Tigercat H820D HARVESTER OPERATOR'S MANUAL - PDF DOWNLOAD

H820D HARVESTER

OPERATOR'S MANUAL SERIAL NUMBER 82031001 – 82032000

ISSUE 2.0, FEBRUARY 2017 Tigercat Industries Inc. P.O. Box 637 Brantford, Ontario Canada N3T 5P9 Tel: (519) 753-2000 Fax: (519) 753-8272

Tigercat H820D Harvester TABLE OF CONTENTS SECTION INTRODUCTION................................................................................................................................................. v MACHINE IDENTIFICATION AND SERIAL NUMBERS..................................................................................... vi SAE STANDARDS FOR MACHINE OPERATOR PROTECTIVE STRUCTURES.............................................vii NON-APPROVED FIELD PRODUCT CHANGES.............................................................................................viii REGULATORY INFORMATION.......................................................................................................................... xi SAFETY...............................................................................................................................................................1 CONTROLS AND OPERATION...........................................................................................................................2 LUBRICATION AND MAINTENANCE.................................................................................................................3

CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.

H820D Available Literature Operator's Manual (this manual).....................................................................................................Part No. 47776AENG Service Manual................................................................................................................................Part No. 47777AENG Parts Catalog...................................................................................................................................Part No. 47778A Vehicle Moving and Transporting Instructions.................................................................................Part No. 44821AMUL Engine Operation and Maintenance Manual, N67 T2.....................................................................Part No. 45045AMUL Engine Operation and Maintenance Manual, N67 T4f....................................................................Part No. 42939AMUL iii

INTRODUCTION................................................................................................................................................. v

Tigercat H820D Harvester 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 H820D Harvester.

Serial numbers: H820D 82031001 – 82032000 NOTE: The 4th digit in the machine serial number indicates the machine model type. For example 1 = Feller Buncher and 2 = Leveling Feller Buncher. For simplicity throughout this manual the 4th digit has been replaced with an asterisk to indicate that both types of machine models are affected, i.e. 8XX*3001 – 8XX*4000.

The H820D Harvester is designed for harvesting trees, thinning and final felling, limbing and debarking applications in plantations and natural stands.

The Operator's manual will assist the operator with the techniques of proper and safe operation of the H820D Harvester. There is also important information regarding the safe operation of the attachment. 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, DANGER, 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.

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

If the machine in question was built after the release date of this manual and there is a discrepancy, call Tigercat service department.

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

All product or company names that may be mentioned in this publication are trade names, trademarks or registered trademarks of their respective owners.

Tigercat Industries Inc.

v

MACHINE IDENTIFICATION AND SERIAL NUMBERS..................................................................................... vi

Introduction

Tigercat H820D Harvester

MACHINE IDENTIFICATION AND SERIAL NUMBERS Please record all serial numbers related to this machine below and have ready before calling for assistance.

Engine Identification Label Location - Earlier Machines

On earlier machines the engine identification label is located on top of the engine beside the oil fill cap.

Machine Serial Number Plate Location– Cab

The machine serial number plate is located inside the cab behind the operator's seat.

800523

Engine Identification Label and Serial Number Stamp Location

On later machines the engine identification label is located on top of the right engine mount lug The engine serial number is also stamped on the right side of the engine, below the exhaust manifold.

Engine Serial Number: Machine Serial Number Stamp Location– Upper Structure

The machine serial number is also stamped on the top side of the upper structure near the boom saddle.

Engine Date of Manufacture:_______________________

Machine Model Number:__________________________

Machine Serial Number:__________________________

Model Year:____________________________________

vi

SAE STANDARDS FOR MACHINE OPERATOR PROTECTIVE STRUCTURES.............................................vii

Tigercat H820D Harvester

Introduction

SAE STANDARDS FOR MACHINE OPERATOR PROTECTIVE STRUCTURES THIS OPERATOR ENCLOSURE MEETS THE FOLLOWING STANDARDS: • ISO 8082-2:2011 ROLL OVER PROTECTION STRUCTURES (ROPS) • ISO 8083:2006 11 600 J FALLING OBJECTS PROTECTION STRUCTURES (FOPS) • ISO 8084:2003 OPERATOR PROTECTION STRUCTURES (OPS) • ISO 2867:1994 • OREGON OSHA 437-007-0775:14a,b,c • SAE J2267:2007 (OFPS)

MODIFICATIONS AND REPAIRS The integrity of the structure, and its continued ability to provide the level of protection it was designed for, could be seriously affected by any modifications to the structure, its mounting, or to the chassis to which it is attached.

Tigercat emphasizes the certification of approval of the structure will become void if any such modifications take place.

Tigercat may officially grant approval for modifications only by: • Written approval of repairs or modifications signed by the Tigercat Engineering Manager; or • Approved modifications officially released by Tigercat.

Approval will be granted, provided the work is carried out in the factory approved manner.

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

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

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

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

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

Tigercat Industries Inc.

vii

NON-APPROVED FIELD PRODUCT CHANGES.............................................................................................viii

Introduction

Tigercat H820D Harvester

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: • 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.

• 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.

viii

Tigercat H820D Harvester

Introduction

REGULATORY INFORMATION The operator's cab is equipped with standard or optional equipment that is capable of emitting radio frequency fields.

Bluetooth and WiFi exposure limits are significantly less than the maximum permitted for public use.

IMPORTANT! The telematics satellite antenna is externally mounted to the operator cab. When transmitting, the external antenna should always be separated from personnel by a minimum distance of 20 cm (8 in). Transmissions can be silenced by placing the telematics system in repair mode.

FEDERAL COMMUNICATIONS COMMISSION NOTIFICATIONS TO USER INTERNAL (OPERATOR'S CAB): Telematics Module (WiFi)

Contains FCC ID: NCMOCG2101

IQAN-G11 (Bluetooth)

Contains FCC ID: VPYLBZY

Radio (Bluetooth)

Contains FCC ID: OPDJHD36A

Radio (Bluetooth)

Contains FCC ID: OPDJHD1635BT

Radio (Bluetooth)

Contains FCC ID: OPDJHD3630BT

EXTERNAL: Inmarsat Modem (Satellite)

Contains FCC ID: B92IDP1XX

Iridium Modem (Satellite)

Contains FCC ID: Q639603N

These devices comply with part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.

Changes or modifications not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment.

This equipment complies with FCC radiation exposure limits set forth for an uncontrolled environment and meets the FCC radio frequency (RF) Exposure Guidelines. This equipment has very low levels of RF energy that is deemed to comply without maximum permissive exposure evaluation (MPE).

INDUSTRY CANADA NOTIFICATIONS TO USER INTERNAL (OPERATOR'S CAB): Telematics Module (WiFi)

Contains IC ID: NCMOCG2101

IQAN-G11 (Bluetooth)

Contains IC ID: VPYLBZY

EXTERNAL: Inmarsat Modem (Satellite)

Contains IC ID: B92IDP1XX

Iridium Modem (Satellite)

Contains IC ID: Q639603N

These devices comply with Industry Canada licence-exempt RSS standard(s). Operation is subject to the following two conditions: (1) this device may not cause interference, and (2) this device must accept any interference, including interference that may cause undesired operation of the device.

This equipment complies with IC radiation exposure limits set forth for an uncontrolled environment and meets RSS102 of the IC radio frequency (RF) Exposure rules. This equipment has very low levels of RF energy that is deemed to comply without maximum permissive exposure evaluation (MPE).

ix

Introduction

Tigercat H820D Harvester

x

SAFETY...............................................................................................................................................................1

Tigercat H820D Harvester SECTION 1– SAFETY Always read and understand the entire contents of THIS MANUAL, and all manuals for any attachments or accessories associated with this machine, prior to operating or servicing this equipment.

CONTENTS – SECTION 1

ISSUE 2.0, FEBRUARY 2017

A

AVOID INJURY FROM BACKOVER ACCIDENTS........................................................................................................ 1.8 B

BATTERY DISCONNECT SWITCH............................................................................................................................ 1.15 BATTERY SAFETY....................................................................................................................................................... 1.8 BOOM SYSTEM PRECAUTIONS............................................................................................................................... 1.18 C

CAB EXITS.................................................................................................................................................................. 1.10 SAFETY INTERLOCK SWITCH– FRONT DOOR.................................................................................................... 1.10 CHAIN SHOT.............................................................................................................................................................. 1.12 COOLING SYSTEM.......................................................................................................................................... 1.17, 1.40 D

DIESEL EXHAUST FLUID (DEF).................................................................................................................................. 1.9 E

ENGINE DOORS......................................................................................................................................................... 1.17 ER BOOM SYSTEM.................................................................................................................................................... 1.21 EXHAUST FUMES............................................................................................................................................ 1.18, 1.19 F

FIRE PREVENTION DRY CHEMICAL CLEANUP PROCEDURES.......................................................................................................... 1.29 FIRE PREVENTION GUIDELINES.......................................................................................................................... 1.26 WHAT TO DO AFTER A MACHINE FIRE HAS OCCURRED.................................................................................. 1.29 WHAT TO DO TO PREPARE IN THE EVENT OF A MACHINE FIRE..................................................................... 1.27 WHAT TO DO WHEN A MACHINE FIRE OCCURS................................................................................................ 1.28 FLUID INJECTION INJURY........................................................................................................................................ 1.21 G

GENERAL SAFETY PRECAUTIONS........................................................................................................................... 1.4 GREASE INJECTION INJURY.................................................................................................................................... 1.22 H

HAZARD ZONE............................................................................................................................................................. 1.5 L

LIGHTENING SAFETY AWARENESS LIGHTNING SAFETY............................................................................................................................................... 1.23 WHAT IS A LIGHTNING STRIKE?........................................................................................................................... 1.23 LOOSE CLOTHING HAZARD..................................................................................................................................... 1.18 M

MACHINE STABILITY AND TRACTION...................................................................................................................... 1.11 O

OPERATING SAFETY PRECAUTIONS........................................................................................................................ 1.9 P

PARKING THE MACHINE........................................................................................................................................... 1.15 PROTECTIVE CLOTHING............................................................................................................................................ 1.4 S

SAFETY INTERLOCK SWITCHES– FRONT DOOR.................................................................................................. 1.10 SAFETY SIGNAL WORDS............................................................................................................................................ 1.4 SERVICING SAFETY PRECAUTIONS....................................................................................................................... 1.16 PRIOR TO WELDING.............................................................................................................................................. 1.20 W

WELDING, PRIOR TO................................................................................................................................................ 1.16 WORKING WITH OIL.................................................................................................................................................... 1.6

Safety

Tigercat H820D Harvester

1.2

Tigercat H820D Harvester

Safety

Noise Level Inside Cab dB(A)

As per Tigercat test ETR00047 Microphone direction: Forward Rear Left Right Driving max speed (High) 77 76 77 76 Driving max speed (Low) 73 72 72 73 Boom operation 72 73 72 73 NOISELEVELS.XLS

Wear a suitable hearing protective device such as earmuffs or earplugs to protect against noise. Prolonged exposure to loud noise can cause impairment or loss of hearing. This machine exceeds 70 dB(A) in the cab and exceeds 85 dB(A) when servicing the machine engine.

Check with your local Safety Commission to determine if hearing protection is required at these levels.

Vibration Level - Whole-body As per Tigercat test ETR007 & ISO 2631-1 Weighted rms acceleration (m/s2) Seat Seat-back Health Comfort Driving max speed (High) 0.2370 x-axis (back-to-chest) 0.5630 0.2310 y-axis (right-to-left) 0.3200 0.4660 z-axis (buttocks-to-head) 0.2110 S 0.6571 0.5700 0.4850 Driving max speed (Low) 0.1140 x-axis (back-to-chest) 0.2150 0.0764 y-axis (right-to-left) 0.0977 0.2170 z-axis (buttocks-to-head) 0.0669 S 0.2890 0.2568 0.1800 Boom operation x-axis (back-to-chest) 0.6140 0.4510 y-axis (right-to-left) 0.2470 0.3710 z-axis (buttocks-to-head) 0.0838 0.4440 S 0.9304 0.7310 0.5070

Feet 0.4020 0.4200 0.6140 0.2850 0.1200 0.1440 0.2230 0.1000 0.1830 0.3300 0.3670 0.1740

Vibration Level - Hand/Arm As per Tigercat test ETR007 Weighted rms acceleration (m/s2) Driving max speed (High) S 1.770 Driving max speed (Low) S 1.170 Boom operation S 0.770 *Note for hand/arm, all weighted RMS acceleration values are below 2.5 m/s 2 as per clause 3.6.3 Machinery Directive 98/37/EC Annex 1.

VIBRATION LEVELS.XLS

1.3

Safety

Tigercat H820D Harvester

SAFETY SYMBOLS

GENERAL SAFETY PRECAUTIONS

IMPORTANT 24 VOLT ELECTRICAL SYSTEM Remember that safety is a prime responsibility of all.

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

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

These safety rules highlight both general and specific measures the operator should be familiar with and adhere to. More specific measures are illustrated with pictograms which may also be attached to the machine in locations pertinent to their respective message.

Keep safety labels in good condition. Repair or replace damaged labels.

UNDERSTANDING SIGNAL WORDS

DANGER DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

• Always read the Operator's manual before operating the machine. Pay close attention to WARNING and HAZARD identifications.

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

• Follow all safety inspector and supervisor instructions.

CAUTION

• 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.

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

NOTICE NOTICE indicates a potentially damaging situation which, if not avoided, may result in property damage and is not related to personal injury.

• Use recommended protective clothing and safety devices such as gloves, safety boots, safety hat, goggles, and ear protection when necessary.

1.4

Tigercat H820D Harvester

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

WARNING

NOTE: Opening the cab front door will stop machine functions. Opening the cab side door will NOT stop machine functions.

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

• Do not jump off the machine at any time.

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

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

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

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

• Do not use the machine foot controls as steps.

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

150m /500ft 68197BUNI R0

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

• When mounting or dismounting the machine always use the three point technique. Use one hand with two feet or two hands with one foot.

WARNING

150 M (500 FT)

150 M (500 FT)

150 M (500 FT)

Avoid mounting or dismounting the machine in areas with slippery surfaces. You should dry, deice, clean up or cover slippery surfaces with an anti-slip material before mounting or dismounting the machine.

150 M (500 FT)

822D-117

Hazard Zone

WARNING

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

Do not walk on machine surfaces with steel cleated foot wear. Steel cleats on steel surfaces are slippery and do not provide a safe foot hold.

1.5

Safety

Tigercat H820D Harvester WARNING

It is not recommended to walk on machine surfaces that are not designated walking areas.

No attempt should be made to walk on angled steel surfaces or surfaces that are irregular in shape.

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

Walking surfaces on the machine must be covered with anti-slip materials to provide a safe foot hold and prevent slipping.

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

These anti-slip surfaces should be maintained on a regular basis. If the surface shows signs of wear, the anti-slip material must be replaced immediately.

Some advice which should be observed: • Oils used in this machine may be hot enough to cause serious burns.

• To reduce risk of 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. Always turn OFF the engine before cleaning machine.

• Avoid contact with oil, particularly heated oil.

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

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

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

• Don't put oily rags in your pockets.

• Machine should be washed completely at every major service.

• Oil soiled clothing should be changed as soon as possible.

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

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

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

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

• Check windows and door guards for damage.

• Avoid breathing in oil fumes.

• Check protective windows for cracks. A damaged window has reduced strength to stop flying objects.

All damaged windows must be replaced with original equipment.

• Wash hands and arms frequently, for example, at each meal break or as often as possible.

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

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

• Check all fluid levels.

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

1.6

Tigercat H820D Harvester

Safety

SAFETY HAZARDS – VITON SEALS

• 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.

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

• Maintain a distance of 3 m (10 ft) between the machine or boom and any power line carrying up to 50,000 volts or less plus 10 mm (0.5 in) for each addition 1,000 volts above the 50,000 volt level.

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:

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

• Visually inspect any seals or gaskets which have suffered from heat damage. They will appear black and sticky. If these are found, DO NOT TOUCH!

• The machine must be adequately secured to the transporting vehicle if it is to be transported. Refer to the Vehicle Moving and Transporting Instructions booklet supplied with the machine. Refer to the contents page of this manual for the booklet part number if required.

• Determine the material composition of any seals or gaskets, If fluoroelastomer 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.

• Stopping the engine immediately after it has been working under load can result in overheating and premature wear of the engine components.

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

• Reduce engine speed to LOW IDLE and let run for approximately five 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.

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

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

SAFETY HAZARDS – OPERATING • Maintain a charged fire extinguisher on the vehicle at all times and know how to use it.

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

• 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.

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

• Do not allow anyone who may be unfit, physically or mentally, or who may be under the influence of alcohol or drugs, to operate the machine.

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

• 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.

1.7

Safety

Tigercat H820D Harvester 2. Disconnect the negative starter motor cable from both battery posts.

WARNING

3. Disconnect the positive master solenoid cable from both battery posts.

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.

NOTE: Connect the ground terminal last when reconnecting.

• Do not short out the battery terminals for any reason.

Serious burns or an explosion can result.

WARNING

AVOID INJURY FROM BACKOVER ACCIDENTS

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

Wash hands after handling.

• Before moving the machine, be sure all persons are clear of the area.

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

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

CAUTION

• To avoid backover accidents:

Lead-acid batteries contain sulfuric acid which can severely damage eyes or skin on contact.

Always wear a safety face shield, rubber gloves and protective clothing to reduce risk of accidents.

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

• Keep the machine motion alarm in working condition. The motion alarm must sound when the machine is moving forward or in reverse.

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

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

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

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

• Keep all windows, mirrors and lights in good condition.

• Do not attempt to charge a frozen battery. It can explode.

• Dust, heavy rain, fog, snow, etc., can reduce visibility. As visibility decreases, reduce speed and use proper lighting.

• Before working on electrical systems, disconnect the battery as follows: 1. Turn OFF the battery disconnect switch in the cab.

1.8

Tigercat H820D Harvester

Safety

OPERATING SAFETY PRECAUTIONS

FOR TIER 4F MACHINES ONLY

• Turn OFF the engine when refuelling – DO NOT refuel the machine while smoking or near an open flame or sparks.

41581AUNI R0

• Attach a grounding strap to an unpainted metal surface on the machine if the refuelling tank or nozzle is so equipped.

• Diesel Exhaust Fluid (DEF) may irritate eyes or skin.

Do not get in eyes. Do not get on skin.

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

First Aid treatment: DEF Contains Urea. If swallowed call a Poison Control Center or doctor immediately. Do not induce vomiting. If in the eyes, rinse with water for 15 minutes. If on the skin, rinse well with water. If irritation persists seek medical treatment.

• Sound the machine horn before starting the machine.

WARNING Use only DEF which meets ISO 22241 specifications. NEVER fill the DEF tank with any other fluid.

DEF is injected into the exhaust gas stream during normal operation of the Selective Catalytic Reduction (SCR) aftertreatment system.

• The operator seat is equipped with lap and shoulder harness belts. Always use both of these restraint systems at all times when operating the machine.

Use of other fluids may cause component damage, or a fire risk which could result in death or serious injury.

• Start the engine according to the instructions in this manual. Refer to OPERATING MACHINE in SECTION 2.

WARNING Never use a liquid starting aid to start an engine.

This machine is equipped with a computer controlled heating element in the engine intake system. Starting fluids will explode on contact with the heating element.

• Before moving the machine to the work site, all doors, panels, and access covers must be installed properly and secured.

1.9

Safety

Tigercat H820D Harvester

CAB EXITS

SAFETY INTERLOCK SWITCH– FRONT DOOR

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

A

Front door– This is 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– FRONT DOOR in this section.

B

C

Side door– This door should be used for emergency exits only. Do not use this door to routinely enter or leave the cab. This door is not equipped with a safety interlock switch and therefore, when left open, will not deactivate the pilot controls in the cab. Always turn OFF the engine before using the side door exit.

