on a firm and stable piece of ground.

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

5. Do not race engine before shut-off.

6. Activate PILOT SHUT OFF switch.

7. Stop engine by turning ignition switch to the OFF position.

8. Cutting disc must have stopped before you exit.

9. Perform daily maintenance at the end of the shift (Greasing, cleaning engine compartment).

This allows the machine time to cool down while under the watchful eye of the operator.

2.42

Tigercat 830 Feller Buncher

Controls and operation

CARE OF THE MACHINE

REMOVING HAIRLINE SCRATCHES

1. Ensure that all fluid levels are always at the proper level. Use the lubrication and maintenance schedule in SECTION 3 of this book.

Scratches and minor abrasions can be removed or minimized by using a mild automobile polish.

Three such products that tend to polish and fill scratches are Johnson Paste Wax, Novus Plastic Polish #1 & #2, and Mirror Glaze Plastic Polish. It is suggested that a test be made on a sample of LEXAN sheet with the product selected and that the instructions provided by the polish manufacture be followed.

2. Follow proper procedure for cleaning windows described in this section.

3. Always install door safety struts before working in the engine area.

4. Apply grease to all lubrication points at required intervals.

SOME IMPORTANT DON’TS DO NOT use abrasive or highly alkaline cleaners on LEXAN sheet products.

5. Do not apply load to a cold engine.

6. Close and secure all doors and access covers.

Never scrape LEXAN sheet products with squeegees, razor blades or other sharp instruments.

7. Do not allow branches, twigs, leaves or pine needles to build up around radiator intake doors or anywhere else on the machine. Clean as operating conditions warrant but at least once day all debris must be remove from the machine interior.

Benzene, gasoline, oil, acetone or carbon tetrachloride should never be used on LEXAN sheet products. DO NOT clean LEXAN sheet products in hot sun or at elevated temperatures.

8. Always harvest trees in LOW driving range.

9. Never park machine with felling head raised off the ground. Be sure that the felling head is resting on the ground before servicing or parking the machine.

Compatible Cleaning Agents Aqueous Solutions of Soaps and Detergents Formula 409 Top Job Freon T.F. VM&P grade Naphtha Joy Windex with Ammonia D Palmolive Liquid

CLEANING INSTRUCTIONS FOR LEXAN WINDOWS

GRAFFITI REMOVAL

NOTE: On the Tigercat 822 and 830 all of the windows are made of LEXAN MARGARD.

(A) Butyl Cellosolve (For removal of paints, marking pen inks, etc.) The use of masking tape, adhesive tape or lint removal tools works well for lifting off old weathered paints.

1. Rinse with lukewarm water.

2. Using a soft cloth or sponge, gently wash the sheet with a mild solution of soap or detergent and lukewarm water. DO NOT scrub or use brushes or squeegees.

(B) To remove labels, stickers, etc., the use of kerosene, VM&P Naphtha, or petroleum spirits is generally effective. When the solvent will not penetrate sticker material, apply heat (hair dryer) to soften the adhesive and promote removal. GASOLINE SHOULD NOT BE USED.

3. Rinse with clean lukewarm water.

4. Dry thoroughly with a chamois or moist cellulose sponge to prevent water spotting.

To remove wet paint, glazing compound or grease, rub lightly (not in direct sunlight) with a good grade of VM&P naphtha, isopropyl alcohol or butyl cellosolve (2-Butoxy Ethanol), then wash and rinse thoroughly. DO NOT USE GASOLINE. Gasoline or oil will cause uncoated LEXAN to become opaque. MARGARD coated lexan will start to become opaque around the edges and creep in.