Escape hatch – This is a third cab exit for use if the front exit or side door exit become blocked. This hatch is not equipped with a safety interlock switch and therefore, when left open, will not deactivate the pilot controls in the cab. Always turn OFF the engine before using the escape hatch exit.

822D-022

A Pilot Interlock Switch B Actuator (On Door) C Cab Dome Light Switch

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 turned OFF).

Push the red PILOT OFF switch and confirm the PILOT OFF Icon is activated (yellow) on the MD4 display before removing seat belt. DO NOT use the front door interlock switch to turn pilot OFF.

IMPORTANT! The operator of the machine must be familiar with these emergency exits and how to use them.

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

All operators should practice using all the cab exits to become familiar with escape procedures should they need to perform them in the dark, when the machine is in a rolled position, or other possible adverse conditions.

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

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

To Operate

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

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.

Close the front door and press the green PILOT ON RESET switch. The PILOT ON icon will be activated (green) on the MD4 display.

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

WARNING

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

1.10

Tigercat H820D Harvester

Safety

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

• When travelling, position the attachment and the boom to avoid visual impairment.

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

• Never travel near co-workers or other pieces of equipment with attachments running.

CAUTION

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

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

• Do not turn on the attachment until the machine is at the harvesting site.

Anyone opening the door or screen and holding on to it could be pulled out of the cab and injured.

WARNING

• Use only prearranged and approved signalling practices.

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

MACHINE STABILITY AND TRACTION When working on slopes, travel straight up or down the slope to reduce the risk of roll-over.

NEVER travel across a STEEP slope or side hill: • As logs are added to the accumulator pocket, the handling and the stability of the machine will change.

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

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

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

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

• Secure loose items in the cab.

• Do not overload the machine as this can create an unstable condition and cause a roll-over.

• All equipment controls must be checked, prior to commencing work, to ensure the machine responds correctly.

• Make sure that all safety screens and guards, are installed and properly secured.

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

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

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

1.11

Safety

Tigercat H820D Harvester

CHAIN SHOT – LOGGING SAFETY

HOW CHAIN SHOT OCCURS

Chain Shot is the high-speed ejection of chain parts that can occur in the event of a derailed or broken chain.

While the risk of a chain shot event can't be eliminated, it can be minimized by following some simple operational recommendations.

1. After a chain breaks, the free end of the chain begins to whip away from the break.

A

WARNING There is risk of serious injury or death to machine operators and bystanders from chain shot. Follow the manufacturer's application and maintenance instructions and those provided for the equipment on which the cutting chain is used.

Generally, chain shot originates near the driven end of the cutting system, but can also originate from the guide bar tip area. In either situation, it poses the same risk of serious injury or death to the machine operator and any ground personnel nearby.

D

B C

575-499

A B C D

Chain Travel Guide Bar Tip Chain Break Drive Sprocket

Figure 1

2. If the chain is not contained by the saw box or by a chain shot guard, the broken saw chain’s free end can speed up rapidly, carrying immense dynamic energy.

A

575-500

B

A Chain Travel B Chain's Free End

Figure 2

3. At the peak of the whip, chain parts may break loose and be ejected at high speed, especially if the free end of the saw chain strikes the saw box.

Saw chain pieces usually travel in the cutting plane of the guide bar, but can deviate to either side. Although the 'Shot Cone Zone' reflects the most likely chain shot path, deflection can occur, substantially expanding the distance and area chain pieces may travel.

1.12

Tigercat H820D Harvester

Safety CAN CHAIN SHOT BE ELIMINATED? A

575-501

A Chain Travel

A

Figure 3

A

575-503

WARNING It is the operator's responsibility to ensure any bystanders and themselves are not in the plane of the cutting chain.

Orient bar and chain so high velocity parts are thrown away from people and equipment.

Refer to applicable manuals for additional safety information

A Shot Cone Zone

In simple terms, no, it can’t. Properly designed chain shot guards and shields reduce the danger of a chain shot from the drive sprocket area. However, there is currently no known way to place similar guards in the guide bar tip area without significant disruption to the cutting operation. Because no guarding is currently possible in the guide bar tip area, chain shots can be generated and pose the same risk of serious injury or death as those generated at the drive sprocket area.

Care should be taken to minimize the exposure of the machine operator and ground personnel to the cutting plane of the cutting system and Shot Cone Zone.

Ground personnel should stay back at least 150 m (500 ft) away and outside the Shot Cone Zone of a working machine.

B A 575-502

A Cutting Plane

A 860C-446

A Hazard Zone B 150 m (500 ft)

Chain shot projectiles travelling at the speed of a bullet can travel far beyond the above recommended stay back distance.

The stay back distance will help reduce the risk of a chain shot injury, but not eliminate it.

1.13

Safety The following items should be observed in accordance with the saw manufacturer's recommendations:

Tigercat H820D Harvester IN COLD CUTTING CONDITIONS: • Use a lighter weight lubricant, if possible, doubling the flow rate.

• Cutting system maintenance.

• Saw chain maintenance.

• Periodically cycle the guide bar without cutting (air cuts), this increases lubricant present on the cutting system.

• Clean and dress guide bars on a regular basis.

• Replace worn drive sprockets.

Do not exceed the manufacturer’s recommendations for chain speed. Cutting systems must be inspected frequently. Dull, damaged saw chains should be immediately removed from service for inspection, repair or replacement. Saw chain loops which have broken twice, must be removed from service.

• Reduce bar feed force.

CONDUCT PROPER GUIDE BAR MAINTENANCE: • Clean the guide bar groove from bar tip to bar tail and keep the oil hole open.

• Turn the guide bar over on a daily basis to equalize wear.

Drive sprockets must be aligned with the groove of the guide bar. Ensure the saw chain/guide bar lubrication system is functioning properly: 0.404 – pitch cutting systems should use approximately 7.6 L (2 US gal) of guide bar/chain lubricant or more per eight hour shift in harvesting operations – more when used in processing operations. Three-quarter-pitch cutting systems should use approximately 9.5 L (2.5 US gal) or more per eight hour shift in harvesting applications – more when used in processing operations.

• Cycle the guide bar several times to remove moisture from the guide bar tip.

• Ensure you maintain proper chain tension, checking it often.

• During work breaks and at the end of each shift, relieve chain tension to prevent damage to the guide bar tip, saw motor and/or the chain as the chain cools and contracts.

OPERATIONAL RECOMMENDATIONS In general: • Never begin a cut with the machine operator and ground personnel in the Shot Cone Zone.

• Always begin a cut as close to the ground as possible.

• Always use new and approved parts when assembling and repairing chain.

• Maintain chain in agreement with chain manufacturer’s recommendations.

• Reduce chain speed.

In simple terms, your attachment, when operational, should be treated as if it is two loaded guns (the bar tip and the bar tail) that pose a risk of serious injury or death to the machine operator and ground personnel.

The risk of a chain shot event cannot be eliminated, but the risks can be reduced by following the recommendations provided by your cutting system manufacturer, and the operational recommendations presented here.

• Never force a dull chain to cut. A sharp chain places less wear and tear on the cutting system.

• Chain should be sharpened or replaced with a sharp chain at least once per operational shift, or more often if damaged.

• Depth gauges (rakers) must be maintained through the life of a chain.

• Never exceed your chain manufacturer’s operation recommendations.

1.14

Tigercat H820D Harvester

Safety

PARKING THE MACHINE Park the machine in a cleared area at least 15 m (50 ft) away from other equipment. In the event of a fire, this distance will minimize the chance of the fire spreading to other equipment.

Before leaving the cab, lower the attachment onto the ground.

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

Before transporting the machine, all doors, panels and access covers must be installed properly and secured.

Improperly secured doors or panels pose a serious danger to pedestrians and other vehicles.

If you will be out of the cab for an extended period, turn OFF the machine.

• Park on level ground only and engage the swing brake.

• Do not park on a hillside or incline.

• Lower the attachment onto level ground.

• Turn OFF the engine.

• Turn OFF the battery disconnect switch if the vehicle is to be parked for an extended period of time, e.g., overnight.

A

LX830D-032

A Battery Disconnect Switch

NOTE: Tier 2 machines are equipped with an After Run Relay which delays the power disconnect to the engine ECU for 90 seconds after the battery disconnect switch has been turned off. The Engine ECU is still powered during the 90 seconds.

NOTE: Tier 4f machines are equipped with an After Run/ Accessory Relay which delays the power disconnect to engine related fuses and relays ECU (ECM)/ATS relay, NOX Sensor relay, NOX Sensor fuse, ECU (ECM) Power fuse). Whenever the engine is stopped all DEF solution is pumped back to tank before the engine power system is turned off. This process takes approximately 90 seconds.

Refer to AFTERTREATMENT SYSTEM in SECTION 3 for more information.

NOTE: The aftertreatment system and its related components are applicable to Tier 4f machines only.

1.15

Safety

Tigercat H820D Harvester

SERVICING SAFETY PRECAUTIONS • Conduct maintenance inspections at least as frequently as recommended in SECTION 3.

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

The cooler package should be cleaned and serviced at least daily to maintain moderate engine temperatures.

• Read, understand and follow all operating safety precautions specified by the harvesting attachment manufacturer.

OFF

WARNING

ON 24863A R0

• When servicing or repairing equipment, turn OFF the engine, turn OFF the battery disconnect switch and lock out the switch in accordance with local regulations.

• Before servicing the machine, allow the engine cooling system, fuel system, exhaust system, hydraulic system and machine surfaces to cool down.

• Use a thermometer to check surface and system temperatures to ensure it is safe to begin service work.

• DO NOT begin service work until the surface or system temperature has cooled down to below 38°C (100°F).

This machine is equipped with a remotely operated battery disconnect relay. Some wiring on the machine is live even when the battery disconnect switch is OFF. When servicing the electrical system, remove the battery cables from the batteries, disconnecting the negative cables first.

WARNING

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

Diesel fuel or hydraulic fluid that is under pressure can penetrate the skin and cause serious personal injury, blindness, or death.

If any fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with treating this type of injury.

• Never use your bare hand to check for fluid leaks.

1.16

Tigercat H820D Harvester

Safety

• 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.

IMPORTANT!

A C

PRESSURIZED HYDRAULIC TANK

PARKING BOOM-HARVESTER

Parking the Boom

35 KPA (5 PSI) MAXIMUM 7 KPA (1 PSI) NOMINAL

A

B

A Stick Cylinder Fully Extended B Hoist Boom Fully Retracted C Head Flat on Ground with Tip Supported

• Lower the attachment to the ground, turn OFF the engine and relieve trapped pressure before performing work on components or disconnecting any hoses. Refer to Parking the Boom diagram. The accumulators will self drain within two minutes of turning OFF the engine.

B

C LX830D-030

A Air Vent Valve B Open/Close Lever C Pressure Gauge

Before servicing the hydraulic system, release the air pressure from the tank using the air vent valve.

Eye protection is required. Refer to HYDRAULIC SYSTEM– HYDRAULIC TANK PRESSURIZATION INSTRUCTIONS in SECTION 3.

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

Handle Perpendicular to Valve (shown) = Valve Closed Handle Parallel to Valve = Valve Open After service is completed, close the air vent valve.

• Turn OFF the engine. Only remove the coolant fill cap when it is cool enough to touch with bare hands.

Slowly loosen the fill cap to the first stop to relieve pressure before removing the fill cap completely.

• Do not change any pressure or relief settings 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.

Pressure can be maintained in a hydraulic system long after the power source and pump have been shut down.

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

1.17

Safety

Tigercat H820D Harvester WARNING DO NOT operate this machine to lift or move any objects other than what it is designed to lift or move.

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

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

• Do not use the boom to service other equipment.

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

• Work in a ventilated area. If it is necessary to run an engine in an enclosed area, use an exhaust pipe extension to allow toxic exhaust fumes to be routed outdoors.

• Do not modify the boom system.

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

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

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

Maintain a safe operating distance between the machine, the workers and all other personnel. It is the duty of the operator to ensure no person approaches the machine while in use.

Failure to follow the above instructions could result in serious injury or death.

• Dispose of fluids properly.

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

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

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

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

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

1.18

Tigercat H820D Harvester

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

• Work in a ventilated area. If it is necessary to run an engine in an enclosed area, use an exhaust pipe extension to allow toxic exhaust fumes to be routed outdoors.

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

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

• Read, understand and follow all operating safety precautions specified by the harvesting attachment manufacturer.

WARNING Always follow the instructions and safety warnings provided by the attachment manufacturer before approaching the attachment head to make adjustments.

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

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

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

Anyone opening the door or screen and holding on to it could be pulled out of the cab and injured.

1.19

Safety

Tigercat H820D Harvester

PRIOR TO WELDING

A

Prior to welding on any part of the machine, the repair area 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.

822D-100

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

A XA2-A1 Control Module (Engine/Pump Compartment Area) B Multi-pin Connector

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

B

3. Disconnect the multi-pin connector from the XA2 control module (right side of engine compartment).

A

A

B

B

822D-100

A Engine ECU B Multi-pin Connectors

LX830D-030

A XA2-A0 Control Module (Hydraulic Tank Compartment) B Multi-pin Connector

1. Disconnect the two multi-pin connectors from the engine ECU (left side of the engine).

A

4. Disconnect the multi-pin connector from the XA2 control module (hydraulic tank compartment).

A

B LX830D-027

B

A MD4 Computer and Display B Multi-pin Connectors

2. Disconnect the multi-pin connector from the back of the MD4 Computer (cab).

822D-013

A XS2-A0 Control Module (Cab Electrical Panel ) B Multi-pin Connector

5. Disconnect the multi-pin connector from the XS2 control module located inside the electrical panel in the back-right corner of the cab.

1.20

Tigercat H820D Harvester ER BOOM SYSTEM

Safety FLUID INJECTION INJURY

WARNING

WARNING

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

Greater attention is required when servicing the ER Boom System as 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 a different cylinder at the same time.

Before attempting to disconnect hydraulic hoses or perform work on the boom system: • The machine must be parked on level ground with the head laying flat on the ground.

• The stick cylinders must be fully extended or the hoist cylinder must be fully retracted.

• The tip of the stick boom must be supported.

Diesel fuel or hydraulic fluid under pressure can penetrate the skin and could result in serious injury or death. If any fluid is injected under the skin, a medical doctor familiar with the treatment of this type of injury must surgically remove it within a few hours.

Hydraulic and diesel fuel systems on forestry machines operate at very high pressures, often 207 bar (3000 psi) and above. If a loose connection or a defect in a hose should occur, a fine, high velocity stream of fluid will result. Even for systems pressurized to as little as 7 bar (100 psi), this fluid stream can penetrate human skin as if it were a hypodermic needle.

Initially, an accidental fluid injection beneath the skin may only produce a slight stinging sensation. There is a danger that you will tend to ignore this, thinking that it will get better with time. Most often, it does not! Within a very short time, the wound may begin to throb painfully, indicating that tissue damage has already begun.

Similarly, fluid injected directly into a blood vessel can spread rapidly through your circulatory system. The human body has little ability to purge injected fluid.

Time becomes critical as tissue damage progresses rapidly. The longer you delay getting professional medical attention, the more damage that can occur.

Although fluid injection accidents are rare, the resulting injury has, on occasion, required the amputation of a finger, a hand or in some cases the entire limb. The longer the delay in getting professional medical aid, the further up the limb the tissue damage can spread. An injury of this type can become very serious or even fatal if not dealt with promptly and properly.

1.21

Safety

Tigercat H820D Harvester

IN THE EVENT OF ANY SUSPECTED FLUID INJECTION INJURY:

GREASE INJECTION INJURY WHEN USING PNEUMATIC GREASE GUNS

• REPORT THE INJURY TO YOUR SUPERVISOR IMMEDIATELY.

Pneumatic grease guns can deliver grease at pressures from 17 – 400 bar (246 – 5801 psi). It takes less than 7 bar (100 psi) to inject a substance through human skin.

• SEEK PROFESSIONAL MEDICAL ATTENTION IMMEDIATELY.

ALWAYS get professional medical treatment immediately after any type of injection injury.

Provide the physician with information on the type of grease, the pressure setting of the gun, and similar details.

The amount of fluid injected, type of fluid (or material), pressure at which it was injected, and the elapsed time between injection and surgery all influence the chances of successful treatment for this type of serious injury.

The best defence against suffering the effects of fluid injection is to prevent the accident from occurring.

When searching for possible fluid leaks:

Prior to using a high pressure pneumatic grease gun, perform the following: • DO NOT OPERATE a high pressure pneumatic grease gun unless you have been trained in the proper operation and are aware of all safety precautions of such a tool.

• All operators of high pressure pneumatic grease guns MUST be trained in the hazards of its operations and the treatment for related injuries.

• Never search for leaks with your bare hands. Always wear thick protective gloves.

• Be sure to wear safety goggles for eye protection.

• Wear proper protective equipment such as gloves, safety hat and safety glasses.

• Keep all body parts well away from the area being investigated for leaks.

• Inspect all parts of the grease gun for wear and tear and replace all worn or damaged parts.

• Use the end of a long piece of wood to move hoses or other obstacles.

• Make sure that protective shrouds are installed on all grease gun nozzles as safety devices.

• Place the end of a long piece of wood in the suspected path of any fluid stream. Never use any part of your body.

• Remove dirt and grease from the grease fittings prior to greasing.

• Replace any defective grease fittings with new fittings immediately.

• Recognize the source of the leak and the fluid streaming from it may be very small and not easily visible. You may only be able to see the fluid that accumulates as a result of the fluid stream.

• When badly positioned fittings are identified, replace them with angled or swivel fittings for easier access.

When performing any service work: • Turn OFF the engine and relieve all diesel fuel or hydraulic pressure before disconnecting any lines or otherwise working on the system.

• Never grab any hydraulic or diesel fuel connectors or hoses when they are subjected to pressure.

• Hoses must be rated for the pressures to which they will be subjected.

• Never use any hoses that you suspect could be defective.

1.22

Tigercat H820D Harvester

Safety

LIGHTNING SAFETY AWARENESS

LIGHTNING SAFETY

WHAT IS A LIGHTNING STRIKE?

In spite of the popular myth that being struck by lightning is an unlikely event, the facts show that lightning strikes occur frequently. As a result loggers are at high risk because their work is outdoors and close to known strike points such as tall trees and heavy equipment.

Lightning is a discharge of the electricity produced by a thunderstorm. As the thunderstorm develops, many small particles of ice within the storm clouds bump together. These collisions create a positive charge at the top of a cloud and a negative charge at the bottom.

As this continues a second positive charge builds up on the ground beneath the cloud, concentrated around high objects such as hills, trees, buildings, equipment and even people.

Loggers can increase their chances of avoiding a lightning strike by following a few simple safety practices.

Designate a member of your crew to: • Monitor daily weather forecasts

When the difference between the electrical charge in the cloud and on the ground becomes great enough to overcome the resistance of the insulating air between them, an electrical current flows instantly. This is a lightning strike.

• Observe local weather conditions • Alert all other members of the crew when a possible lightning threat develops Don’t start or continue any work that cannot be stopped immediately, when a storm moves nearby.

The electrical potential in a lightning strike can be as much as 100 million volts. Lightning strikes can occur over very large distances, even as much as 60 km (37 mi). Lightning travels both in front of and behind a thunderstorm thus, strikes happen even when rain has not started or has stopped. Lightning can hit in the same place many times, and often spreads out over 18 m (60 ft) within the soil around the strike point.

Anticipate a high-risk situation and take action early by moving to a low-risk location. Do not hesitate. If there is lightning, you are in danger.

Obey the rule – If you see lightning, Flee. If you hear thunder, Clear.

Thunder always accompanies lightning. When lightning occurs, the air through which it travels is instantaneously heated to a temperature more than 28,000°C (50,000°F).

The air expands rapidly due to this heating, then quickly contracts as it cools. It is this contracting shock wave that we hear as thunder.

In many areas of the world, lightning strikes are second only to flooding as the greatest cause of storm related deaths and injuries. Although only 10% of lightning strike victims are killed, virtually all from cardiac or respiratory arrest, over 70% of those that survive suffer severe, life-long injury and disability. The symptoms of a lightning strike include memory loss, fatigue, chronic pain, dizziness, sleeping difficulty and the inability to complete several tasks at one time.

Do not follow the now obsolete guideline to take shelter when the time between seeing lightning and hearing thunder is 30 seconds or less. This does not provide sufficient time to ensure safety. Always follow step 4.

Remain in your safe location for 30 minutes after the last sight of lightning or the last sound of thunder.

The safest location during lightning activity is inside a fully enclosed, substantially constructed building, a house, office, school, shopping area, etc. These are the safest because of the electrical wiring and plumbing they contain. Should lightning strike, the electrical current will travel through the wiring or plumbing into the ground.

When such a building is nearby, always seek shelter there first.

Unfortunately loggers do not often work close to buildings and therefore other alternatives need to be considered.

Sheds, weather shelters, hunting blinds, tents and other partially open or small structures are not safe against lightning strikes as they lack the electrically grounded components of larger buildings. They are intended for sun or rain protection only. Do not seek shelter from lightning strikes inside these structures.

1.23

Safety The second safest location during lightning activity is inside a fully enclosed car, van, truck or bus with a metal roof and metal sides. The electrical energy of a lightning strike to these vehicles is carried to ground by the conducting outer metal surfaces. This is called the skin effect.

Tigercat H820D Harvester IF INSIDE A MOTOR VEHICLE OR FULLY ENCLOSED ROPS EQUIPMENT CAB: • Under no circumstances whatsoever step outside of the vehicle or off the equipment to move to another shelter. Very dangerous electrical pathways to ground may go through you.

Do not seek safety from lightning strikes in vehicles with fibreglass or plastic body shells or in convertible top vehicles. None of these are safe, as they do not offer skin effect lightning protection.

• Shut down all operation, turn OFF the engine, close all doors and raise all windows.

• Sit squarely in the seat with your hands in your lap and your feet flat on the floor mat.

Heavy forestry equipment, such as a skidder, loader, feller buncher, forwarder, etc. with a fully enclosed rollover protective structure (ROPS) cab, takes advantage of the skin effect and are therefore safe in electrical storms.

However, machines with only a rollover canopy, are not safe against lightning strikes as they are open to electrically conductive rainwater and do not benefit from the skin effect. Operators of this equipment must abandon their machines and get to a safer location before lightning strikes.

• Do not touch any metallic objects referenced to the outside of the vehicle. Do not touch any door and window handles, control levers, foot pedals, steering wheels, cab interior walls and any other inside to outside metal objects.

• Do not touch any radio or telephone connected to an outside antenna.

IF YOU ARE CAUGHT OUTSIDE AND HAVE NOWHERE TO GO: • Avoid wide-open areas where you project above the surrounding landscape.

NOTE: The rubber tires on motor vehicles and heavy equipment do not increase safety from lightning strikes.

Lightning has already travelled a great distance through the air to strike the vehicle. In comparison a few inches of rubber in a tire offers absolutely no additional insulation.

• Seek shelter in a low place, such as a ditch, ravine, valley, canyon or cave.

• Get away from open water such as ponds or streams.

WHAT TO DO IF YOU ARE OUTSIDE AND SEE LIGHTNING OR HEAR THUNDER

• Do not take shelter under any isolated tall trees or small groups of trees.

IF YOU CAN, GET INSIDE:

• Seek shelter amongst the dense, thick growth of the shortest trees.

Run to the nearest building, motor vehicle or fully enclosed ROPS equipment cab immediately. Being anywhere outside is not safe.

• Avoid entering any small enclosures or shelters.

• Do not seek shelter under any motor vehicle or heavy equipment.

IF INSIDE A BUILDING: • Don’t watch the lightning storm from open windows or doorways. Stay in inner rooms.

• Keep clear of any materials that can conduct electricity such as wire fences and gates, metal pipes, poles, rails and tools.

• Stay well away from corded telephones, electrical appliances, lighting fixtures, radio microphones, electrical sockets and plumbing pipes and fixtures.

• Stay at least 15m (50 ft) away from metal objects such as a fuel tank, a vehicle or machinery without a cab, motorcycle, ATV, etc.

• Stay at least 5m (16 ft) apart from any other members of a group so that lightning won’t travel between you.

• Do not use the telephone except for emergencies.

1.24

Tigercat H820D Harvester

Safety

WHAT TO DO IF YOU FEEL YOUR SKIN TINGLING, YOUR HAIR STANDS ON END, LIGHT METAL OBJECTS VIBRATE OR YOU HEAR A CRACKLING SOUND: • Lightning is probably about to strike. You only have a few seconds to act.

• Put your feet together. Crouch down like in a baseball catcher’s position. Hold your head down.

Cover your ears to protect them against the noise of the thunder.

• Do not lie flat on the ground. By touching as little of the ground as possible, the lightning may not move across the ground to you.

WHAT TO DO IF A CO-WORKER HAS BEEN STRUCK BY LIGHTNING: • The victim does not carry any electrical charge.

There is no danger to anyone helping this person.

You can touch him or her immediately.

• Call your local emergency response telephone number immediately.

• If the victim has no pulse, their heart has stopped or they have stopped breathing, start cardiopulmonary resuscitation (CPR) or mouth-to-mouth resuscitation immediately. Use a portable defibrillator if one is available.

• Be careful about staying in the storm to take care of the victim. You can get hit by lightning too. If you can, move the victim to a building as soon as possible.

• To further increase your awareness about lightning safety, see the following web sites: • National Weather Service Lightning Safety http://www.lightningsafety.noaa.gov • National Lightning Safety Institute http://www.lightningsafety.com

1.25

Safety

Tigercat H820D Harvester

FIRE PREVENTION

• 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 may cause a fire.

However, when mixed with fuel, oil or grease in a hot or confined place, the danger of fire is greatly increased.

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

The following guidelines will help to keep your equipment up and running efficiently and keep the risk of fire to a minimum: • Maintain a CHARGED fire extinguisher on the machine at all times and KNOW HOW TO USE IT. • Remove debris and blow out dust regularly from the air intake doors, engine radiator and charge air cooler, hydraulic oil cooler, diesel fuel cooler and air conditioning condenser core to prevent overheating of the engine and hydraulics and to maintain efficient operation of the machine. Refer to CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR in SECTION 2 of the OPERATOR’S MANUAL. • Blow off all forest debris and fine organic material 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 when working in logging conditions where large amounts of combustible forest debris are present.

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 smoulder. If dislodged this smouldering debris can fall into other areas of the machine and thereby spread a fire.

• Inspect the machine regularly for any signs of diesel fuel or hydraulic system leakage. Check for worn or eroded fuel or hydraulic lines before starting up any equipment.

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

• Steam clean the engine, hydraulic pumps, transmission, brake, fuel and hydraulic tank compartments and all machine belly pans at least once a month or more frequently when working in logging conditions where large amounts of combustible forest debris are present.

• Use only non-flammable solutions for cleaning the machine and components.

• Inspect the exhaust system daily for any signs of leakage. Check for worn, cracked, broken or damaged pipes or muffler. Also check for missing or damaged bolts or clamps. Should any exhaust leaks or defective parts be found, repairs must be made immediately. Engine exhaust leaks can cause fires.

Do not operate the machine until the exhaust leak is repaired.

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

• Park the machine at least 15 m (50 ft) away from other equipment at the end of each shift.

• Never leave the machine parked with boom, arch or blade suspended off the ground. Should their supporting hydraulic hoses burn through during a fire, pressurized hydraulic oil may be injected into the fire and the boom, arch or blade will fall rapidly to the ground.

• Turn the battery disconnect switch to OFF at shut down to de-energize all electrical circuits.

1.26

Tigercat H820D Harvester • Remain with the machine for at least 45 minutes at the end of operations while the machine cools.

Safety WHAT TO DO TO PREPARE IN THE EVENT OF A MACHINE FIRE

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

• Prevent the fire from happening in the first place by ensuring that all machine systems are frequently inspected and always well maintained.

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

• Ensure that any hand held fire extinguishers are charged and in working order. Fire extinguishers require routine care. Follow the manufacturer’s instructions for inspection and maintenance shown on the label of the fire extinguisher and in the extinguisher manufacturer's manual.

• Ensure that any pressurized water systems on the machine (if applicable) are charged and in working order. Refer to PRESSURIZED WATER SYSTEM MAINTENANCE in SECTION 3 of THIS MANUAL. • Ensure that you have the proper fire extinguishers on site. Most fires involving mobile forestry equipment will be Class A or B. Dry chemical extinguishers should be rated ABC and pressurized water extinguishers should be rated A. Class A fires involve ordinary combustibles such as wood, cloth, paper, rubber and many plastics, Class B fires occur with flammable liquids such as diesel fuel, oil and grease and Class C fires apply to energized electrical equipment.

• Make sure the nozzle of any hand held extinguisher and pressurized water system available on the machine and at the work site fits within the fire extinguisher access holes in the doors of the machine.

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

• Ensure that your fire detection system* is in working order. Refer to FIRE DETECTION SYSTEM in SECTION 2 of the OPERATOR’S MANUAL.

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

• Ensure that your fire suppression system** is charged and in working order. Refer to FIRE SUPPRESSION SYSTEM in SECTION 2 of the OPERATOR’S MANUAL.

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

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

• Ensure that you are familiar with the recommended procedures for fire contained in the emergency action plan of your company.

NOTICE Equipment fires adversely effect your ability to log, may increase your insurance premiums dramatically or prevent you from obtaining insurance coverage at all.

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Safety

Tigercat H820D Harvester

• Ensure that you follow all national, state/provincial and local regulations dealing with fire fighting in effect in your specific geographic region. Regulations will vary from region to region but most will usually require that:

Before deciding to fight the fire, be certain that: 1. The fire is small and not rapidly spreading.

2. There is always a clear, safe escape route to your back.

• Workers assigned to fire fighting duties must be physically capable of performing them safely and effectively.

3. You have received training in the use of the available fire extinguishing systems and are confident that you can operate them effectively.

• Workers designated to use fire fighting equipment as part of an emergency action plan must receive full and proper training from a qualified instructor.

4. If in any doubt about whether or not to fight the fire – DON’T. Instead stand well clear of the fire and wait for help to arrive.

• Whenever portable fire extinguishers are provided for use in the workplace, training must be provided to familiarize workers with the general principles of fire extinguisher use and the hazards involved with fire fighting.

5. Be aware that, hoses containing engine coolant, diesel fuel or hydraulic hoses could fail during a fire.

If this happens, hot coolant, fuel or oil could possibly be ignited by the fire.

• Training must be provided upon initial employment and at least annually thereafter.

• Ensure that after you have received the training as outlined above, that you know how to use the fire extinguisher, the pressurized water system (if applicable) and the fire suppression system** on your machine. There is not enough time available to read instructions during a fire emergency.

6. If possible a dry chemical fire extinguisher or fire suppression system** should be used first to fight a machine fire. Then immediately afterwards use the pressurized water hose supplied with the machine (if applicable) or a pressurized water extinguisher (if available). A fire suppressed by dry chemical may re-ignite from the heat retained by any debris or hot machine components in the area. The water will cool the area, reducing the chances of re-ignition.

• Use the PASS method. This is the most effective use of a fire extinguisher.

• Ensure that all information necessary for you to immediately contact all sources of help (local fire department, etc) in the event of a fire emergency is recorded and readily available at all times.

• Pull the pin at the top of the extinguisher that keeps the handle from being pressed. Break the plastic seal as the pin is pulled.

WHAT TO DO WHEN A MACHINE FIRE OCCURS

• Aim the nozzle at the base of the fire. Do not aim the nozzle at the flames. In order to put out the fire, you must extinguish the fuel, not the flames. Hose nozzles are often clipped to the extinguisher body. Release the hose before taking aim.

If operating the machine when a fire occurs: 1. Lower all working attachments to the ground.

2. Turn OFF the engine.

3. Activate the fire suppression system**.

• Squeeze the handle to release the pressurized extinguishing agent. The handle can be released at any time to stop the discharge.

4. Radio or call for help. Be certain to report a fire immediately.

5. Exit the machine taking fire extinguisher and pressurized water system hose (if applicable) with you.

• Sweep from side to side at the base of the fire until the fire is completely out or the fire extinguisher is empty

6. 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. All fires can be very dangerous and life threatening.

7. Only if you can safely do so, turn OFF the battery disconnect switch.

1.28

Tigercat H820D Harvester

Safety DRY CHEMICAL CLEANUP PROCEDURES Both ABC dry chemical fire extinguishers and fire suppression systems discharge a chemical powder to extinguish the fire. The chemical makeup and the small particle size of the powder as well as the force of the discharge all contribute to the fire fighting capability.

These same characteristics also permit the powder to penetrate into and fully cover all components in the vicinity of the discharge.

The following are recommendations for the cleanup and neutralizing of areas exposed to dry chemical powder:

20229A

TYPICAL FIRE EXTINGUISHER ACCESS HOLE

NOTE: Workers performing this work should wear protective clothing, safety goggles and a fine particle dust mask to minimize their personal exposure to the dry chemical powder.

• Ensure that all electrical systems have been completely de-energized prior to any cleanup.

• Place the nozzle of the fire extinguisher into the appropriate fire extinguisher access hole and discharge the extinguisher.

• In areas of the machine that remained cool and dry during the fire, the dry chemical will stay in powder form. Be certain to clean these areas immediately to prevent any settled residual powder from coming into contact with moisture whether through direct contact or humidity in the air. Remove the powder residue by blowing off with air, sweeping, dusting or vacuuming using a HEPA filter capable of trapping the small dry chemical particles. Then wipe all surfaces with a damp cloth.

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

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

• Make sure the machine and all components have cooled down sufficiently after a fire so that re-ignition does not occur.

• In areas exposed to moisture, the dry chemical powder will combine with water to form a paste that is mildly acidic.

• Remain with the machine until help arrives.

WHAT TO DO AFTER A MACHINE FIRE HAS OCCURRED

NOTE: All surfaces covered by this dry chemical paste including electrical contacts are vulnerable to corrosive attack.

• Before returning the machine to work: • Make sure the cause of the fire is determined and all appropriate repairs are completed.

To neutralize the acidic paste on large surfaces, spray or wash these areas with a mixture of 3 parts hot water to 1 part baking soda. Allow this mixture to stand for several minutes before rinsing with warm water. Wash the area with a mild soap and water solution. Rinse thoroughly with water. Blow-dry to remove all residual water. Cleaning of electrical contacts should be done using an electrical contact cleaner that has no flash or fire point and is noncorrosive and non-conductive such as CRC Contact Cleaner 2000.

• Make sure the fire detection system* or the fire suppression system** is properly serviced and in working order (if applicable).

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

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

• In areas exposed to heat during the fire, the dry chemical powder will melt forming a coating that cakes or crusts on all surfaces. To break down the caked dry chemical, spray or wash these areas with a 50/50 mixture of hot water and Isopropyl alcohol.

Allow this mixture to stand in place for several minutes. The caked dry chemical when exposed to moisture is also mildly acidic. Therefore when the break down procedure has been completed, follow this immediately with the neutralizing procedure as described in step 2.

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

1.29

Safety SAFETY LABELS The following safety labels must be periodically cleaned and inspected to ensure legibility is maintained. Replace any label that becomes illegible, damaged or removed.

Tigercat H820D Harvester REMOVE IGNITION KEY BEFORE SERVICING THE MACHINE

OPERATOR'S MANUAL LOCATION

This label indicates the storage location of the OPERATOR'S MANUAL.

READ OPERATOR'S MANUAL AND USE THE SEAT BELT AT ALL TIMES

Prior to performing any service work or maintenance on the machine, turn OFF the engine, REMOVE THE IGNITION KEY and store it in a safe place.

READ MANUAL Always read the operator’s manual before operating the machine. Pay close attention to WARNING and HAZARD identifications.

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

USE SEAT BELT The operator's seat is equipped with lap and shoulder harness belts. Use both of these restraint systems at all times when operating the machine. Do not attempt to move or operate the machine until the seat belt is fastened correctly.

1.30

Tigercat H820D Harvester HOT SURFACES

Safety CRUSH HAZARD

This label warns of hot machine and machine component surfaces. Be aware when performing service and maintenance tasks that surfaces and grab handles in and around the engine, hydraulic tank and cooling system may become very hot when the machine has been running. DO NOT TOUCH these hot surfaces.

Contact with hot surfaces may cause injury.

• Before servicing the machine, allow the engine cooling system, fuel system, exhaust system, hydraulic system and machine surfaces to cool down.

• Use a thermometer to check surface and system temperatures to ensure it is safe to begin service work.

• DO NOT begin service work until the surface or system temperature has cooled to below 38°C (100°F).

This label warns of the CRUSH HAZARD caused by boom movement. It is located on the hoist boom mounting saddle.

Movement of booms and cylinders COULD RESULT IN DEATH OR SERIOUS INJURY! Keep all personnel clear of the machine before operating boom functions.

Do not approach the machine until the boom is lowered to the ground and the engine is turned OFF.

1.31

Safety

Tigercat H820D Harvester

CRUSH AND THROWN OBJECT HAZARDS

CUTTING HAZARD

High speed ejection of saw blade parts, heavy branches, wood chips and debris could enter the cab resulting in death or serious injury.

This label informs you of the cutting hazards of the cooling fan blade when the engine is running.

Do not operate the machine unless the cab doors are closed and the window openings are covered with proper protective glazing and/or screens.

Never position the head so the saw blade is in line with any bystanders, other machines or the cab.

Maintain a safe operating distance between the machine and workers and all other personnel. It is the duty of the operator to ensure no person approaches the machine while in use. The risk (hazard) zone is 150 m (500 ft).

KEEP CLEAR of cutting hazards caused by rotating components.

DO NOT PLACE HANDS OR FINGERS IN THIS AREA. Rotating parts such as cooling fan blades can cause entanglement of body parts resulting in serious injury.

KEEP HANDS AND FINGERS CLEAR OF ROTATING FAN BLADES! Before performing any service work on these parts or in this area, turn OFF the engine and wait for rotating parts to come to a complete stop.

Before operating this machine CLOSE ALL WINDOWS AND DOORS. All protective coverings must be properly installed.

1.32

Tigercat H820D Harvester

Safety

ENTANGLEMENT HAZARD

ER BOOM WARNING

55987BUNI R0

36779BUNI R0

This label warns of an ENTANGLEMENT HAZARD (rotating parts) zone.

This label warns the machine is equipped with an ER boom system.

DO NOT PLACE HANDS OR FINGERS IN THESE AREAS. Rotating parts such as pulleys, belts and drives can cause entanglement of body parts resulting in serious injury.

Read the Operator's Manual to become familiar with the operation and movement of the ER boom system.

KEEP HANDS AND FINGERS CLEAR OF ROTATING BELT, DRIVE OR PULLEY! Before performing any service work on these parts or in this area, turn OFF the engine and wait for rotating parts to come to a complete stop.

Never permit persons to stand under the boom or attachment. Contact COULD RESULT IN DEATH OR SERIOUS INJURY. The attachment must be resting securely on the ground before performing any of the following functions: • Activating the ER Switch valve.

• De-energizing the pilot circuit • Opening the front door.

• Turning OFF the engine.

1.33

Safety

Tigercat H820D Harvester

ER BOOM WARNING

CRUSH HAZARD

This label warns the machine is equipped with an ER boom system. Because of this, it may behave in an unexpected manner when performing any service work or maintenance on the machine. Ensure no persons are near the machine.

This label warns of a downward force crush zone caused by swinging or falling logs and boom movement.

Read and understand the servicing procedures in the Service Manual. The boom and attachment must be properly supported before attempting to adjust pressures or disconnect hydraulic lines. SERIOUS INJURY OR DEATH COULD RESULT FROM CRUSHING.