2.43

Tigercat 830 Feller Buncher

Controls and operation

2.44

Tigercat 830 Feller Buncher SECTION 3 - LUBRICATION & MAINTENANCE JUNE 2003

CONTENTS - SECTION 3 AIR INTAKE CLEAN-OUT COVER PLATE .............................................................. 3.19 AIR INTAKE SEAL .................................................................................................... 3.19 EFFICIENT REACH (ER) BOOM SYSTEM .............................................................. 3.10 EMERGENCY EXITS, CHECK MONTHLY ................................................................. 3.3 ENGINE AIR CLEANER ............................................................................................ 3.18 FILTER RESTRICTION INDICATOR .................................................................... 3.19 ENGINE AIR CLEANER UNLOADER VALVE .......................................................... 3.18 FILTER AND LUBRICATION SCHEDULE ................................................................. 3.8 FILTERS CHANGING CHARGE FILTERS ........................................................................... 3.16 CHANGING HYDRAULIC RETURN FILTERS ..................................................... 3.14 CHARGE PRESSURE FILTER, FAN DRIVE ....................................................... 3.16 ENGINE AIR FILTER ............................................................................................ 3.18 FUEL FILTER/WATER SEPARATOR .................................................................. 3.12 FUEL TANK STRAINER ........................................................................................ 3.13 HYDRAULIC OIL RETURN FILTERS ................................................................... 3.14 HYDRAULIC OIL RETURN STRAINERS/DIFFUSERS ....................................... 3.17 PILOT CHARGE FILTER, MEDIUM PRESSURE ................................................. 3.16 REMOVE AND REPLACE ..................................................................................... 3.12 SERVICING GUIDELINES FOR OIL FILTERS .................................................... 3.15 FIRE PREVENTION .................................................................................................... 3.3 FUEL SHUT-OFF VALVE .......................................................................................... 3.12 GENERAL MAINTENANCE ........................................................................................ 3.3 HYDRAULIC OIL FILTERS ....................................................................................... 3.14 HYDRAULIC OILS ....................................................................................................... 3.7 LUBRICATE GEARBOX LOWER BEARINGS ........................................................... 3.9 LUBRICATION POINTS DIAGRAM ............................................................................ 3.6 LUBRICATION SCHEDULE ........................................................................................ 3.8 NEW MACHINE MAINTENANCE ...............................................................................

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

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

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

3.2 3.2 3.2 3.2

OIL LOST FROM LEAKAGE ....................................................................................... 3.2 PRESSURE SETTING PROCEDURES. SEE SERVICE MANUAL PRESSURE SETTING VALUES. SEE SERVICE MANUAL PREVENTIVE MAINTENANCE SCHEDULE .............................................................. 3.2 PUMP DRIVE GEARBOX MAINTENANCE GUIDE .................................................. 3.11 RETURN FILTERS ~ HYDRAULIC OIL .................................................................... 3.14 SCHEDULED MAINTENANCE FREQUENTLY .........................................................................................................

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

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

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

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

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

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

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

LUBRICATION POINTS DIAGRAM ........................................................................

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

3.3 3.4 3.4 3.5 3.5 3.6 3.6 3.6 3.6 3.9

TORQUE CHART, GENERAL ................................................................................... 3.23 TORQUE SETTINGS, RECOMMENDED ................................................................. 3.22

Tigercat 830 Feller Buncher

Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE FOR 830 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 Engine mounting bolts Pump mounting bolts

IMPORTANT

Track shoe bolts

BEFORE DRIVING MACHINE ENSURE THAT THE TRACK TENSION (SAG) IS SET CORRECTLY. TRACK SAG MAY BE SET LESS THAN SPECIFIED FOR SHIPPING PURPOSES. REFER TO SECTION 11 IN THE SERVICE MANUAL FOR THIS PROCEDURE.

Track roller retaining bolts Track sprocket retaining bolts 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 830 Feller Buncher

Lubrication and Maintenance

GENERAL CHECK EMERGENCY EXITS MONTHLY~

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.

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.

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.

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

Clean up spills as soon as possible.

FIRE PREVENTION

Always release pressure in hydraulic tank Before breaking a connection.

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

Always use clean oil and containers.

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

Drain dirty oil while still warm.

Do not exceed recommended fluid levels.

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

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

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

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

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

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

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

Clean away all branches, bark and chips.

Clean up all traces of oil to avoid fires.

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

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

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

Always have a fire extinguisher at hand.

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

Always install door safety struts when working on machine.

Clean fire suppression system sensors.

3.3

Tigercat 830 Feller Buncher

Lubrication and Maintenance

SCHEDULED MAINTENANCE Lubricate:~

FREQUENTLY:~

• Swing pinion; 1-fitting - 10 shots

• Check engine cooling air intake screens for possible restriction.