Approaching personnel are subject to crush injuries by falling or swinging logs and boom downward movement which COULD RESULT IN DEATH OR SERIOUS INJURY. DO NOT start the machine until other personnel are a safe distance away from the machine.

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

Maintain a safe operating distance between the machine and workers and all other personnel. It is the duty of the operator to ensure no person approaches the machine while in use, the risk (hazard) zone is 150 m (500 ft).

DO NOT attempt to service or work on the machine UNTIL THE LOAD IS REMOVED from the attachment, the VEHICLE IS IN THE PARKED POSITION WITH THE BOOM AND ATTACHMENT RESTING ON THE GROUND and the ENGINE IS TURNED OFF.

1.34

Tigercat H820D Harvester

Safety

STORED ENERGY HAZARD

ELECTROCUTION HAZARD

This label warns of a STORED ENERGY HAZARD.

This label warns of a potential ELECTROCUTION HAZARD. Contact with electric lines WILL RESULT IN DEATH OR SERIOUS INJURY!

The machine is equipped with an accumulator. The accumulator has stored energy in the form of hydraulic pressure. Servicing the accumulator, hydraulic tank or any hydraulic components before releasing pressure COULD RESULT IN DEATH OR SERIOUS INJURY. DO NOT SERVICE ACCUMULATOR OR ANY HYDRAULIC COMPONENTS BEFORE RELEASING PRESSURE.

Before beginning work in any area, study the area thoroughly and become familiar with any potential hazards, especially electrocution hazards from electric lines.

DO NOT MOVE ANY PART OF THE MACHINE OR LOAD WITHIN 3 M (10 FT) PLUS TWO TIMES LINE INSULATOR LENGTH OF ANY ELECTRIC LINES!

1.35

Safety

Tigercat H820D Harvester

NO RIDERS

ELECTRICAL SHOCK HAZARD

55992BUNI R0

NO RIDERS INSIDE OR OUTSIDE OF THE MACHINE. Do not carry passengers either in the cab or anywhere else on the machine. The vehicle seating accommodation is for one operator only. Persons riding on the outside of the machine are subject to hazards such as falling off the machine, crush hazards, thrown object hazards and many other hazards WHICH COULD RESULT IN DEATH OR SERIOUS INJURY. If any person attempts to climb onto the machine during operation, STOP THE MACHINE IMMEDIATELY. DO NOT operate the machine until other personnel are a safe distance away from the machine.

KEEP BACK

This label warns of the potential of a severe electrical shock hazard.

When servicing the electrical system, turn OFF the battery disconnect switch before removing the battery compartment cover. Remove the battery cables from the batteries, disconnecting the negative (-) cables first.

Perform the service work, then attach the battery cables, reconnecting the positive (+) cables first.

Do not short out the battery terminals for any reason.

Serious burns and/or an explosion can result.

Refer to GENERAL SAFETY PRECAUTIONS in this section.

150m /500ft 68197BUNI R0

This label warns personnel to KEEP BACK 150 m (500 ft) due to flying projectiles and falling trees.

Danger exists predominantly around the attachment.

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

1.36

Tigercat H820D Harvester

Safety

EMERGENCY EXIT, CAB, LEFT SIDE DOOR

EMERGENCY EXIT, HAND TIGHTEN ONLY

This label indicates the escape hatch can also be used as an emergency exit.

This label alerts the operator that, in the event of an emergency this door can be used as an emergency exit.

The label also indicates the escape hatch knobs should be hand tightened only to allow for easy exit.

This label also reminds the operator that this door should not be used as a point of entry into the cab, except in the case of an emergency where emergency personnel need to gain access to the operator.

Ensure all exit locations are functioning properly.

Refer to EMERGENCY EXIT– MAINTENANCE GUIDE in SECTION 2.

Ensure the exit and escape doors and the escape hatch are functioning properly at all times.

Refer to EMERGENCY EXIT– MAINTENANCE GUIDE in SECTION 2.

1.37

Safety

Tigercat H820D Harvester

EXPLOSION HAZARD

FIRE PREVENTION

WARNING • EXPLOSION HAZARD. • DO NOT USE ETHER. • ENGINE EQUIPPED WITH HEATER STARTING AID. • USE OF ETHER COULD RESULT IN DEATH OR SERIOUS INJURY. 36782BENG R0

This label warns of an EXPLOSION HAZARD. The engine is equipped with a heater starting aid, DO NOT USE ETHER to assist in starting the engine.

USING ETHER COULD CAUSE AN EXPLOSION WHICH COULD RESULT IN DEATH OR SERIOUS INJURY. This label advises operators of the following: READ, UNDERSTAND AND FOLLOW THE FIRE PREVENTION GUIDELINES IN THIS MANUAL. These guidelines provide all the necessary action required to preventing fires on this machine. DO NOT OPERATE THIS MACHINE until you have read these instructions and have performed any necessary maintenance required that will prevent the potential of a fire from starting on this machine.

It is also important to note that fire prevention inspections and maintenance MUST BE PERFORMED FREQUENTLY (several times per day). A clean combustible free machine as well as frequent inspections of the exhaust components, hydraulic hoses and electrical cables and performing any necessary repairs immediately will help prevent fires.

Maintain a CHARGED fire extinguisher on the machine at all times, know where it is and KNOW HOW TO USE IT!

1.38

Tigercat H820D Harvester

Safety

CHECK DAILY

FIRE EXTINGUISHER ACCESS HOLE

In addition to the Fire Prevention label, This label is a reminder to check the machine daily for the possibility of debris build-up, leaks, damaged wires and hoses and take the necessary action required to clean up any debris accumulation, and repair any leaks, damaged wires or hoses.

This label indicates the location of each fire extinguisher access hole.

The label also advises to check and ensure all fire fighting devices are in good working order.

1.39

Safety

Tigercat H820D Harvester

EXPLOSIVE RELEASE OF HOT COOLING SYSTEM PRESSURIZED FLUID

SLIPPERY SURFACE – NO STEP

This label warns of a slippery surface, DO NOT STEP or WALK on the surface.

The right service door is equipped with a non skid work surface. Standing and working on the work surface only, is recommended.

33952AUNI R0

This label warns of a PRESSURE AND FLUID SPRAY HAZARD when the coolant in the radiator is hot.

DO NOT stand or work on the area of the door panels that are not equipped with a non skid work surface material. Falls caused by slippery surfaces can result in personal injury.

DO NOT LOOSEN THE COOLANT FILL CAP UNTIL COOL. Explosive release of fluids from a pressurized cooling system can cause serious burns.

Turn OFF the engine. Only remove the coolant fill cap when it is cool enough to touch with bare hands. Slowly loosen the cap, to the first stop, to relieve pressure before removing completely.

1.40

Tigercat H820D Harvester

Safety

MAXIMUM WEIGHT RESTRICTION

NOTICE LABELS HEAD CONTACT WITH CAB AND TRACKS

MAX 225 kg (500 lb)

52484BUNI R0

This label warns of a maximum weight restriction on the right service door. MAXIMUM 225 kg (500 lb). Exceeding the weight limit can cause failure of the service door WHICH COULD RESULT IN PERSONAL INJURY.

This label shows the harvesting head could potentially be put in a position where it could make contact with the tracks or cab. To prevent personal injury or machine damage, care should be taken to avoid putting the harvesting head in this position.

1.41

Safety

Tigercat H820D Harvester

1.42

CONTROLS AND OPERATION...........................................................................................................................2

Tigercat H820D Harvester SECTION 2– CONTROLS AND OPERATION Always read and understand the entire contents , and all manuals for any attachments or accessories associated with this machine, prior to operating or servicing this equipment.

CONTENTS – SECTION 2

ISSUE 2.0, FEBRUARY 2017

A

ACCESS DOORS AND COVERS............................................................................................................................... 2.72 A/C / DEFROST SWITCH........................................................................................................................................... 2.18 ADJUSTMENT PROCEDURE ADJUSTMENT EXAMPLE....................................................................................................................................... 2.58 AFTERTREATMENT SYSTEM................................................................................................................................... 2.71 AIR SOURCE SWITCH............................................................................................................................................... 2.18 ANTI-STALL, SWITCH WITH LIGHT.......................................................................................................................... 2.79 ATTACHMENT, INSTRUCTIONS AND PRECAUTIONS............................................................................................ 2.85 AUXILIARY INPUT...................................................................................................................................................... 2.22 AUXILIARY POWER OUTLET, 12 V................................................................................................................. 2.21, 2.22 B

BATTERY BOOSTER CABLE CONNECTION............................................................................................................ 2.74 BATTERY DISCONNECT SWITCH............................................................................................................................ 2.13 BELT ROUTING, SERPENTINE................................................................................................................................. 2.78 BOOM CONTROLS....................................................................................................................................................... 2.9 C

CAB DOME LIGHT SWITCH....................................................................................................................................... 2.19 CAMERA........................................................................................................................................................... 2.14, 2.21 CLEAN OUT COVERS................................................................................................................................................ 2.81 COLD WEATHER STARTING..................................................................................................................................... 2.81 COMPUTER ADJUSTMENT EXAMPLE....................................................................................................................................... 2.58 ADJUSTMENT MENU.............................................................................................................................................. 2.37 OIL GRADE SELECTION..................................................................................................................................... 2.37 ALERT MESSAGES................................................................................................................................................. 2.68 CLAMP EXAMPLE................................................................................................................................................... 2.58 CRITICAL MESSAGES............................................................................................................................................ 2.67 DEFAULT SETTINGS TABLE.................................................................................................................................. 2.58 DISPLAY MESSAGES ALERT MESSAGES, YELLOW............................................................................................................................ 2.68 CRITICAL MESSAGES, RED............................................................................................................................... 2.67 INFORMATION MESSAGES, BLUE.................................................................................................................... 2.71 ENGINE MENU........................................................................................................................................................ 2.35 INFORMATION MODE SELECTION....................................................................................................................... 2.41 MAIN MENU SCREEN............................................................................................................................................. 2.42 ADJUST MENU.................................................................................................................................................... 2.50 HYDRAULICS.................................................................................................................................................... 2.54 MACHINE PARAMETERS................................................................................................................................. 2.50 MEASURE MENU................................................................................................................................................. 2.45 AFTERTREATMENT......................................................................................................................................... 2.49 ANTI-STALL....................................................................................................................................................... 2.48 HARVESTER..................................................................................................................................................... 2.49 HYDRAULICS.................................................................................................................................................... 2.46 INPUTS.............................................................................................................................................................. 2.45 IQAN STATUS................................................................................................................................................... 2.47 J1939 PARAMETER INPUTS............................................................................................................................ 2.48 OUTPUTS.......................................................................................................................................................... 2.46 SENSORS......................................................................................................................................................... 2.47

Controls and Operation

Tigercat H820D Harvester

SYSTEM MENU.................................................................................................................................................... 2.42 LOGS MENU..................................................................................................................................................... 2.44 MODULES MENU............................................................................................................................................. 2.43 SYSTEM INFO MENU....................................................................................................................................... 2.43 MD4 COMPUTER DISPLAY MESSAGES............................................................................................................... 2.66 MESSAGES– ALERT DIESEL EXHAUST FLUID LEVEL <5%................................................................................................................ 2.69 DIESEL EXHAUST FLUID LEVEL <10%.............................................................................................................. 2.69 DIESEL EXHAUST FLUID LEVEL EMPTY................................................................................................. 2.69, 2.70 DIESEL EXHAUST FLUID QUALITY.................................................................................................................... 2.70 WARMUP MODE..................................................................................................................................................... 2.36 CONTROL PANEL LEFT ARMREST...................................................................................................................................................... 2.17 LOWER-RIGHT........................................................................................................................................................ 2.12 REAR-RIGHT........................................................................................................................................................... 2.22 UPPER-LEFT........................................................................................................................................................... 2.18 UPPER-RIGHT......................................................................................................................................................... 2.15 CONTROL PEDALS, TRACK DRIVE.......................................................................................................................... 2.11 CONTROLS AIR CONDITIONING................................................................................................................................................ 2.18 JOYSTICK BUTTONS AND TRIGGER.................................................................................................................... 2.10 JOYSTICK LEVER..................................................................................................................................................... 2.9 LIGHTS.................................................................................................................................................................... 2.19 PEDAL CONTROLS................................................................................................................................................. 2.11 TRAVEL SPEED.............................................................................................................................................2.11, 2.17 COOLING FAN SWITCH............................................................................................................................................. 2.19 CRITICAL MESSAGES, RED..................................................................................................................................... 2.67 D

DEFAULT SETTINGS TABLE...................................................................................................................................... 2.58 DEF TANK ACCESS DOOR........................................................................................................................................ 2.74 DIESEL EXHAUST FLUID (DEF) LEVEL MESSAGE................................................................................................. 2.69 DIESEL EXHAUST FLUID (DEF) QUALITY MESSAGE............................................................................................. 2.70 DISPLAY, VIDEO......................................................................................................................................................... 2.21 E

ELECTRONIC DEVICE HOLDER............................................................................................................................... 2.14 EMERGENCY EXITS CHECKING PROCEDURE FOR ESCAPE HATCH................................................................................................. 2.28 CHECKING PROCEDURE FOR SIDE DOOR:....................................................................................................... 2.28 ESCAPE HATCH...................................................................................................................................................... 2.27 ESCAPE HATCH REMOVAL/REPLACEMENT....................................................................................................... 2.28 MAINTENANCE GUIDE........................................................................................................................................... 2.28 SIDE DOOR............................................................................................................................................................. 2.27 ENGINE ANTI-STALL, SWITCH WITH LIGHT............................................................................................................ 2.79 ENGINE COMPARTMENT POWER ROOF SWITCH................................................................................................. 2.15 ENGINE FAULT CODE MESSAGES.......................................................................................................................... 2.69 ENGINE HOT WATER SHUT-OFF VALVES..................................................................................................... 2.20, 2.27 ENGINE IDLE SPEED SWITCH................................................................................................................................. 2.17 ENGINE, RESTARTING AFTER ENGINE RUNS OUT OF FUEL............................................................................... 2.83 ENGINE, STOPPING.................................................................................................................................................. 2.83 ER BOOM SYSTEM, INSTRUCTIONS....................................................................................................................... 2.86 ESCAPE HATCH REPLACEMENT............................................................................................................................. 2.29 F

FAN SPEED SWITCH................................................................................................................................................. 2.18 FILTERS....................................................................................................................................... SEE ALSO SECTION 3 FIRE EXTINGUISHER, CAB....................................................................................................................................... 2.22 FIRE EXTINGUISHER, PORTABLE........................................................................................................................... 2.23 2.2

Tigercat H820D Harvester

Controls and Operation

FIRE SUPPRESSION SYSTEM................................................................................................................................. 2.23 DISCHARGE OF THE SYSTEM.............................................................................................................................. 2.25 MANUAL ACTUATOR.............................................................................................................................................. 2.23 SYSTEM ALARM..................................................................................................................................................... 2.24 FIRE SUPPRESSION SYSTEM, OPTIONAL AUTOMATIC OPERATION...................................................................................................................................... 2.25 DISCHARGE OF THE SYSTEM.............................................................................................................................. 2.25 IN CASE OF FIRE:................................................................................................................................................... 2.25 INSPECTION OF THE FIRE SUPPRESSION SYSTEM AND PORTABLE EXTINGUISHERS.............................. 2.26 MANUAL OPERATION............................................................................................................................................ 2.25 FIRE SUPPRESSION SYSTEM, USING.................................................................................................................... 2.24 FUEL HEATER............................................................................................................................................................ 2.80 FUEL, REFUELLING................................................................................................................................................... 2.75 FUEL TANK REFUELLING........................................................................................................................................................... 2.75 H

HEAT/COOL TEMPERATURE KNOB......................................................................................................................... 2.18 HEATER CONTROL PANEL, ENGINE COOLANT (OPTIONAL)............................................................................... 2.16 HORN/SAFETY ALERT SWITCH............................................................................................................................... 2.17 HOT WATER SHUT-OFF VALVES, ENGINE.................................................................................................... 2.20, 2.27 HYDRAULIC ADJUSTMENTS TABLE........................................................................................................................ 2.60 I

INFORMATION MESSAGES, BLUE........................................................................................................................... 2.71 INSPECTION OF THE FIRE SUPPRESSION SYSTEM AND PORTABLE EXTINGUISHERS.................................. 2.26 J

JOYSTICK CONTROLS, BUTTONS AND TRIGGER................................................................................................. 2.10 JOYSTICK CONTROLS, LEVER.................................................................................................................................. 2.9 K

KEY SWITCH.............................................................................................................................................................. 2.12 L

LIGHTS....................................................................................................................................................................... 2.19 LOAD SENSING, OPERATING TIPS.......................................................................................................................... 2.85 M

MACHINE PREPARATION.......................................................................................................................................... 2.84 SYSTEM TEST AND WARM-UP.............................................................................................................................. 2.84 MASTER ALARM........................................................................................................................................................ 2.15 MASTER ALARM, LIGHT............................................................................................................................................ 2.15 MD4 COMPUTER AND DISPLAY..................................................................................................................... 2.14, 2.32 MAIN DISPLAY........................................................................................................................................................ 2.33 O

OIL GRADE SELECTION............................................................................................................................................ 2.37 OPERATING MACHINE.............................................................................................................................................. 2.76 PRESTART CHECKS.............................................................................................................................................. 2.76 OPERATING TIPS WITH LOAD SENSING................................................................................................................ 2.85 OPERATOR'S MANUAL.............................................................................................................................................. 2.22 OPERATOR'S SEAT......................................................................................................................................... 2.30, 2.31 ADJUSTMENTS....................................................................................................................................................... 2.30 P

PICTOGRAMS.............................................................................................................................................................. 2.5 PILOT SYSTEM OFF, PUSH BUTTON SWITCH........................................................................................................ 2.13 PILOT SYSTEM RESET SWITCH.............................................................................................................................. 2.12 POWER ROOF AND DOOR, ENGINE........................................................................................................................ 2.73 POWER ROOF AND DOOR, ENGINE– ELECTRIC PUMP........................................................................................ 2.73 PUMP COMPARTMENT ACCESS DOORS................................................................................................................ 2.73 PUMP, HAND, HYDRAULIC, ENGINE COMPARTMENT ROOF AND DOOR........................................................... 2.73 2.3

Controls and Operation

Tigercat H820D Harvester

R

RADIO......................................................................................................................................................................... 2.21 REFUELLING.............................................................................................................................................................. 2.75 S

SAW SWITCH............................................................................................................................................................. 2.13 SCREEN, SIDE WINDOW.......................................................................................................................................... 2.86 SERPENTINE BELT ROUTING.................................................................................................................................. 2.78 SERVICE/ACCESS DOORS AND COVERS.............................................................................................................. 2.72 SERVICE WORK LIGHT SWITCH AND INDICATOR LIGHT..................................................................................... 2.15 SLOPE INDICATORS.................................................................................................................................................. 2.15 STARTING ENGINE.................................................................................................................................................... 2.80 COLD WEATHER STARTING.................................................................................................................................. 2.81 SWING BRAKE SWITCH............................................................................................................................................ 2.18 SWING CONTROL, JOYSTICK.................................................................................................................................... 2.9 SWITCH A/C / DEFROST....................................................................................................................................................... 2.18 AIR SOURCE........................................................................................................................................................... 2.18 BATTERY DISCONNECT........................................................................................................................................ 2.13 CAB DOME LIGHT................................................................................................................................................... 2.19 COOLING FAN......................................................................................................................................................... 2.19 ENGINE COMPARTMENT POWER ROOF............................................................................................................. 2.15 ENGINE IDLE SPEED............................................................................................................................................. 2.17 FAN SPEED............................................................................................................................................................. 2.18 HORN/SAFETY ALERT........................................................................................................................................... 2.17 IGNITION KEY......................................................................................................................................................... 2.12 PILOT SYSTEM OFF............................................................................................................................................... 2.13 PILOT SYSTEM RESET.......................................................................................................................................... 2.12 SAW......................................................................................................................................................................... 2.13 SERVICE WORK LIGHT.......................................................................................................................................... 2.15 SWING BRAKE........................................................................................................................................................ 2.18 TRACK DRIVE......................................................................................................................................................... 2.17 WORK LIGHTS........................................................................................................................................................ 2.19 T

TRACK DRIVE, CONTROL PEDALS.......................................................................................................................... 2.11 TRACK DRIVE SWITCH............................................................................................................................................. 2.17 TRAVELLING, BOOM RAISED................................................................................................................................... 2.85 TRAVEL SPEED CONTROL..............................................................................................................................2.11, 2.17 U

USB CONNECTION.................................................................................................................................................... 2.22 V

VIDEO DISPLAY, CAMERA......................................................................................................................................... 2.21 W

WARMUP MODE......................................................................................................................................................... 2.36 WORK LIGHT SWITCHES.......................................................................................................................................... 2.19

2.4

Tigercat H820D Harvester

Controls and Operation

PICTOGRAM DESCRIPTIONS Diagrams in pictorial form are used to represent machine function operation. They are a simple universal language of symbols or pictograms that illustrate a function or component without the use of words.

Examples of these pictograms are the turtle SLOW = or FAST = .

and the rabbit

that are often used to describe speed such as

= Accumulator Arms AUTO

= Boom IN or

= Accumulator Arms OPEN

= Boom OUT or

= Accumulator Arms CLOSE

= Boom UP or

= Adjustment Menu = Boom DOWN or

= Air Conditioner ON

= Boom IN– TELESCOPIC

= Air Conditioner OFF = Air Source, FRESH AIR

= Boom OUT– TELESCOPIC

= Air Source, RECIRCULATE = Clamp Arms CLOSE = Alert Message = Clamp Arms OPEN = Auxiliary Power Outlet 12 V = Control Lever Multiple Direction

= Auxiliary Power Outlet 24 V = Battery Connect

= Critical Error Message Saved

= Battery Disconnect

= Critical Message

= Diesel Exhaust Fluid (DEF)

2.5

Controls and Operation

Tigercat H820D Harvester

= Defrost, Front Window

= Engine Speed – RPM

= Disc Saw = Engine WAIT TO START = Engine Menu =ER Boom Function ON = Engine Anti-Stall = ER Boom IN = Engine Anti-Stall ON = ER Boom OUT = Engine Anti-Stall OFF = Fan Auto Reversing/Cleaning

= Engine Boost Pressure

= Fan Full ON = Engine Charge Air Pressure Filter = Fan Reverse/Clean = Engine Charge Air Temperature = Fan Ventilation Blower = Engine Coolant Temperature = Feed Rollers – Forward

= Engine Diagnostics = Engine Emission Filter

= Feed Rollers – Reverse

= Engine Emission Inhibit Mode

= Fluid Level High

= Engine Emission System Temperature = Fluid Level Low = Engine – Percentage of Load = Foot Pedal Control = Engine Oil Pressure = Fuel Consumption Rate = Engine Oil Temperature

2.6

Tigercat H820D Harvester

Controls and Operation

= Fuel – Diesel

= Horn

= Fuel Heater

= Hours – Machine

= Fuel Information

= Hours – Engine

= Fuel Reset = Hydraulic OIL FILTER BYPASS

= Fuel – Temperature = Fuel – Water in Fuel

= Hydraulic Tank

= Harvester Head

= Hydraulic Oil GRADE

= Harvester Head – TILT FLOAT

= Hydraulic Oil LEVEL

= Harvester Head – TILT DOWN

= Hydraulic Oil TEMPERATURE

= Information Menu = Harvester Head – TILT UP = Information Message = Harvester Head – ROTATE (CW)

= Lights = WORK

= Lights – ENGINE SERVICE

= Harvester Head – ROTATE (CCW)

= Metric/Imperial Toggle = Head Tilt Forward = Pilot System OFF = Head Tilt Back

2.7

Controls and Operation

Tigercat H820D Harvester = Switch OFF

= Pilot System ON (Reset)

= Switch ON = Roof CLOSE (Switch Icon) = Temperature = Roof OPEN (Screen icon) = Track LEFT FORWARD/ REVERSE and TRAVEL = Roof OPEN (Switch icon)

= Track RIGHT FORWARD/ REVERSE

= Vacuum

= Saw CUT

= Wheel Arms– CLOSE = Side Door OPEN (Screen Icon) = Wheel Arms– OPEN

= Speed CREEP or Very Slow

= Wrist COUNTERCLOCKWISE

= Speed FAST or HI = Speed SLOW or LOW

= Wrist CLOCKWISE = Swing BRAKE

= Swing RIGHT (CW)

= Swing LEFT (CCW)

2.8

Tigercat H820D Harvester

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.

JOYSTICKS CONTROLS Each joystick has four primary functions as outlined below:

RIGHT JOYSTICK

LEFT JOYSTICK

855C-016A

855C-016

HOIST BOOM, UP/DOWN

STICK BOOM, FORWARD/BACK

• Move the joystick back to raise the boom UP.

• Move the joystick back to move the boom IN toward the machine.

• Move the joystick forward to lower the boom DOWN.

• Move the joystick forward to move the boom OUT away from the machine.

ATTACHMENT, ROTATE • Move the joystick right to rotate the attachment CW.

SWING, LEFT/RIGHT

• Move the joystick left to rotate the attachment CCW.

• Move the joystick right to swing the upper structure to the RIGHT (CW).

• Move the joystick left to swing the upper structure to the LEFT (CCW).

2.9

Controls and Operation

Tigercat H820D Harvester

JOYSTICK BUTTONS/TRIGGERS

3. Tap the desired function from the upper part (A).

NOTE: The icons that are greyed out cannot be selected as these functions are not available on your machine model.

The joystick buttons and trigger are programmable to allow customized operator selections for both joysticks.

NOTE: This information is only relevant to machines that are factory equipped with programmable joysticks.

4. Repeat steps 1 – 3 for all desired buttons and triggers.

The desired function is now displayed in the lower part against the selected button or trigger.

A

B

C 822D-008

A Function Pictograms B Joystick Buttons and Trigger C Joystick Configuration Icon

1. Tap the joystick configuration icon on the touchscreen display to access the configuration menu (C).

The center part displays the joystick buttons and triggers to be selected for configuration. The lower part displays the functions configured for each button and trigger.

822D-011

EXAMPLE 5. Hold down the left trigger button on the joystick.

The icon for the button or trigger selected will illuminate on the centre part of the screen.

6. Tap the Rotate Wrist CCW icon in the upper part.

The Rotate Wrist CCW icon is now displayed against the left trigger in the lower part.

The left trigger is now configured for Rotate Wrist CCW.

2. Hold down the joystick button or trigger to be customized.

The button or trigger (B) will highlight in the centre part of the screen.

2.10

Tigercat H820D Harvester PEDALS CONTROLS

Controls and Operation TRAVEL SPEED CONTROL The travel speed control feature allows the operator to set the maximum speed of the machine to maintain a constant speed without having to feather the drive pedals.

NOTE: The default is set to maximum.

A

B

822D-109

A Left Foot Pedal B Right Foot Pedal

LEFT FOOT PEDAL– LEFT TRACK DRIVE • Depress the left control pedal with the toe to drive the left track forward.

• Depress the left control pedal with the heel to drive the left track reverse.

RIGHT FOOT PEDAL– RIGHT TRACK DRIVE • Depress the right control pedal with the toe to drive the right track forward.

• Depress the right control pedal with the heel to drive the right track reverse.

TRAVELING

A

B

Travel is accomplished by depressing both control pedals simultaneously. Travel over distances should be done in the forward direction to reduce wear on the track components.

NOTE: Track drive gearboxes are considered to be at the rear of the machine for travelling in the forward direction.

MD0040

A Track Speed Indicator B Track Speed Adjuster

Tap and slide the track speed adjuster to the left along the line to decrease ( ) the maximum speed of the machine.

Tap and slide the track speed adjuster to the right along the line to increase ( ) the maximum speed of the machine.

The green track speed indicator is a secondary visual indicator and displays the speed as the adjustment is made. This function can be used while the machine is in motion in either HIGH or LOW travel speed selections.

NOTE: When the ignition key is turned OFF and then turned back ON, the travel speed control resets back to maximum speed.

2.11

Controls and Operation

Tigercat H820D Harvester

CONTROL PANEL (LOWER-RIGHT) A

B

C

D

E

822D-018

A Ignition Key Switch B Pilot System Reset Switch C Pilot System OFF Switch

D Saw Switch E Fire Suppression System Control Panel* *Refer to FIRE SUPPRESSION SYSTEM in THIS SECTION

IGNITION KEY SWITCH

PILOT SYSTEM RESET SWITCH

This is a three-position switch with STOP/RUN/START positions.

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 icon ( ) will be activated (green) on the MD4 Computer display module.

STOP Position – All electrical power through the key switch is turned OFF.

WARNING

Electrical power is still available for the horn, radio, two-way radio/CB, cab interior light, defroster fan, work lights and service lights.

DO NOT defeat the door pilot switch. It is an important safety feature. Failure to comply could result in death or injury.

RUN Position – The battery is connected to all functions.

Used for normal machine operation.

START Position – Turning the key to this position starts the engine by connecting the battery to the start relay.

The key will return to the RUN position when released.

NOTE: The front door must be closed to activate the pilot system (Pilot Interlock Switch). The side door exit will not de-activate the pilot system when opened.

NOTE: The pilot system must be OFF to start the engine. To de-activate the pilot system, push the red PILOT OFF switch (C) DOWN.

2.12

Tigercat H820D Harvester

Controls and Operation

PILOT SYSTEM OFF SWITCH (UPPER-LEFT PILLAR)

BATTERY DISCONNECT SWITCH (RIGHT SIDE PANEL)

A A

B

822D-022

A Pilot Interlock Switch B Actuator (On Door)

This is a push OFF spring return switch. This switch turns OFF the pilot system, deactivating all operating functions as well as applying the track drive brake and swing brake. The pilot OFF icon ( ) will be activated (yellow) on the MD4 Computer display module.

The pilot system can be reactivated when the PILOT RESET button is pressed with the front door closed.

IMPORTANT! If the pilot off switch does not stop functions, turn OFF the ignition key.

LX830D-032

A Battery Disconnect Switch

This manually operated switch completely disconnects all electrical circuits on the machine from the battery except for the fire suppression and service light circuits.

NOTE: Tier 2 machines are equipped with an After Run Relay which delays the power disconnect to the engine ECU for 90 seconds after the battery disconnect switch has been turned off. The Engine ECU is still powered during the 90 seconds.

This saw switch supplies power to the attachment`s control systems.

NOTE: Tier 4f machines are equipped with an After Run/ Accessory Relay which delays the power disconnect to engine related fuses and relays ECU (ECM)/ATS relay, NOX Sensor relay, NOX Sensor fuse, ECU (ECM) Power fuse). Whenever the engine is stopped all DEF solution is pumped back to tank before the engine power system is turned off. This process takes approximately 90 seconds.

A lockout button is incorporated into the switch to prevent the switch from being turned on accidentally.

Refer to AFTERTREATMENT SYSTEM in SECTION 3 for more information.

To turn the switch to ON, slide and hold the lockout button toward the ON position and then place the switch in the ON position.

NOTE: The aftertreatment system and its related components are applicable to Tier 4f machines only.

SAW SWITCH This is a two-position locked saw switch labelled (ON) / (OFF). On Harvester Model Machines.

NOTE: Place the engine idle speed switch to the HIGH position before turning the attachment ON. NOTE: If the engine is turned OFF or the pilot shut-off system is tripped (Front Door opened) with the saw switch left in the ON position, the attachment will not start up when the engine is restarted or the front door is closed. You must press the PILOT RESET button and then, turn the saw switch OFF and then ON. NOTE: The function of this switch may vary depending on the attachment model used and method of installation. Verify all functions before operating this machine.

2.13

Controls and Operation

Tigercat H820D Harvester

MD4 COMPUTER AND DISPLAY (RIGHTCENTRE PILLAR)

CAMERA (LEFT-FRONT PILLAR)

A A

822D-120

A Camera

A digital camera, mounted near the bottom of the leftfront pillar, provides the operator with a better view of the overhead operation that cannot be seen due to the cab roof. See VIDEO DISPLAY, CAMERA in THIS SECTION.

B

822D-114

A MD4 Computer and Display B Electronic Device Holder

The computer, electronic control and display module is the operator interface with the electronic control system. The MD4 Computer display is the central unit in the control system which works as both a master controller and a display unit. It has a seven inch backlit colour graphic touchscreen display for reading system information.

Refer to MD4 COMPUTER DISPLAY MESSAGES in THIS SECTION for complete operating instructions and system details.

ELECTRONIC DEVICE HOLDER (RIGHTCENTRE PILLAR) The machine is equipped with an electronic device holder, located near the bottom of the right-centre pillar, to secure your mobile phone (or other electronic devices). The securing arms are spring loaded and designed to fit various sizes of electronic devices.

2.14

Tigercat H820D Harvester

Controls and Operation

CONTROL PANEL (UPPER-RIGHT) A

SERVICE WORK LIGHT SWITCH AND INDICATOR LIGHT

B

This is a two-position switch. Place the switch in the position to turn ON the service work lights. The amber indicator light will turn ON to notify the operator the service work lights are ON. Place the switch in the alternate position to turn OFF the service work lights.

C

D

E

The service lights are located in the following areas: • Pump compartment • Engine compartment

G

• Cooling compartment

F

• Hydraulic tank compartment

822D-152

A B C D E F G

Engine Compartment Power Roof Switch Service Work Light Switch Service Work Light Indicator Light Engine Coolant Heater Control Panel Slope Indicators Master Alarm Light Master Alarm

ENGINE COMPARTMENT POWER ROOF SWITCH This is a three-position momentary switch labeled (open) – (close), with a spring return to the centre OFF position. Push and hold the switch in the OPEN position to OPEN the roof and side engine door. Push and hold the switch in the CLOSE position to CLOSE the roof and side engine door.

MASTER ALARM AND MASTER ALARM LIGHT The MD4 Computer displays messages and activates the master alarm and red master alarm light whenever a system fault occurs.

NOTE: The MD4 Computer automatically performs a test at engine start up to ensure the alarm and alarm light are functioning. Refer to MD4 COMPUTER DISPLAY MESSAGES in THIS SECTION.

SLOPE INDICATORS Two slope indicators are provided. One indicates forward and backward slope angle and the other indicates sideto-side slope angle.

CAUTION Watch for personnel in the area of the power door before opening the door.

NOTE: The power door is equipped with a motion alarm that sounds when it is moved.

The power door is operated by a dedicated Electric Pump Hydraulic System located at the front of the pump compartment on the right side of the machine next to the boom. This system is self-contained with its own oil tank.

For more information, refer to SERVICE/ACCESS DOORS AND COVERS in THIS SECTION.

2.15

Controls and Operation

Tigercat H820D Harvester

HEATER CONTROL PANEL, ENGINE COOLANT (OPTIONAL) B C

A

D D F

LS855D-015

A B C D E F

E

ON/OFF Button Rotary Knob LCD Screen Status Indicator Light(s) Micro USB Service Port Selection Button

This heater, heats and circulates the engine coolant through the engine, the hydraulic tank, and the cab.

This digital control panel is used on machines equipped with the optional diesel-operated engine coolant heater.

There is a solenoid valve controlling the flow of coolant to the hydraulic tank heater. This solenoid valve is controlled directly by the heater unit. The programming of the heater unit in the cab determines when the heater is ON and OFF. Consult the MANUFACTURER INSTRUCTION MANUAL for additional information.

Refer to ENGINE COOLANT HEATER (OPTIONAL) in SECTION 3 for additional information.

2.16

Tigercat H820D Harvester CONTROL PANEL (LEFT ARMREST) A

B

Controls and Operation 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 one to two seconds, due in part to the infinitely variable displacement drive motors used. When travelling on relatively flat terrain it is not necessary to place the range switch in the LOW position.

ENGINE IDLE SPEED SWITCH C

822D-020

A Track Switch B Engine Idle Speed Switch C Horn

TRACK DRIVE SWITCH This is a two-position switch with LOW ( ) and HIGH ( ) options. Refer to TRAVEL SPEED CONTROL in THIS SECTION. LOW: Place the switch in the LOW position to provide the slowest travel speed but with increased torque or driving force. Place the switch in the HIGH position to provide a faster travel speed range but with a lower driving force.

It is recommended that during all harvesting functions and when travelling on slopes, the range switch be placed in the LOW position to maximize drive motor life.

The TRACK LOW icon is also displayed on the MD4 Computer display.

HIGH: When this switch is in the HIGH 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 the available torque when travelling at maximum speed is only half of that in LOW. The HIGH 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 all the way down to LOW, this will be dependent on the terrain conditions encountered.

This is a three-position momentary switch connected into the engine CPU circuit to adjust the engine speed between the LOW IDLE and HIGH IDLE set points. The default center position is OFF. Press and hold this switch in the HIGH position to increase engine speed. Release the switch at the desired speed or continue to hold to place the engine at the HIGH IDLE setting.

Press and hold this switch in the LOW position to decrease engine speed. Release the switch at the desired speed or continue to hold to place the engine at the LOW IDLE setting.

Maintaining Correct Engine Speed It is most important the LOW and HIGH idle speeds of the engine be correct at all times: • LOW IDLE– 950 rpm (No Load) • HIGH IDLE– 1820 rpm max (No Load) • RATED WORKING– 1800 rpm NOTE: At start-up, the engine will always default to LOW IDLE. These speeds are with the hydraulic and engine oil at normal operating temperatures and no functions activated and without the pilot system engaged. The speeds are preset into the engine CPU (computer) and cannot be adjusted without the proper electronic equipment programming software. Check the engine speed regularly with engine diagnostics module.

IMPORTANT! Under no circumstances allow the high idle engine speed to vary from the recommended settings; particularly faster, this could cause serious damage to the pumps.

HORN/SAFETY ALERT SWITCH This is a two-position momentary switch. Press and hold this switch in the position to sound the safety alert horn.

Always use this horn prior to starting the engine and to alert other personnel in the area of your presence.

2.17

Controls and Operation

Tigercat H820D Harvester

CONTROL PANEL (UPPER-LEFT) C

D

E

F

G

H

I

B

A

822D-021

A B C D E

Heat/Cool Temperature Knob Fan Speed Knob Swing Brake Switch Air Source Switch A/C / Defrost Switch

HEAT/COOL TEMPERATURE KNOB This is a variable, rotary knob used to adjust the temperature of the air for the cab by controlling the flow of engine coolant through the heater core.

F G H I

The brake is also engaged whenever the pilot system is turned OFF. As a safety precaution, the brake should always be applied with this switch when leaving the cab.

CAUTION

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. Refer to HOT WATER SHUT-OFF VALVES, ENGINE in THIS SECTION. Refer to CHECKING THE AIR CONDITIONING SYSTEM in SECTION 3.

FAN SPEED KNOB This is a rotary, five-position (OFF/1/2/3/4) knob to control the speed of the blower fan (1=low, 4=high).

SWING BRAKE SWITCH This is a two-position switch to engage/disengage the swing brake. Place the switch in the position to engage the swing brake and prevent the upper structure from turning. Place the switch in the alternate position to disengage the swing brake. The swing brake is a spring apply, hydraulic release, multi-disc brake.

Cab Dome Light Switch Work Light Switch Work Light Switch System Cooling Fan Switch

• 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.

AIR SOURCE SWITCH This is a two-position switch used to select fresh outside air or recirculation of inside cab air. Place the switch in the position to introduce fresh external air into the cab. Place the switch in the position to recirculate the cab air.

A/C / DEFROST SWITCH This is a three-position switch labelled A/C / DEFROST. The center position is OFF. Place the switch in the position to turn ON the A/C compressor for cooling.

Place the switch in the position to activate the defrost mode.