• Cylinders, Levelling; 4-fittings total - purge • ‡ Boom joints:

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

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

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

Efficient Reach System; 12-fittings - purge • ‡ Cylinders; boom, stick & tilt; Standard Boom; 6-fittings - purge

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

Efficient Reach System; 8-fittings - purge ‡ Lubricating cylinder pins and boom joints:1. Ensure machine is on level ground 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.

Clean:~

EVERY 8 HOURS:~ • Perform "frequently" maintenance

• Oil cooler, engine radiator and enclosure screens.

And in addition:~

• Remove potentially damaging limbs or sticks.

Check:~

• Check engine coolant level • Check engine oil level • Check pump drive gearbox PTO oil level in bottle

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

• Drain water from fuel/water separator

• For loose nuts, bolts and fittings.

• Check intake and discharge areas of engine air precleaner

• Condition and tension of fan belts.

• Check pump drive gearbox oil level

• Visually check condition of tracks.

• Check air cleaner unloader valve

• Conduct an overall visual inspection.

• Check air filter resriction indicator

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

• Check hydraulic oil level

EVERY 24 HOURS :~ • Perform "frequently"maintenance • Perform 8 hour maintenance And in addition:~ • Lubricate swing bearing; 1-fitting - 10 shots while swinging

3.4

Tigercat 830 Feller Buncher

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 125 HOURS:~

EVERY 250 HOURS:~

• Perform "frequently" maintenance

• Perform "frequently" maintenance

• Perform 8 hour maintenance

• Perform 8 hour maintenance

• Perform 24 hour maintenance

• Perform 24 hour maintenance

And in addition check:~

• Perform 125 hour maintenance

• Return filter bypass warning light is NOT ON with engine running at high idle and oil flow when oil is at operating temperature

And in addition Lubricate:~ • Check all hydraulic pressures

• Medium pressure pilot filter restriction indicator with engine running at high idle and oil flow • Track drive gearbox oil level with one level plug at 6 O'Clock and the other at 9 O'Clock • Fluid level in batteries unless maintenance free • Engine r.p.m.

• Leveller, intermediate pivot points; 2-fittings total - purge.

Remove/replace protection plugs to access.

• Leveller, upper pivot points; 4-fittings total - purge.

Remove/replace protection plugs to access.

• Pump drive gearbox input shaft spline; 1 fitting - 1 shot. - Fitting located in centre of gearbox between pumps. Do not use a power grease gun.

• Hydraulic pump and motor securing bolts • Torque tightening points as per new machine maintenance Visually check for damage to:~

• Lubricate swing drive gearbox lower bearing; 2-fittings - 5 shots each ‡

• Main and stick booms • Tracks, track frames and carbody • Swing bearing area • Attachment Make repairs immediately Visually inspect for:~ • Frayed electrical wiring and hydraulic hoses NOTE: Neglecting the propper maintenance of these items can result in fire.

‡ With swing gearbox at operating temperature slowly add 5 shots of lithium based EP2 to each side of the gearbox. Note: During cold weather applications the swing function must be operated for several hours to achieve operating temperature. Caution: Do not force grease, gearbox failure may result. Do not use winter grease. Grease should purge from gearbox pinion seal.

• Replace engine oil and filter.

• Replace oil in pump drive gearbox.

• Wear in any other components Clean/replace:~

• Replace engine fuel filter(s).

• Inspect for debris buildup between radiator and oil cooler

• Replace filter in fuel filter/water separator.

• Air conditioner re-circulation filter

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

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

3.5

• Replace air intake primary element.

Tigercat 830 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 charge pilot filter.†

• Replace air cleaner unloader valve

• Hydraulic oil charge filter, fan drive.† Lubricate:~

EVERY 2000 HOURS:~

• Power door hinges; 2 fittings - 1 shot.

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

• Door cylinder pins apply oil liberally.

• Other door hinges; apply oil liberally.

Check:~

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

• Torque on swing bearing and swing gearbox retaining bolts.

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

• Torque on track drive gearboxes and motor mounting bolts.

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

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

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

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

LEVELLING CYLINDER 2 FTG/8 !

LEVELLING CYLINDER 2 FTG/8 !

•

• • • UPPER PIVOT BEARING

THRUST BEARING

2 FTG/250 !

1 FTG/8 !

2 SIDES 830-09

•

2 SIDES

LEVELLER COMPONENT LUBRICATION POINTS 3.6

INTERMEDIATE PIVOT BEARING 1 FTG/250 !