2.18

Tigercat H820D Harvester

Controls and Operation

CAB DOME LIGHT SWITCH

SYSTEM COOLING FAN SWITCH

This is a two-position switch to turn the interior cab dome lights ON/OFF. Place the switch in the position to turn ON the interior cab done lights. Place the switch in the alternate position to turn OFF the interior cab dome lights.

This is a three-position switch, labelled (CLEAN) / AUTO / (FULL ON). This switch, along with an electronic fan control module, controls the operation of the hydraulically-driven cooling fan.

B

A

822D-022

A Cab Dome Light Switch B Actuator (On Door)

The front door of the cab is also equipped with a plunger switch. When the door is opened, the switch is released and the interior cab dome lights turn ON.

WORK LIGHTS SWITCHES A

When the switch is in the AUTO position and the fan runs at minimum speed due to low charge air, engine coolant or hydraulic oil temperatures, turning ON the A/C will cause the fan control to increase the cooling fan speed when the engine is at high idle. This ensures sufficient air flow is available for the cab A/C even while the machine is still warming up.

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

A

A 822D-030

AUTO POSITION– This is the normal operating position for the fan control switch. When the switch is in the AUTO position, the fan will operate completely in an automatic mode. It will start, speed up or slow down all based on the temperature of the charge air, engine coolant and/or the temperature of the hydraulic oil. The electronic control module automatically adjusts the fan speed to the minimum required level to maintain optimal operating conditions, and default to fan at full speed if an error in the controller exists.

NOTE: Placing the switch in the FULL ON position activates an alarm to advise the switch has been placed in the FULL ON position. Also while the switch is in the FULL ON position the Automatic Cleaning cycle is prevented.

822D-138

CAUTION

A Work Lights

Before placing the fan switch in the CLEAN position, there must be no personnel near the REAR of the machine in the area where the fan will expel debris.

These are two-position switches. Place a switch (G) (H) in the position to turn ON the work lights. Place a switch in the alternate position to turn OFF the work lights.

CLEAN – Momentarily press (no need to hold the switch down) the switch in the CLEAN position to automatically start reversing the direction of fan rotation. Reverse rotation is used to clean the charge air cooler, radiator, oil cooler, A/C condenser and air intake door screens. By reversing the flow of the fan, air flow is propelled in the opposite direction, thereby forcing dust and debris off of the radiator.

2.19

Controls and Operation

Tigercat H820D Harvester HOT WATER SHUT-OFF VALVES (ENGINE)

NOTE: The pilot system must be ON to operate the clean cycle.

The electronic fan control will also turn the A/C system OFF for as long as the fan is in the CLEAN mode.

When the CLEAN cycle is complete the fan automatically returns to normal rotation direction.

A

NOTE: The CLEAN cycle also operates automatically via the timed purge function of the MD4 Computer system (frequency is adjustable). Refer to MD4 COMPUTER DISPLAY MESSAGES– INFORMATION MESSAGES in THIS SECTION.

B

822D-024

NOTE: If engine speed falls to 875 rpm or less the speed control is automatically overridden and fan speed defaults to the forward direction.

A

B

822D-105

A B C D

Screw-type Shut-off Valve (Right Side) Hose to A/C / Heater Unit Ball-type Shut-Off Valve (Left Side) Hose from A/C / Heater Unit

To maximize the efficiency of the air conditioning, the heat/cool switch on the upper-left control panel must be rotated to the MAX COLD position. During times when cab heating is not required, close the screw-type hot water shut-off valve on the engine block to prevent hot water from seeping through the A/C unit and thereby reducing the effectiveness of the cooling system.

2.20

Tigercat H820D Harvester

Controls and Operation

RADIO

PILLAR (RIGHT-FRONT) A

B

A 845D-111

A Radio B Bluetooth Microphone

The machine is equipped with a bluetooth-enabled AM/ FM radio that includes four speakers (two at the front of the cab and two in the rear of the cab). There is also a microphone to the left of the radio in the header above the Operator’s head. Refer to the stereo manufacturer’s manual for operation and safety warnings.

B

822D-114

A Video Display for Camera B Auxiliary Power Outlet (12V)

VIDEO DISPLAY, CAMERA This machine is equipped with a video display that is connected to a camera to provide the operator with a better view of the overhead operation that cannot be seen due to the cab roof. Refer to CAMERA in THIS SECTION.

AUXILIARY POWER OUTLET This is a 12 V outlet with a 7.5 A capacity for portable devices, e.g., mobile phones, MP3 player, etc.

2.21

Controls and Operation

Tigercat H820D Harvester

CONTROL PANEL (RIGHT-REAR) A

REAR WALL, CAB B A

B C 845D-113

A Auxiliary Input B USB Connection C Auxiliary Power Outlet (12V)

AUXILIARY INPUT

822D-029

This is a 3.5 mm (0.125 in) audio jack that allows input from an external audio device to the radio, e.g., mobile phones, storage devices, etc.

A Operator's Manual Box B Portable Fire Extinguisher

OPERATOR’S MANUAL BOX

USB CONNECTION This connector allows connection of an external audio device to the radio, e.g., mobile phones, MP3 player, etc.

The box contains the machine Operator’s Manual, as well as all other associated manuals and, is located on the rear wall of the cab directly behind the operator seat.

AUXILIARY POWER OUTLET

FIRE EXTINGUISHER, PORTABLE

This is a 12 V outlet with a 7.5 A capacity for portable devices, e.g., mobile phones, MP3 player, etc.

The portable fire extinguisher is located on the rear wall of the cab, directly behind the operator’s seat, next to the Operator’s Manual box.

2.22

Tigercat H820D Harvester

Controls and Operation

FIRE SUPPRESSION SYSTEM

A

FIRE SYSTEM– MANUAL ACTUATOR KNOB (LEFT-FRONT PILLAR)

B

A

B C

822D-122

A Actuator Knob B Locking Pin

822D-118

A Pressure Gauge Pointer must be in Green Zone B Electrical Actuator C Pressurized Cylinder

The fire suppression system installed on this machine uses a dry chemical powder which is stored in a 23 kg (50 lbs) pressurized cylinder. It is discharged through six nozzles strategically placed in the engine compartment and hydraulic areas.

In the event of a power failure, the fire suppression system can be activated by the nitrogen actuator knob located on the front left pillar of the cab.

1. Remove locking pin.

2. Strike down hard on actuator knob.

FIRE EXTINGUISHER– PORTABLE

A

822D-029

A Portable Fire Extinguisher

The portable fire extinguisher is located on the back wall, directly behind the operator’s seat.

2.23

Controls and Operation

Tigercat H820D Harvester

USING THE FIRE SUPPRESSION SYSTEM A

SYSTEM ALARM When either the heat detection circuit has detected fire or the Manual Actuation Switch has been depressed, the following sequence will occur:

B

1. System OK LED will turn OFF.

G

2. The alarm buzzer will sound continuously.

C

F

3. The FIRE LED will illuminate.

E

4. The relay will engage at the expiry of the programmed delay (default is 0 seconds).

D

5. The Relay Reset LED will illuminate.

822D-018

A B C D E F G

Fire Suppression System Control Panel

6. The Service System LED will illuminate.

System OK LED Audible Alarm Alarm Silence Button and LED 'Push to Test' Button Service System LED Relay Reset Button and LED Fire Alarm LED

7. The Service System LED will flash four times to indicate actuator trouble.

When the FIRE LED first comes on, it will flash a number of times to indicate which hazard zone is in alarm.

The heat detection circuit corresponds to one zone and the manual actuation switch correspond to another zone.

The machine leaves the factory with the fire suppression system fully activated.

The alarm flash codes are as follows:

NOTE: Machines shipped to international destinations have the fire suppression system deactivated to prevent accidental discharge. The in-line fuse for the power lead wire to the battery (in the battery compartment) is removed and wire tied to the fuse holder.

• Heat Zone 1 Alarm

1 Flash

• Heat Zone 2 Alarm

2 Flashes

• Both Zones in Alarm

3 Flashes

The system is not certified for use, certification must be performed by an approved local dealer.

The system will remain in alarm until the system has been serviced and the actuator has been replaced.

NOTE: A pre-delivery inspection of the fire 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 FIRE SUPPRESSION SYSTEM AND PORTABLE EXTINGUISHERS in THIS SECTION.

SERVICE SYSTEM In the event of a system fault: • The Service System LED will illuminate.

• The alarm will pulse.

The Service System LED will flash to signify the fault source. The source of the fault can be determined as follows:

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

Refer to FIRE SUPPRESSION SYSTEM, OPTIONAL in THIS SECTION for complete details.

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

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.

When the panel is connected to an operational configuration, the system will illuminate the green 'System OK' LED.

• Main Power Trouble

1 Flash

• Heat Zone 1 Trouble

2 Flashes

• Heat Zone 2 Trouble

3 Flashes

• Actuator Trouble

4 Flashes

• Backup Battery Trouble

5 Flashes

• Pressure Switch Trouble

7 Flashes

When a system fault is detected there is a five second delay before notification. For main power trouble, the delay for notification is 20 seconds.

2.24

Tigercat H820D Harvester

Controls and Operation

AUTOMATIC OPERATION

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 a Factory Certified Personnel before returning the machine to service.

There are six thermostats mounted in the engine and hydraulic enclosures which are wired to the 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 which activates the system.

DISCHARGE OF THE SYSTEM

MANUAL OPERATION

When an electrical signal (automatic or manual) is received by the control panel, it sends a discharge signal to the electrical actuator located on top of the pressurized cylinder. When activated, the electrical/ pneumatic 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. The control panel will also automatically turn OFF the engine and all electrical power.

A

NITROGEN B ACTUATOR 2

C

C

822D-018

NOTE: The engine does not shut down automatically when the fire suppression system is activated using the nitrogen actuator. When using the nitrogen actuator to activate the fire suppression system, the operator must turn OFF the engine manually.

860-123

A Red Fire Button B Actuator Knob C Locking Pin

The automatic engine shutdown feature will either turn OFF the engine immediately when the fire suppression system is discharged (non-leveling machines) or will delay the shutdown for a period of between 10 – 15 seconds for leveling machines. The time delay period is a factory setting that allows the operator to lower the load or move the machine to a safer location before the engine turns OFF. The operator can extend the engine shutdown delay feature by pressing the relay 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 relay reset button does not delay the discharge of the fire suppression system.

If a fire starts in any space protected by the system, DO NOT wait for the system to operate automatically. The fire suppression system can be activated manually using the manual actuation button: 8. Safely lower the boom to the ground.

9. Pull the locking pin (C).

10. Press the red FIRE button (A).

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

In the event of a power failure the system can be activated by the Nitrogen Actuator located on the front left pillar of the cab:

CAUTION

11. Remove the locking pin (C).

Wear protective clothing and masks when cleaning up after a discharge.

12. Strike down hard on the actuator knob (B).

IMPORTANT! Turn OFF the engine before discharging the system to keep the dry chemical in the engine area. Get away from the machine. If possible and safe to do so, take the portable fire extinguisher with you (located inside the cab on the rear wall behind the operator seat) or obtain one from another location.

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

Before cleaning up after a discharge, read the fire suppression system manual. If water mixes with the dry chemical it becomes corrosive and can seriously damage wiring connections.

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

2.25

Controls and Operation

Tigercat H820D Harvester

INSPECTION OF THE FIRE SUPPRESSION SYSTEM AND PORTABLE EXTINGUISHERS

A

IMPORTANT! Upon machine delivery, the fire suppression system installation needs to be inspected and signed off by a certified Amerex Technician prior to using the machine for the first time.

DAILY • Check the pressure gauges on all agent cylinders and N2 cylinders for proper operating pressure (pointer is in the ‘green pie’ zone). The agent cylinder is located in the radiator/engine compartment next to the cooler package on the right side of the machine behind the engine.

A

822D-033

A Typical Thermostat

• Ensure that all thermostats are clean.

• Operate the machine and depress the 'Push to Test' button to confirm the automatic engine shutdown feature is working. Depressing the 'Push to Test' (diamond-shaped) button will illuminate all LED’s, sound the alarm and engage the relay. The 'Push to Test' function will not cause a system discharge.

B

• Check the manual actuation switches to ensure all tamper indicators are in place, operating instructions are visible and access is unobstructed.

822D-029

A Pressure Gauge Pointer Must be in Green Zone B Portable Fire Extinguisher

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

NOTICE

The portable fire extinguisher is located inside the cab on the rear wall behind the operator seat.

Take care not to damage heat sensors or wiring.

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 an accidental discharge of the system. Refer to FIRE SUPPRESSION SYSTEM COMPONENTS in SECTION 3.

• Make sure the green System OK LED on the system control panel is illuminated.

WEEKLY • Inspect all parts for damage, rust, corrosion or dirt.

Replace any damaged parts immediately.

• Check that all components are in place and unobstructed.

• Check that all chemical delivery hoses and nozzles are connected and tight.

• Check the fire suppression electrical network for cut, frayed, stripped or damaged wires.

2.26

Tigercat H820D Harvester

Controls and Operation

EMERGENCY EXITS

If you are unable to use either the front or side doors, due to blockage or lack of access, use the roof escape hatch (third emergency exit). Turn OFF the engine before using this exit.

SIDE DOOR

There 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.

A

822D-025

A

A Side Door Lever

This side door serves as one of three emergency exit routes from the cab. Turn OFF the engine before using this exit. Opening the side door WILL NOT deactivate the pilot system, therefore, only use this door in the event the front door cannot be used.

ROOF ESCAPE HATCH

822D-032

A Escape Hatch External Retaining Knobs

This escape hatch can also be opened from the outside of the cab. Turn both knobs counterclockwise. If they are too tight to turn by hand, you can kick the knob at either end to loosen it. Once the knobs are removed, lift the escape hatch from the cab roof.

WARNING Removal of these knobs from the outside will cause internal knobs and brackets to fall freely, possibly striking the operator and causing additional injury.

B

A

For more information refer to EMERGENCY EXITS– MAINTENANCE GUIDE in THIS SECTION.

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 proper maintenance procedures can result in the exit being unusable in an emergency.

822D-012

A Escape Hatch B Escape Hatch Internal Retaining Knobs

2.27

Controls and Operation

Tigercat H820D Harvester

EMERGENCY EXIT– MAINTENANCE GUIDE Two alternate exit routes are provided. One on the left side and one on the roof of the cab. These are only to be used if the front door cannot be opened.

A

These emergency exits must be checked at least once per month or after major impacts to the cab to ensure they are fully operational.

It is also important that clear any snow, debris and particularly ice build up in these areas. Check frequently and remove any accumulation immediately.

860C‑227

CHECKING PROCEDURE FOR SIDE DOOR A

822D-025

B

A Escape Hatch

4. Disengage the clamp brackets from the slot on the cab roof attachment bracket.

The escape hatch should move without using excessive force by pushing up on one side. If the escape hatch does not move without excessive force, refer to ESCAPE HATCH REMOVAL FOR MAINTENANCE OR REPAIR and ESCAPE HATCH REPLACEMENT in THIS SECTION.

822D-102

A Side Door Latch (Interior) B Side Door Latch (Exterior)

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 any part of the mechanism that requires attention.

CHECKING PROCEDURE FOR ESCAPE HATCH A

5. Engage the clamp bracket in the slot of cab roof bracket and hand-tighten the hand knobs.

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

ESCAPE HATCH REMOVAL FOR MAINTENANCE OR REPAIR

B

A

822-D30

A Clamp Bracket B Retaining Knob

3. Unscrew both interior retaining knobs four complete revolutions.

822-D31

A Escape Hatch Clamp Bracket

6. Unscrew both of retaining knobs and remove the two clamp brackets.

7. Push open the escape hatch from the inside. In the event the hatch has become bonded to the cab roof due to improper maintenance, use a pry bar taking care not to damage the sealing surface of the roof.

2.28

Tigercat H820D Harvester

Controls and Operation 11. Replace the nylon inserts in each stud, leaving approximately 3.5 mm (0.125 in) protruding at each end. These are to prevent the hand knobs from becoming loose under vibration.

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 can also bond the exit panel.

12. Apply an anti-seize compound to the stud threads on the escape hatch and engage the hand knob threads three revolutions with washer and clamp bracket in place as illustrated.

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

A

8. Refer to ESCAPE HATCH REPLACEMENT in THIS SECTION for instructions on the proper method to use when replacing the escape hatch.

B C

F

D

ESCAPE HATCH REPLACEMENT D

A E LH830-06

A B C D E F

B

13. To prevent foam seal or rubber 'C' channel from sticking to escape hatch or roof over time, apply a thin film of Tigercat part number AM926 dielectric non-curing silicone lubricant to the contact surfaces of foam seal and rubber 'C' channel. Remove excess spray with a dry rag so no build up remains.

C

822-01 822-02

A B C D

Cross Section of Escape Hatch Seal

Foam Seal Escape Hatch 'C' Channel Rubber Cab Roof Apply Lubricant to 'C' Channel Rubber Apply Lubricant to Top Surface of the Foam Seal

IMPORTANT! Too much lubricant will cause the roof escape hatch to stick to the cab roof.

Escape Hatch Cab Retaining Knob Nylon Insert

14. Install the escape hatch on the roof and engage the clamp bracket in the slot of the cab roof bracket.

NOTE: Do not apply silicone sealant between the Escape Hatch and the Cab Roof

15. Hand-tighten the knobs.

Silicone sealant in these areas can bond the escape hatch to the cab, preventing removal of the escape hatch.

9. 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.

10. Ensure the escape hatch gasket is in good condition; replace if damaged.

2.29

Controls and Operation

Tigercat H820D Harvester

OPERATOR'S SEAT– AIR RIDE

• To increase Seat Firmness (C) – Push the air valve knob to add air for a firmer seat. Release the knob when the desired seat firmness is achieved.

• To Decrease Seat Firmness (C) – Pull the air valve knob to soften the seat by removing air. Release the knob when the desired seat firmness is achieved.

• Fore/Aft Slide (B)– Move and hold fore/aft slide lever.

Roll seat forward or backward to the desired position relative to the foot pedal controls.

D

E

• Back Angle Adjustment (E) – Rotate back angle adjustment knob to place seat at the desired angle.

A

C S855C-020

A B C D E

A

B

Height Adjustment Lever Fore/Aft Slide Lever Air Ride Adjustment Knob Lumbar Adjustment (Refer to Right Side of Seat) Back Angle Adjustment Knob

B

332-6

Right Side

A 2-Way Lumbar Horizontal Adjustment B Armrest Adjustment

WARNING The seat and shoulder restraint belts must be used at all times when operating this machine.

• Lumbar Adjustment (A) – For fore-and-aft displacement, rotate horizontal adjustment knob.

• Armrest Adjustment (B) – Each armrest has two adjustments to place it in the required position.

Loosen the adjustment locking wing bolts to reposition armrest height and fore/aft position.

ADJUSTMENTS • Height Adjustment (A) – The spring-assisted height adjustment is controlled by the height adjustment lever located on the front-left side of the seat chassis.

• To Raise – Firmly lift up on the height adjustment lever to disengage it. Hold the lever up, while partially lifting the operator’s body weight from the seat. When the seat is at the desired height, release the lever to allow it to engage (a click should be heard).

• To Lower – Firmly lift up on the height adjustment lever to disengage it. Hold the lever up while applying operator body weight to the seat until the seat is at the desired height. Release the lever to allow it to engage (a click should be heard).

2.30

Tigercat H820D Harvester

Controls and Operation

PROBLEMS AND CORRECTIVE ACTION

A

B

E C

D S855C-020B

A Back Angle Adjustment B Lumbar Adjustment C Height Adjustment

Seat Adjustments

D Fore/Aft Slide E Air Ride Adjustment Knob

• Rides is 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 the height adjustment lever to raise the seat.

• Seat is too high/seat too low Adjust seat to the desired position. If the proper height cannot be achieved using the height adjustment lever, 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..

• Rides is too soft or bottoms out and pinches the 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.