2 SIDES

Tigercat 830 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 swing brake.

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

Tigercat

HYDRAULIC OIL OPERATING RANGE (Not suitable for axle applications)

OPERATING TEMP. RANGE LOWEST START-UP TEMP.

HYDRAULIC OIL TEMPERATURE -40

OIL TYPE

-40

-30 -20

-20 0

-10

0 20

10 40

20 60

30 80

40

50

60

70

100

120

140

160

80 180

90 200

100

˚C 220˚F

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

CAUTION

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

5168AR03

3.7

Tigercat 830 Feller Buncher

Lubrication and Maintenance

Tigercat® Model 830 and LEVELLER FILTER AND LUBRICATION SCHEDULE REFER TO Tigercat OPERATOR'S MANUAL FOR FURTHER INFORMATION CAPACITY

57

15

25.5

6.75

QTY

USG

REMARKS/LUBRICANT

LITRE

2000 !

1000 !

500 !

250 !

8!

DESCRIPTION

125 !

SERVICE POINT NO.

SERVICE EVERY

1

COOLING SYSTEM

CHK

CHANGE COOLANT EVERY 2 YEARS

2

ENGINE OIL/FILTER; SISU ENGINE

CHK

REP

3

FUEL FILTER (ENGINE)

4

FUEL/WATER SEPARATOR

5

IN-TANK FUEL STRAINER

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 †

2

12

HYDRAULIC FAN DRIVE CHARGE PRESSURE FILTER

REP †

1

13

PUMP DRIVE GEARBOX;

REP DRN

15

16

CHK

1 REP

1

REP

CHK

CHK

- SPLINE ADAPTERS LUBRICATION PUMP POSITIONS 'A' AND 'B' (TOP)..

PUMP POSITION 'C' (BTM)………...…

CHK CHK

D/R

19

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

LUB

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

LUB

1

1

1

1

1 SHOT

D/R

LUB 24HR *** LUB

SWING PINION

35 ..66

3.75

CHK

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

134 ..250

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 ON LATER MACHINES

CHECK OIL LEVEL AT SIGHT GAUGE. FILL WITH MIL-L-2105C OR API-GL-5 BELOW -10°F (-23°C) USE 75W-90 UP TO 100°F (38°C) USE 80W-90 ABOVE 100°F (38°C) USE 85W-140

CHECK PTO (POWER TAKE OFF) OIL LEVEL IN RESERVOIR BOTTLE FILL WITH MIL-L-2105C OR API-GL-5

CHK ‡

18

1

D/R

LUB

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

17

20

1 CHK

- OIL LEVEL

SWING BEARING ***

SEE ENGINE MANUFACTURER’S SERVICE MANUAL 1

REP

- SPLINE ADAPTER LUBRICATION INPUT SHAFT……………………..…..

14

60/40 ANTIFREEZE **

LUB³

6

1.5

7.6

2

1

10 SHOTS

1

10 SHOTS

1

5 SHOTS EACH FITTING

2

LITHIUM BASE EP2 GREASE " 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

PURGE 6 12 12

LITHIUM BASE EP2 GREASE " PURGE PURGE

8 10

21

LEVELLER CYLINDERS

LUB

PURGE

4

LITHIUM BASE EP2 GREASE "

22

LEVELLER THRUST BEARING

LUB

PURGE

2

LITHIUM BASE EP2 GREASE "

23

LEVELLER PIVOTS

24

POWER DOOR HINGES

LUB LUB

25

DOOR CYLINDER PINS

LUB

26

FELLING ATTACHMENT

PURGE

4

LITHIUM BASE EP2 GREASE "

1 SHOT

6

LITHIUM BASE EP2 GREASE "

LUB

2

APPLY OIL LIBERALLY

SEE MANUFACTURER'S MAINTENANCE SCHEDULE

" LITHIUM BASED EP2 GREASE CONTAINING MOLYBDENUM DISULFIDE

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

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

830LUBCHART.XLS R2 05/03

3.8

Tigercat 830 Feller Buncher

Lubrication and Maintenance

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

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

LUBE FITTINGS

••

••

845B-D33

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

3.9

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

• TIP OF STICK BOOM FULLY SUPPORTED 830-07

ER. BOOM SYSTEM. FIG.1

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

3.10

Lubrication and Maintenance

Tigercat 830 Feller Buncher PUMP DRIVE GEARBOX MAINTENANCE GUIDE

Lubrication and Maintenance

INTERNAL LUBRICATION

••

The internal components of the pump drive gearbox are "splash" lubricated by the action of the gears when turning. It is very important to maintain the correct level of oil in the gearbox at all times. An oil level sight gauge is remote mounted to the side of the upper frame. A drain/fill hose is located close to the sight gauge. Oil level must be check with oil HOT, but always wait at least 5 minutes after stopping engine before checking oil level.

FEED LINE CONNECTION

••

VENT LINE CONNECTION 830-D13 PUMP PAD SPLINE LUBRICATION the splines and couplings to receive lubricant. The lubricant, (see chart) is stored in a reservoir bottle and is gravity fed through three hoses connected to the bottom ports of the adapters pads. Three additional hoses connected to the top adapter ports vent the lubrication lines back to the top of the reservoir bottle.

PUMP DRIVE GEARBOX OIL LEVEL GAUGE

•• PUMP DRIVE GEARBOX DRAIN/FILL HOSE

PUMP DRIVE GEARBOX

VENT LINE CONNECTION

•• PUMP DRIVE GEARBOX OIL LEVEL GAUGE The oil in the gearbox should be changed at the specified time intervals in the lubrication schedule chart or whenever the oil shows traces of dirt or effects of high temperature evidenced by discoloration or strong odor. Always drain oil while still warm and examine for contamination of metal particles which if present could indicate worn gear teeth or imminent bearing failure.

PUMP PAD SPLINE LUBRICATION The three pump mounting adapter pads on this gearbox each incorporate a lubrication port to allow RESERVOIR BOTTLE

•

BREATHER HOSE

•• ••

VENT RETURN LINES

830-D14 PUMP PAD SPLINE LUBRICATION INPUT SHAFT LUBRICATION

The input shaft spline and mating spline on the flexible drive plate are grease lubricated. A grease fitting is installed in the end of the input shaft. The grease fitting is located in between the centers of the three pump mounting pads and is accessible from the front of the gearbox.

Refer to FILTER AND LUBRICATION SCHEDULE and SCHEDULED MAINTENANCE in THIS SECTION for the oil and grease specifications, quantities and frequency.

GREASE FITTING SHAFT SEAL

••

PUMP DRIVE GEARBOX

••

••

830-D12

BREATHER

••

830-D09

LUBRICANT FEED LINES

••

PUMP DRIVE GEARBOX

INPUT SHAFT

••

830-D05

RESERVOIR BOTTLE 3.11

•• •

••

INPUT SHAFT LUBRICATION

Tigercat 830 Feller Buncher FILTERS - REMOVE AND REPLACE

Lubrication and Maintenance 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.

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

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.

822-D34

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

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

•

PRIMING PUMP

WATER SEPARATOR BOWL

DRAIN TAP

•• 822-D53

••

FUEL FILTER/WATER SEPARATOR

FUEL SHUT-OFF VALVE

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.

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.

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

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

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

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

2. Open engine enclosure doors fully.

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

3. Turn battery disconnect switch to the OFF position.

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

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

3.12

Tigercat 830 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.

CLEANOUT COVER

•• DRAIN PLUG

•• 822-D56

FUEL TANK STRAINER

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

822-D55

8. Check for an accummulation of foreign materials where the strainer screws onto the pipe and elbow.

FUEL TANK CLEANOUT COVER

9. Reinstall the strainer using the hex on end.

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

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

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.

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

REMOVE THE LIGHT HOUSING/STEP DOOR AND ADJACENT CORNER PANEL

••

830-D41

••

ACCESS TO FUEL TANK

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

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

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

3.13

Tigercat 830 Feller Buncher

Lubrication and Maintenance

HYDRAULIC FILTER SERVICING GUIDELINES

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

IMPORTANT

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

HYDRAULIC TANK PRESSURE GAUGE

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

•

••

•• •• ••

••

1 - WATER ABSORBING RETURN FILTER (COLOUR BLUE)

HYDRAULIC OIL FILTERS

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

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

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

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

•

••

422-07

RETURN MANIFOLD

5 - HYDRAULIC RETURN FILTERS

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

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

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

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

3.14

Tigercat 830 Feller Buncher

Lubrication and Maintenance FILTER HEAD

•

AIR VENT VALVE

• GASKET

•

DRIP TRAY DRAIN HOLE/HOSE

SQUARE SECTION GASKET INSTALLATION

•

FILTR_SEALS 2

Tighten filter an additional 3/4 turn.