2.31

Controls and Operation

Tigercat H820D Harvester

MD4 COMPUTER AND DISPLAY The computer, electronic controller and display is the operator interface with the electronic control system. It is the central unit in the control system which works as both a master controller and a display unit.

D

E

F

G

It has a 178 mm (7 in) backlit colour touchscreen display for reading and altering system information and controls.

H

I

J

K

L M

C

N4

B

O P Q

A

R

PP

S T

OO

U V NN W MM X Y

LL

Z KK

AA BB

CC

JJ

DD

II

HH

GG

FF

MD0001

2.32

EE

Tigercat H820D Harvester

Controls and Operation MD4 COMPUTER AND DISPLAY– MAIN SCREEN

A Hydraulic Oil Level

V

Fuel Level Warning (Icon is Greyed-out When Roof is Open)

B Water In Fuel

W DEF Level Indicator (Tier 4f machines only)

C Pilot System ON/OFF

X

Engine Horsepower

D Anti-stall (OFF)

Y

Fuel Consumption Rate

E Engine Air Intake Filter Restriction

Z

Tree Counter

F Open Engine Compartment Roof

AA Fuel Trip Reset

G Open Engine Compartment Side Door

BB Toggle Between Metric and Imperial Units

H Track Drive Speed

CC Track Speed

I

Fan Auto

DD Main Menu

J Hydraulic Oil Filter Bypass K Message Review (

EE Backlight FF Joystick Button/Trigger Configuration

)

L Swing Brake

GG Machine Information

M Time

HH Oil Grade and Auto-Accumulator Selections

N Date

II

Engine Information

O Operator Identification

JJ Main Home Screen

P Hydraulic Oil Temperature

KK Hydraulic Oil Temperature

Q Hydraulic Oil Temperature Warning

LL Event Counter

R Hydraulic Oil Grade

MM Harvesting Head Pressure

S Engine Coolant Temperature

NN Joystick Information

T Engine Coolant Temperature Warning

OO Production Information

U Fuel Level (Gauge Needle is Greyed-out When Roof is Open)

PP Tachometer

2.33

Controls and Operation

Tigercat H820D Harvester

MACHINE SETTING ADJUSTMENT INSTRUCTIONS Certain menu selections can be adjusted. These are identified with a Reset button .

Adjustments can be executed in two ways:

• Menu selection-select the desired option

• Value change-tap the / value to the desired setting.

Tap the relevant Reset button ( Reset from the menu.

buttons to adjust the /

) and then tap

This will reset the selected option to the default value.

Tap the check mark button cancel button to exit.

to accept or tap the

2.34

Tigercat H820D Harvester

Controls and Operation • Engine Hours

ENGINE MENU

• Battery Voltage • Fuel Rate

(Volts)

(L/h or gph instantaneous)

Tap to unlock the engine after a derate and lockout. It also erases the fault codes from the system.

NOTE: All faults MUST be corrected before attempting to unlock the engine.

Tap to reset the fault codes in the MD4 Computer.

Tap to toggle between metric or imperial units of measure.

Tap to turn anti-stall ON/OFF.

822D-002

From the home screen, tap the Engine icon.

The Engine menu icon is now active and the related functions are displayed: • Charge Air Temperature

(°C or °F)

• Engine Coolant Temperature • Engine Oil temperature • Fuel Temperature • Engine Speed

(°C or °F)

(°C or °F) (rpm)

• Turbocharger Boost Pressure • Fan Speed

(°C or °F)

(bar or psi)

(rmp)

• Horsepower HP (kW) • Engine Load

%

%

• Engine Oil Pressure

(bar or psi) 2.35

Controls and Operation

Tigercat H820D Harvester

WARM-UP MODE

IMPORTANT! Allow a cold engine to warm-up at LOW IDLE for at least five minutes before applying any load. Check all measured values on the MD4 Computer display often during the warm-up period. If the hydraulic oil is too cold or too hot, the hydraulic pumps will fail at full engine speed.

As the hydraulic oil temperature increases the system will automatically allow the engine speed to increase and the MD4 Computer displays an Information dialogue box that shows the progress of the Warm-up Mode in percentage outstanding. This dialogue box closes when hydraulic oil has reached operating temperature.

NOTE: The track speed at the bottom of the gauge screen will switch back to joystick map whenever the key start signal is on. If the key run signal is on, you can access it via the button.

MD0002

The warm-up mode operates automatically on cold starts within a hydraulic oil temperature range. The temperature range will vary based on the MD4 Computer hydraulic oil settings.

For proper operation, the MD4 Computer hydraulic oil settings should match the type of hydraulic oil in use.

2.36

Tigercat H820D Harvester

Controls and Operation

ADJUSTMENT MENU

OIL GRADE SELECTION

From the home screen, tap the Adjustment icon.

From the Adjustment screen, tap the Oil Grade button to display a list of options.

MD0003 MD0004

The Adjustment icon is active and the menu is displayed: • Oil Grade

.

• Auto Accumulation Mode Status

Tap one of the five options listed to select the oil for your machine:

.

• ISO22 • ISO32 • MULTI • ISO46 • ISO68

2.37

Controls and Operation

Tigercat H820D Harvester

HARVESTER SETTINGS

Pump 1 POR Point

From the Adjustment screen, tap the Harvester Settings to display a list of options.

From the Harvester screen, tap Pump 1 POR Set Point on the screen.

MD0005

The harvester settings menu displays the following: • PUMP1 POR SET POINT • Pump 2 • PUMP 1MARGIN SET

MD0006

This is the fan purge interval (how often the fan runs a purge cycle).

The PUMP 1 POR SET POINTURGE INTERVAL is set to a default value of 248 bar (3600 psi). Tap the / buttons to adjust the setting value.

• PUMP 1 PRESS. CONTROL • PUMP 1 CONTROL MODE

2.38

Tigercat H820D Harvester

Controls and Operation

Pump 2

Pump 1 Margin Set

From the Harvester screen, tap Pump 2 on the screen.

From the Harvester screen, tap Pump 1 Margin Set on the screen.

MD0007

This is the fan purge interval (how often the fan runs a purge cycle).

The TIMED PURGE INTERVAL is set to a default value of 120.00 seconds. Tap the / buttons to adjust the setting value.

MD0008

This is the fan purge interval (how often the fan runs a purge cycle).

The TIMED PURGE INTERVAL is set to a default value of 120.00 seconds. Tap the / buttons to adjust the setting value.

2.39

Controls and Operation

Tigercat H820D Harvester

Pump 1 Press. Control

Pump 1 Control Mode

From the Harvester screen, tap Pump 1 Press. Control on the screen.

From the Harvester screen, tap Pump 1 Control Mode on the screen.

MD0009

MD0010

This is the fan purge interval (how often the fan runs a purge cycle).

This is the fan purge interval (how often the fan runs a purge cycle).

The TIMED PURGE INTERVAL is set to a default value of 120.00 seconds. Tap the / buttons to adjust the setting value.

The TIMED PURGE INTERVAL is set to a default value of 120.00 seconds. Tap the / buttons to adjust the setting value.

2.40

Tigercat H820D Harvester

Controls and Operation • DEF Consumption Information

INFORMATION MODE

• DEF Consumption Trip Information

From the home screen, tap the Information icon.

• DEF Consumption Reset • Machine Serial Number • Machine Hours • Software version Tap the Celsius/Fahrenheit button to toggle between metric or imperial units of measure.

MD0011

The Information icon is active and the following information is displayed: • # Event Counter (Joystick button activation count) • # Tree Counter (Clamp O/C count) • Attachment Pressure • Hydraulic System Pressure • Hydraulic Oil Temperature • Air Intake Filter Restriction • Pilot Pressure • Fuel Consumption Information • Fuel Consumption Trip Information • Fuel Consumption Reset 2.41

Controls and Operation

Tigercat H820D Harvester

MAIN MENU SCREEN From the Home screen, tap the Main Menu icon.

SYSTEM MENU From the Main menu, tap the Info button.

MD0015

MD0014

The Main Menu screen displays the following selections:

The System menu displays the following selections:

• System

• Info

• Measure

• Modules

• Adjust

• Logs

• Preferences The Back button screen.

The Home button

will return you to the previous will return you to the Home screen.

2.42

Tigercat H820D Harvester

Controls and Operation

System Info Menu

Modules Menu

From the System menu, tap the Info button.

From the Info menu, tap the Modules button.

MD0016

The System Info menu displays top-level system information.

MD0017

The Modules menu displays the following machine module information: • MD4 • XA2 MODULE 0 • XA2 MODULE 1 OL • Tigercat/FPT Engine; <no info> • CAB XS2

2.43

Controls and Operation

Tigercat H820D Harvester

Logs Menu From the Info menu, tap the Logs button.

MD0019

The Logs menu displays the following machine logs: • MD4 log • Alarms • Hour Counters / Min/Max

2.44

Tigercat H820D Harvester MEASURE MENU From the Main menu, tap the Measure button.

Controls and Operation Inputs From the Measure menu, tap the Inputs button.

MD0020

MD0019

The Measure menu displays the following selections: • Inputs • Outputs

The Inputs menu displays the value of all active inputs: NOTE: Slide your finger up or down on the screen to view all entries.

• Hydraulics • IQAN Status • Sensors • Anti-stall • J1939 Parameter Inputs • Aftertreatment • Harvester

2.45

Controls and Operation

Tigercat H820D Harvester

Outputs

Hydraulics

From the Measure menu, tap the Outputs button.

From the Measure menu, tap the Hydraulics button.

MD0021

The Outputs menu displays the value of all active outputs:

MD0022

The Hydraulics menu displays the following information: • CLAMP O/C

NOTE: Slide your finger up or down on the screen to view all entries.

• WRIST/TELESCOPIC • LEFT LEVEL CYL • RIGHT LEVEL CYL

2.46

Tigercat H820D Harvester

Controls and Operation

IQAN Status

Sensors

From the Measure menu, tap the IQAN Status button.

From the Measure menu, tap the Sensors button.

MD0023

The IQAN Status menu displays various IQAN related information.

MD0024

The Sensors menu displays the following machine sensor information.

2.47

Controls and Operation

Tigercat H820D Harvester

Anti-Stall

J1939 Parameter Inputs

From the Measure menu, tap the Anti-stall button.

From the Measure menu, tap the J1939 Parameter Inputs button.

MD0025

The Anti-stall menu displays the machine anti-stall information.

MD0026

The J1939 Parameter Inputs menu displays machine J1939 information.

NOTE: Slide your finger up or down on the screen to view all entries.

2.48

Tigercat H820D Harvester

Controls and Operation

Aftertreatment

Harvester

NOTE: The aftertreatment system and its related components are applicable to TIER 4f machines only.

From the Measure menu, tap the Harvester button.

From the Measure menu, tap the Aftertreatment button.

MD0028

MD0027

The Harvester menu displays the harvester information.

The Aftertreatment menu displays information relevant to the machine aftertreatment system.

2.49

Controls and Operation ADJUST MENU From the Main menu, tap the Adjust button.

Tigercat H820D Harvester MACHINE PARAMETERS From the Adjust menu, tap the Machine Parameters button.

MD0029

The Adjust menu displays the following selections: • Machine Parameters

MD0030

The Machine Parameters menu displays the following selections:

• Hydraulics

• Oil Grade

• Harvester

• Auto-Ifle Cfg

• Operators

• TIMED PURGE INTERVAL

• Backlight

• Idle Down Wait Time • PUMP 1 IDLE DOWN RPM • AUTO-IDLE PRESSURE

2.50

Tigercat H820D Harvester

Controls and Operation

Oil Grade

Auto-Idle Cfg

From the Machine Parameters menu, tap the Oil Grade button.

From the Machine Parameters menu, tap the Auto-Idle Cfg button.

MD0032

MD0031

The Oil Grade menu displays the following Oil Grade options:

The Auto-Idle Cfg menu displays the following options: • ON

• ISO 22

• OFF

• ISO 32

• ON– IGNORE PUMP 1

• MULTI • ISO 46 • ISO 68 The Oil Grade default setting is ISO 22.

• ON– PUMP 1 HIGHER RPM Enabling the Auto Idle function allows the engine to return to idle when the system detects that the hydraulic functions are not in use resulting in greater fuel economy.

ON– This will turn the Auto Idle function on and whenever the hydraulic functions are not in use the engine will return to idle. If the LS Pressure sensor is below the set point (AUTO-IDLE PRESSURE) and Pump 1 remains on then the engine will not return to idle.

2.51

Controls and Operation

Tigercat H820D Harvester

OFF– This will turn the Auto Idle function off and the engine will only return to idle when the operator manually adjusts it.

ON-IGNORE PUMP 1– This will turn the Auto Idle function on but the system will ignore Pump 1, so if the LS Pressure Sensor is below the set point (AUTO-IDLE PRESSURE) and Pump 1 remains on then the engine will return to idle.

Timed Purge Interval From the Machine Parameters menu, tap the TIMED PURGE INTERVAL button.

ON-PUMP 1 HIGHER RPM– This will turn the Auto Idle function on but allow a second idle speed to be selected (refer to Pump 1 Idle Down RPM). If the LS Pressure Sensor is below the set point (AUTO-IDLE PRESSURE) and Pump 1 remains on then the engine will return to a preset idle speed. If Pump 1 is off and the LS Pressure Sensor is below the set point then the engine will return to the normal idle speed

MD0033

This is the fan purge interval (how often the fan runs a purge cycle).

The TIMED PURGE INTERVAL is set to a default value of 120.00 MINUTES. Tap the / buttons to adjust the setting value.

2.52

Tigercat H820D Harvester

Controls and Operation

Idle Down Wait Time

Pump 1 Idle Down RPM

From the Machine Parameters menu, tap the Idle Down Wait Time button.

From the Machine Parameters menu, tap the PUMP 1 IDLE DOWN RPM button.

MD0034

The Idle Down Wait Time is set to a default value of 15.00 seconds. Tap the / buttons to adjust the setting value.

MD0035

The PUMP 1 IDLE DOWN RPM is set to a default value of 1400.00 rpm. Tap the / buttons to adjust the setting value.

2.53

Controls and Operation

Tigercat H820D Harvester

Auto-Idle Pressure

HYDRAULICS

From the Machine Parameters menu, tap the AUTOIDLE PRESSURE button.

From the Adjust menu, tap the Hydraulics button.

MD0037 MD0036

The AUTO-IDLE PRESSURE is set to a default value of 180.00 PSI. Tap the / buttons to adjust the setting value.

The Hydraulics menu displays the following selections: • WRIST/TELESCOPIC • Pump 2

2.54

Tigercat H820D Harvester Wrist/Telescopic From the Hydraulics menu, tap the WRIST/ TELESCOPIC button.

Controls and Operation NOTE: When in the WRIST/TELESCOPIC Max Plus line, only the Max current will be applied to the wrist when the function is activated.

NOTE: The Max current range is 0 – 750 mA. The default setting is 500 mA. Tap Max to enter the adjustment mode. Activate and hold the Accumulator Close function on the joystick and at the same time tap the / buttons to adjust the ACCUM O/C Max Plus setting. It may be necessary to switch between Accumulator close and Accumulator open on the joystick to set this adjustment.

Adjustment of this setting determines the speed of the accumulator when closing. Increasing this setting speeds up the accumulator; decreasing the setting slows it down.

NOTE: The Start current range is 0 – 1000 ms. The default setting is 0 ms.

Tap Start to enter the adjustment mode. Tap the / buttons to adjust the ACCUM O/C Start Plus setting. Adjustment of this setting (along with the ACCUM O/C Min Plus setting ) determines how the accumulator will begin to close. Increasing this setting results in a less aggressive start while decreasing the setting results in a more aggressive start.

NOTE: The Stop current range is 0 – 1000 ms. The default setting is 0 ms.

MD0038

Tap Stop to enter the adjustment mode. Tap the / buttons to adjust the ACCUM O/C Stop Plus setting. Adjustment of this setting (along with the ACCUM O/C Min Plus setting) determines how the accumulator stops when the function is deactivated.

Increasing this setting results in a less aggressive stop; decreasing the setting results in a more aggressive stop.

Wrist/Telescopic (Plus) Adjustment

The ACCUM O/C Plus Close adjustment is complete.

NOTE: When in the WRIST/TELESCOPIC Min Plus line, only the Min current will be applied to the wrist when the function is activated.

Accumulator Open (Minus) Adjustment

IMPORTANT! An inaccurate adjustment of the Min Current renders the start and stop ramps inaccurate.

NOTE: The Min current range is 0 – 750 mA. The default setting is 200 mA. Tap Min to enter the adjustment mode. Activate and hold the Accumulator Close function on the joystick and at the same time tap the / buttons to adjust the ACCUM O/C Min Plus setting so the accumulator just starts to creep.

NOTE: When in the ACCUM O/C Min Minus line, only the Min current is applied to the accumulator when the function is activated.

IMPORTANT! An inaccurate adjustment of the Min Current renders the start and stop ramps inaccurate.

NOTE: The Min current range is 0 – 700 mA. The default setting is 300 mA. Tap Min to enter the adjustment mode. Activate and hold the Accumulator Open function on the joystick and at the same time tap the / buttons to adjust the ACCUM O/C Min Minus setting so the accumulator just starts to creep.

2.55

Controls and Operation Pump 2 From the Hydraulics menu, tap the Pump 2 button.

Tigercat H820D Harvester NOTE: The Max current range is 0 – 700 mA. The default setting is 600 mA. Tap Max to enter the adjustment mode. Activate and hold the Accumulator Close function on the joystick and at the same time tap the / buttons to adjust the ACCUM O/C Max Plus setting. It may be necessary to switch between Accumulator close and Accumulator open on the joystick to set this adjustment.

Adjustment of this setting determines the speed of the accumulator when closing. Increasing this setting speeds up the accumulator; decreasing the setting slows it down.

NOTE: The Start current range is 0 – 1000 ms. The default setting is 0 ms.

Tap Start to enter the adjustment mode. Tap the / buttons to adjust the ACCUM O/C Start Plus setting. Adjustment of this setting (along with the ACCUM O/C Min Plus setting ) determines how the accumulator will begin to close. Increasing this setting results in a less aggressive start while decreasing the setting results in a more aggressive start.

NOTE: The Stop current range is 0 – 1000 ms. The default setting is 0 ms.

Tap Stop to enter the adjustment mode. Tap the / buttons to adjust the ACCUM O/C Stop Plus setting. Adjustment of this setting (along with the ACCUM O/C Min Plus setting) determines how the accumulator stops when the function is deactivated.

Increasing this setting results in a less aggressive stop; decreasing the setting results in a more aggressive stop.

MD0038

The ACCUM O/C Plus Close adjustment is complete.

Accumulator Close (Plus) Adjustment

Accumulator Open (Minus) Adjustment

NOTE: When in the ACCUM O/C Min Plus line, only the Min current will be applied to the accumulator when the function is activated.

NOTE: When in the ACCUM O/C Min Minus line, only the Min current is applied to the accumulator when the function is activated.

IMPORTANT! An inaccurate adjustment of the Min Current renders the start and stop ramps inaccurate.

IMPORTANT! An inaccurate adjustment of the Min Current renders the start and stop ramps inaccurate.

NOTE: The Min current range is 0 – 700 mA. The default setting is 300 mA.

NOTE: The Min current range is 0 – 700 mA. The default setting is 300 mA.

Tap Min to enter the adjustment mode. Activate and hold the Accumulator Close function on the joystick and at the same time tap the / buttons to adjust the ACCUM O/C Min Plus setting so the accumulator just starts to creep.

Tap Min to enter the adjustment mode. Activate and hold the Accumulator Open function on the joystick and at the same time tap the / buttons to adjust the ACCUM O/C Min Minus setting so the accumulator just starts to creep.

NOTE: When in the ACCUM O/C Max Plus line only the Max current will be applied to the accumulator when the function is activated.

2.56

Tigercat H820D Harvester Clamp Adjustment

Controls and Operation necessary to switch between Clamp close and Clamp open on the joystick to set this adjustment.