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

AIR VENT VALVE 4. Wearing face protection, Release air from the hydraulic reservoir by opening the AIR VENT VALVE. NOTE: Air pressure expelling from vent valve will blow accumulated loose debis in try 822-D35

FILTER HEAD

• • GASKET

•

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

FILTR_SEALS 2

'O' RING GASKET INSTALLATION

Remove used gasket and clean gasket seat in head.

HYDRAULIC OIL FILTERS

•

Apply clean oil to new gasket surfaces.

DRIP TRAY

DRAIN HOSE

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)

6. Drain away any accululation 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 ELEMENT

$ 'O' Ring Gasket

••

822-D69

FILTER ELEMENT

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.

Square Section Gasket

9. Start the engine and check for leaks.

Remove used gasket and clean groove in head.

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

Apply clean oil to new gasket surfaces.

Install new gasket into groove in filter head.

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

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

3.15

Tigercat 830 Feller Buncher

Lubrication and Maintenance CHARGE PRESSURE FILTER ~ FAN DRIVE

CLOG INDICATOR SIGHT GLASS

••

••

FILTER CLOG INDICATOR

The fan drive charge circuit contains a single element Tigercat hydraulic filter with a restriction indicator sending unit (not used) and a 50 psi third port bypass valve. When a restriction is encountered, the bypass valve in the filter head opens and diverts oil back to tank via the third port to prevent unfiltered oil from entering the fan drive circuit.

PUMP DRIVE GEARBOX OIL LEVEL GAUGE

CHARGE PILOT FILTER

•

FAN DRIVE CHARGE PRESSURE FILTER

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

••

Changing the filters: 1. Park machine on flat ground with with upper structure level and with felling head resting on the ground and stop engine.

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

3. Release air from the hydraulic reservoir by opening the AIR VENT VALVE. 4.

•• 395-15

PILOT FILTER AND FAN CHARGE PRESSURE FILTERS MEDIUM PRESSURE CHARGE PILOT FILTER There is a medium pressure charge pilot filter mounted to the base of the charge/pilot/filter manifold. The filter receives hydraulic oil from the charge pump. The charge pump is a gear pump driven from the power take-off of the main pump and supplies pilot oil via the filter and the charge/pilot/filter manifold to the pilot system.

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.

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

6. Place rags below to catch any spilt oil.

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

Mounted on top of the manifold is 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 50 psi exists across the filter, the indicator will show RED, indicating a clogged filter.

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

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

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

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

11. DO NOT prefill the filter*. Lubricate any new o-rings and seals with clean hydraulic and install the new filter element.

12. Close air vent ball valve.

13. Start the engine and check for leaks.

For service and replacement intervals see SERVICE AND LUBRICATION CHART in THIS SECTION. 3.16

*Refer to HYDRAULIC FILTER SERVICING GUIDELINES on PREVIOUS PAGE.

Tigercat 830 Feller Buncher

Lubrication and Maintenance

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

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

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

STRAINERS

'O' RING

ACCESS COVER

ROUND ACCESS COVER

•

••

•

•• ••

• 409-04

HYDRAULIC OIL TANK

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

• PUMP SUCTION SHUT-OFF VALVE

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

DRAIN PLUG

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

822-06

2. Stop engine.

•

DRAIN PLUG (ONLY ACCESSIBLE WITH MAIN CONTROL VALVE REMOVED)

HYDRAULIC OIL TANK

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

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

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

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

5. Turn BATTERY DISCONNECT SWITCH to the OFF position.

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

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

••

12. Reinstall the strainers using the hex on end.

••

AIR VENT FILTER

14. Connect sensor wires to sensors on access cover.

AIR VENT VALVE

822-D35

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

HYDRAULIC OIL TANK

15. Refill and check for leaks.

16. Ensure that the air vent valve is closed.

3.17

Tigercat 830 Feller Buncher ENGINE AIR INTAKE

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.

TO TURBO CHARGER

•• •

•

AIR CLEANER

•• AIR CLEANER UNLOADER VALVE

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

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

PRECLEANER

•

354-15

AIR CLEANER

•

SAFETY ELEMENT

••

PRIMARY ELEMENT

••

••

•

••

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

ONLY THE PURIFIED AIR GOES TO THE AIR FILTER

822-D57

AIR CLEANER ELEMENTS

AIR CLEANER TURBO 2

PRECLEANER OPERATION

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

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

Refer to AIR CLEANER MAINTENANCE in THIS MANUAL.

DISCHARGE PORT AREA

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

218-21B

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

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

PRECLEANER

3.18

Tigercat 830 Feller Buncher

Lubrication and Maintenance

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

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.

FILTER RESTRICTION INDICATOR

•

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.

822-D42

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

FILTER RESTRICTION INDICATOR

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

•

CHECK CONDITION OF SEAL

••

CLEAN OUT COVER

822-D58

PRECLEANER

AIR INTAKE SEAL

• Continued on page 20

421-15A

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

3.19

Tigercat 830 Feller Buncher

Lubrication and Maintenance

Continued from page 19

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

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

Looks can be deceiving. A filter that looks dirty is actually more efficient than one that is clean. A filter with dust build up on the media reaches nearly 100% dust cleaning efficiency.

Only when a filter is so clogged with dirt that air restriction goes beyond engine manufacturer’s guidelines, should a filter be replaced.

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

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

4. Always clean the inside of the outlet tube.

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

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

NOTE: This does not apply to oil filters.

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

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

3.20

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.

Tigercat 830 Feller Buncher

Lubrication and Maintenance

3.21

Tigercat 830 Feller Buncher

Lubrication and Maintenance

TORQUE CHART LOCATION

THREAD DIAMETER

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

TORQUE (LUBRICATED) lbf-ft Nm

M18

6980 270

9460 367

M16

3522 197

4780 267

M16

4159 126

5640 171

M22

3200 480

4340 650

Cylinder pin retaining bolts

M20

380

515

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

M20

400

530

1" UNC

475

625

7/8" UNC

450-500

620-680

Swing gearbox mounting bolts

M16

200

275

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

M24 M22 M12 M12

675 540 80 80

925 725 110 110

3/8" UNC M10

33-36 47

45-49 63

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

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

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

Cab securing bolts Swing bearing Swing bearing bolts

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

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

3.22

Tigercat 830 Feller Buncher

Lubrication and Maintenance

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

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

IMPERIAL

GRADE 5 BOLTS

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

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

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

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

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

METRIC

SIZE

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

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

M6 M8 M10

4.8 12 23

3.5 8.5 17

6 15 29

4.5 11 21

9 22 43

6.5 16 32

11 28 55

8.5 20 40

13 32 63

9.5 24 47

17 40 80

12 30 60

15 37 75

11.5 28 55

19 47 95

14.5 35 70

M12 M14 M16

40 63 100

29 47 73

50 80 125

37 60 92

75 120 190

55 88 140

95 150 240

70 110 175

110 175 275

80 130 200

140 225 350

105 165 225

130 205 320

95 150 240

165 260 400

120 190 300

M18 M20 M22

135 190 260

100 140 190

175 240 330

125 180 250

260 375 510

195 275 375

330 475 650

250 350 475

375 530 725

275 400 540

475 675 925

350 500 675

440 625 850

325 460 625

560 800 1075

410 580 800

M24 M27 M30

330 490 675

250 360 490

425 625 850

310 450 625

650 950 1300

475 700 950

825 1200 1650

600 875 1200

925 1350 1850

675 100 1350

1150 1700 2300

850 1250 1700

1075 1600 2150

800 1150 1600

1350 2000 2700

1000 1500 2000

M33 M36

900 1150

675 850

1150 1450

850 1075

1750 2250

1300 1650

2200 2850

1650 2100

2500 3200

1850 2350

3150 4050

2350 3000

2900 3750

2150 2750

3700 4750

2750 3500

ISSUE 3 800

3.23

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

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

Tigercat 830 Feller Buncher

Lubrication and Maintenance

3.24