Adjustment of this setting will determine the speed of the clamp when closing. Increasing this setting will speed the clamp up while decreasing the setting will slow it down.

Tap the / buttons to adjust the CLAMP O/C Start Plus setting. Adjustment of this setting (along with the CLAMP O/C Min Plus setting) will determine how the clamp will begin to close. Increasing this setting will result in a less aggressive start while decreasing the setting will result in a more aggressive start.

Tap the / buttons to adjust the CLAMP O/C Stop Plus setting. Adjustment of this setting (along with the CLAMP O/C Min Plus setting) will determine how the clamp stops when the function is deactivated. Increasing this setting will result in a less aggressive stop while decreasing the setting will result in a more aggressive stop. The CLAMP O/C Plus Close adjustment is now complete.

Clamp Open (Minus) Adjustment NOTE: When in the CLAMP O/C Min Minus line, only the Min current will be applied to the clamp when the function is activated.

IMPORTANT! An inaccurate adjustment of the Min Current renders the start and stop ramps inaccurate.

822D-069

From the Hydraulics menu, tap the CLAMP O/C button.

Clamp Close (Plus) Adjustment NOTE: When in the CLAMP O/C Min Plus line, only the Min current will be applied to the clamp when the function is activated.

Activate and hold the Clamp Open function on the joystick and at the same time tap the / buttons to adjust the CLAMP O/C Min Minus setting so the clamp just starts to creep.

NOTE: When in the CLAMP O/C Max Minus line, only the Max current will be applied to the clamp when the function is activated.

IMPORTANT! An inaccurate adjustment of the Min Current renders the start and stop ramps inaccurate.

Activate and hold the Clamp Close function on the joystick and at the same time tap the / buttons to adjust the CLAMP O/C Max Minus setting. It may be necessary to switch between Clamp close and Clamp open on the joystick to set this adjustment.

Activate and hold the Clamp Close function on the joystick and at the same time tap the / buttons to adjust the CLAMP O/C Min Plus setting so the accumulator just starts to creep.

Adjustment of this setting will determine the speed of the clamp when closing. Increasing this setting will speed the clamp up while decreasing the setting will slow it down.

NOTE: When in the CLAMP O/C Max Plus line only the Max current will be applied to the clamp when the function is activated.

Tap the / buttons to adjust the CLAMP O/C Start Minus setting. Adjustment of this setting (along with the CLAMP O/C Min Minus setting) will determine how the clamp will begin to open. Increasing this setting will result in a less aggressive start while decreasing the setting will result in a more aggressive start.

Activate and hold the Clamp Close function on the joystick and at the same time tap the / buttons to adjust the CLAMP O/C Max Plus setting. It may be

2.57

Controls and Operation

Tigercat H820D Harvester

Tap the / buttons to adjust the CLAMP O/C Stop Minus setting. Adjustment of this setting (along with the CLAMP O/C Min Minus setting) will determine how the clamp stops when the function is deactivated. Increasing this setting will result in a less aggressive stop while decreasing the setting will result in a more aggressive stop. The CLAMP O/C Minus Open adjustment is now complete.

Clamp Default Settings At any time during the adjustment procedures, you can reset to the factory default settings. Tap the Cancel/ Reset button, tap 'Reset' and then tap the button.

NOTE: This action will reset all values within the current menu.

CLAMP EXAMPLE (DEFAULT SETTINGS) • Min mA =300 • Max mA =700 • Start Slope =0 ms • Stop Slope =0 ms

822D-039

NOTE: The graph reflects the default settings and as the Start and Stop Slopes are set to 0 ms there is no ramp up or down showing the clamp will travel immediately at max speed once the button is activated.

Clamp Example (Slope Settings Adjusted)

822D-001

Above, is an illustration of the Clamp settings shown after an adjustment has been made to the Start and Stop Slopes.

2.58

Tigercat H820D Harvester

Controls and Operation The graph below reflects the adjustments made to the start and stop slopes. This will affect the clamp operation in three ways. The overall time it takes for the clamp to open or close will be longer. The initial movement of the clamp will be slower when the button is activated and the final movement of the clamp will also be slower when the button is deactivated.

• Min mA = 300 • Max mA = 700 • Start Slope =500 ms • Stop Slope = 500 ms

822D-002

822D-040

2.59

Controls and Operation

Tigercat H820D Harvester

H820D/LH820D HYDRAULIC ADJUSTMENTS TABLE Range

Adjustments HARVESTER HEAD ADJUSTMENT Pump1 POR Set Point Pump1 Margin Set Pump1 Pressure Control Pump1 Control Mode

Units

1000 0

to to

4600 1500

psi psi

P1 Pressure Min Current Max Current Start Slope Stop Slope

0 0 0 0

to to to to

1500 1500 1000 1000

mA mA ms ms

P1 DISP Min Current Max Current Start Slope Stop Slope

0 0 0 0

to to to to

1500 1500 1000 1000

mA mA ms ms

Pump2/Warm Up Min Current Max Current Start Slope Stop Slope Min Current Max Current Start Slope Stop Slope

0 0 0 0 0 0 0 0

to to to to to to to to

1500 1500 1000 1000 1500 1500 1000 1000

mA mA ms ms mA mA ms ms

0 0 0 0 0 0 0 0 0 0 0 0

to to to to to to to to to to to to

1000 1000 100 100 600 600 600 600 600 600 600 600

ms ms % % mA mA mA mA mA mA mA mA

LEVELER ADJUSTMENT Leveler Stop Ramp Leveler Start Ramp Forward Leveling Speed Rear Leveling Speed Right Cylinder -Retract Min Right Cylinder -Retract Max Right Cylinder +Extend Min Right Cylinder +Extend Max 820DH_LH820D HYDRAULIC ADJUSTMENTS TABLE (MD4) Left Cylinder -Retract Min Left Cylinder -Retract Max Left Cylinder +Extend Min Left Cylinder +Extend Max

2.60

Default Settings

350 350 100 100 300 448 300 469 300 442 300 475

Tigercat H820D Harvester

Controls and Operation BACKLIGHT From the Adjust menu, tap the Backlight button.

822D-090

In the Backlight menu, the following functions can be adjusted as required: • Night Backlight Intensity • Day Backlight Intensity

2.61

Controls and Operation

Tigercat H820D Harvester

Night Backlight Intensity

Day Backlight Intensity

From the Backlight, tap the Night Backlight Intensity button.

From the Backlight menu, tap the Day Backlight Intensity button.

822D-091

822D-092

This allows the operator to adjust the backlight intensity for night use.

This allows the operator to adjust the backlight intensity for day use.

Tap the / buttons to change the value of the NIGHT BACKLIGHT INTENSITY for the display.

Tap the / buttons to change the value of the DAY BACKLIGHT INTENSITY for the display.

Tap the check mark button cancel button to exit.

Tap the check mark button cancel button to exit.

Tap the back button

to accept or tap the

to return to the adjust menu.

Tap the back button

2.62

to accept or tap the

to return to the adjust menu.

Tigercat H820D Harvester

Controls and Operation

PREFERENCES

Display

From the Adjust menu, tap the Preferences button.

From the Preferences, tap the Display button.

822D-093

In the Preferences menu, the following functions can be adjusted as required:

822D-094

Tap the / buttons to change value for the following information:

• Display

• Backlight (20-100% in increments of 10%)

• Date/Time

• Screen saver (Screen: Off– Dimmed – Black)

• Language

• Timeout (five second minimum default for Screen saver) • Dimmed light (10-90%) Tap the back button

2.63

to return to the adjust menu.

Controls and Operation

Tigercat H820D Harvester

Date/Time

Date

From the Preferences, tap the Date/Time button.

From the Date/Time, tap the Date button.

822D-095

In the Date/Time menu, the following functions can be adjusted as required: • Date • Time

822D-096

Tap the Day.

/

buttons to change the Year, Month or

Tap the check mark button cancel button to exit.

Tap the back button

2.64

to accept or tap the

to return to the adjust menu.

Tigercat H820D Harvester

Controls and Operation

Time

Language

From the Date/Time, tap the Time button.

From the Preferences, tap the Language button.

822D-097

Tap the

822D-098

/

buttons to change the Hour and Minute.

Tap the check mark button cancel button to exit.

Tap the back button

to accept or tap the

Tap the button for the desired Language.

Tap the back button

to return to the adjust menu.

2.65

to return to the adjust menu.

Controls and Operation MD4 COMPUTER DISPLAY MESSAGES The MD4 Computer displays messages and activates the master alarm and alarm light whenever a system fault occurs.

NOTE: The MD4 Computer will automatically perform a bulb test at engine start-up to ensure the alarm and alarm light are functioning. Refer to STARTING ENGINE in THIS SECTION.

Tigercat H820D Harvester In some instances it is necessary to immediately stop the machine, turn OFF the engine and repair the problem causing the message.

Active fault messages that have been hidden, can be reviewed by tapping the Alert icon. Recalled messages will be displayed in order starting with the highest priority first.

There are three different types of messages and alarms that appear on the screen as a block message: • CRITICAL MESSAGE– • ALERT MESSAGE– • INFORMATION MESSAGE–

MD0042

All messages can be hidden or acknowledged by tapping the Hide button.

2.66

Tigercat H820D Harvester CRITICAL MESSAGES (

)

Critical messages advise the operator that a critical machine fault is about to occur or a system fault has occurred.

Controls and Operation Critical messages flash the critical symbol in the top icon bar at the top of the display when active messages are hidden. The symbol continues to flash until the problem is resolved and the fault becomes inactive.

Critical messages have the highest level of priority and are used to alert the operator that immediate action must be taken to prevent damage to machine or to ensure operator safety.

When a critical message is displayed, the master alarm and alarm light sounds and flashes continuously. The message remains on the screen until it is hidden by the operator.

The message will give brief details of the fault and advise what action is necessary.

In some instances the machine requires immediate action to correct the problem which requires the operator to stop machine operation, turn OFF the engine and service the machine to correct the problem.

Active messages that have been hidden can be reviewed by tapping the critical symbol button in the top icon bar at the top of the display.

Critical messages: • Hydraulic Oil Level Low

However, if the machine cannot be stopped immediately for safety reasons, the operator can hide the message.

In this instance the machine should only be operated long enough to make the machine safe, then stop machine operation and turn OFF the engine before serious machine damage can occur.

• Hydraulic Oil Temperature High

Messages can be hidden by tapping the Hide button.

• Hardware Fault – XA2

• Engine Stop • Hardware Fault – Computer Display • Hardware Fault – Engine

• Engine Coolant Temperature High • Engine Coolant Level low • Engine CAC Temperature High • Engine Oil Pressure Low • Engine Fault Code Messages

2.67

Controls and Operation ALERT MESSAGES (

Tigercat H820D Harvester

)

Alert messages advise the operator that machine operation will be compromised.

Alert messages have the second level of priority and are used to indicate to the operator that action is required to prevent future damage to the machine.

All alert messages provide brief details of the fault and advise what action is necessary.

Action should be taken to service the machine to correct the problem at the earliest opportunity to prevent future damage to the machine.

Alert messages flash the alert symbol button in the top icon bar at the top of the display when active messages are hidden.

NOTE: Active hardware fault alert messages are acknowledged by tapping the Hide button. To recall these messages turn the key OFF and ON. On screen messages will indicate to the operator that an active hardware fault has been hidden.

Interactive alert messages:

Active messages that have been hidden can be reviewed by tapping the alert symbol button. The symbol will continue to flash until the problem is resolved and the fault becomes inactive.

• Pilot/Charge Pressure Filter Messages – Alert

NOTE: If both a critical level fault and an alert level fault are present the critical symbol will take priority until the critical fault becomes inactive.

• LH Joystick DM1 – Alert

There are two types of alert messages:

• Module XA2 Alert Message

• Engine Warning Message – Alert • Engine Fault Code Messages – Alert

• Module Computer Display Alert Message

• Programmed messages – generally activated by machine function related conditions.

• RH Joystick DM1 Alert

• Computer system – generated messages generally activated by MD4 Computer error and fault related conditions.

• DOUT Hardware Fault Message

• COUT Hardware Fault Message

• DIN Hardware Fault Message • VIN Hardware Fault Message

When an alert message is displayed, the external alarm and light will sound and flash three times to alert the operator of the message. Messages can be hidden by tapping the Hide button.

• High Exhaust System Temperature • Low Fuel • Air Filter Restriction • Pilot Pressure Low • Hydraulic Oil Level Low • Fan Full On • Roof Open • Power Side Door Open

2.68

Tigercat H820D Harvester

Controls and Operation

Engine Fault Code Messages– Alert

Diesel Exhaust Fluid Level Messages NOTE: DEF level is applicable to Tier 4f machines only.

The engine ECU generates three levels of diesel exhaust fluid level messages: • Diesel exhaust fluid level <10% • Diesel exhaust fluid level <5% • Diesel exhaust fluid level empty In all instances, immediate action should be taken to avoid affecting engine performance and damage to the diesel oxidation catalyst/selective catalytic reduction (DOC/SCR) aftertreatment system components:

When an alert engine fault code message is received from the engine electronic control module, an alert engine fault message is displayed, an alarm light flashes and an audible alarm sounds.

• Turn OFF the engine

These alerts provide the Suspect Parameter Number (SPN) code and the Fault Mode Identifier (FMI) code, as well as a message describing the fault (when available).

• Fill the DEF tank • Turn ON the engine to clear the message Refer to DIESEL EXHAUST FLUID TANK in THIS SECTION.

Alert engine fault codes are lower priority messages than critical level engine fault code messages. Alert messages can be hidden but action (service engine) is required to resolve the cause of the fault.

Diesel Exhaust Fluid Level <10%

An example of an alert engine fault message is shown above.

NOTE: Some less common engine fault codes will appear without a message describing the fault. Make a note of the SPN and FMI codes and contact service for more information.

Refer to engine OPERATION AND MAINTENANCE manual for specific information regarding the engine.

NOTE: Contact your Tigercat dealer to obtain an Engine Fault Codes chart. An up to date copy should be kept in the Operator’s Manual Box (in the cab on the wall behind the operator’s seat). The chart is updated regularly by the engine manufacturer, so it is important to check periodically with the Tigercat dealer to ensure you have a current copy of the Engine Fault Codes chart.

When the engine ECU detects the diesel exhaust fluid level is below 10%, a message is displayed along with a flashing alarm light and an audible alarm.

Diesel Exhaust Fluid Level <5%

When the engine ECU detects the diesel exhaust fluid level is below 5%, a message is displayed along with a flashing alarm light and an audible alarm.

NOTE: Beginning immediately after a DEF level <5% message, there will be a ramp down of the engine speed (60%) and torque (65%) over 40 minutes.

2.69

Controls and Operation

Tigercat H820D Harvester

Diesel Exhaust Fluid Level Empty

Diesel Exhaust Fluid Quality

When the engine ECU detects the diesel exhaust fluid level is empty, a message is displayed along with a flashing alarm light and an audible alarm.

NOTE: Beginning immediately after a DEF level empty message, the engine is derated to idle within 30 minutes.

An Engine Torque Derate Active message is also activated as the engine begins to derate.

When the engine ECU detects a diesel exhaust fluid quality problem, a message is displayed along with a flashing alarm light and an audible alarm.

Immediate action should be taken to avoid affecting engine performance and damage to the diesel oxidation catalyst/selective catalytic reduction (DOC/SCR) aftertreatment system components: To correct the DEF quality problem: 1. Clean the area around the DEF tank.

2. Drain the DEF tank.

3. Refill the DEF tank with clean DEF which meets ISO 22241 specifications This message results in the following derate and engine lockout sequence if no action is taken to correct the problem: 1. Beginning 1 hour after the DEF quality message there is a ramp down of engine speed (60%) and torque (65%) over 40 minutes.

2. After 2 hours at derated engine speed and torque the engine is derated to idle within 30 minutes.

An Engine Torque Derate Active message is also activated as the engine begins to derate. Refer to MD4 COMPUTER DISPLAY MESSAGES– CRITICAL – ENGINE TORQUE DERATE ACTIVE in THIS SECTION. Refer to ENGINE MENU in THIS SECTION for details about cancelling an engine lockout.

2.70

Tigercat H820D Harvester Refer to DIESEL EXHAUST FLUID TANK in THIS SECTION and DRAINING THE DIESEL EXHAUST FLUID TANK in SECTION 3.

Controls and Operation INFORMATION MESSAGES (

)

Refer to AFTERTREATMENT SYSTEM in SECTION 3 for more information regarding the use of DEF and its function in the DOC/SCR aftertreatment system.

WARNING Use only diesel exhaust fluid (DEF) which meets ISO 22241 specifications. NEVER fill the DEF tank with any other fluid.

DEF is injected into the exhaust gas stream during normal operation of the of the Selective Catalytic Reduction (SCR) aftertreatment system.

Use of other fluids may cause component damage, or a fire risk which could result in death or serious injury.

Information messages give the operator information regarding an event or problem condition while the event or problem exists.

Information messages have the lowest priority. They provide the operator information that is useful to the operator, but requires no action to prevent immediate or future damage to the machine When an information message is displayed on the screen the message will either automatically disappear when the condition no longer exists or stay on the screen until the operator acknowledges the message.

Information messages can be acknowledged by tapping the exit icon within the message. Acknowledged information messages are removed from the screen.

Information messages do not have an indicator after they are acknowledged and most cannot be reviewed.

Recurrence of an event or problem condition related to an information message or, restarting the machine, may cause the message to be shown again.

2.71

Controls and Operation

Tigercat H820D Harvester

SERVICE/ACCESS DOORS AND COVERS A

B

C

D E

I

H

G

F

822D-009

A B C D E F G H I J K L

Engine Roof Fuel Tank Emergency Exit – Cab Roof Front Door – Cab Pump Compartment Hydraulic Pump Compartment Front Access Door Hydraulic Pump Compartment Side Access Door Engine Compartment Engine and Pump Compartment Side Access Door Side Door – Cab (Emergency/Service Access) DEF and Bottom Fuelling Access Door Hydraulic Tank Compartment

J

822D-008

2.72

K

A

L

Tigercat H820D Harvester

Controls and Operation

ENGINE COMPARTMENT ROOF AND DOOR

ENGINE COMPARTMENT ROOF AND DOOR HAND PUMP OPERATION

A

A

822D-048 822D-151

A Electric Pump – Roof

The engine compartment roof and door are opened hydraulically using an electric pump and hydraulic cylinders.

A Pump Valve

The hand pump can be used to hydraulically open the roof and side compartment door (if required).

1. Turn the pump valve (CW) in all the way.

2. Release the valve detent.

A

3. Insert the handle in the pump lever.

The handle is stored inside the pump side access door (see PUMP ACCESS DOORS).

4. Pump the engine door open.

5. Push the valve detent back in when finished. This will manually close the roof.

800007

PUMP COMPARTMENT ACCESS DOORS

A Roof Switch

B

CAUTION Be sure all personnel are clear of the power engine-door before opening the door.

A

C

The switch (A), located in the cab, on the upper-right control panel, is used to open and close the roof and side engine/pump compartment door.

The roof and side compartment door circuit does not normally require scheduled maintenance other than lubrication of cylinder and pivot points. Tigercat recommends the use of DEXRON III TYPE transmission fluid in this circuit. Total circuit capacity is approximately 2 L (0.53 US gal). The fill port is located on the pump.

This machine is equipped with a manual back-up roof and side compartment door hand pump mounted behind a cover plate on the left side of the pump access door.

Refer to HYDRAULIC OIL FILL PUMP in SECTION 3.

822D-130

A Securing Bolts B Pump Compartment Front Door C Pump Compartment Side Door

1. Remove the pump side access door latch pin and open door fully.

2. Remove the four securing bolts at the top of the pump access door.

3. Use handles to pull pump access door forward.

2.73

Controls and Operation

Tigercat H820D Harvester BATTERY BOOSTER JUMPER CABLE CONNECTION

DEF TANK ACCESS DOOR

A

A

822D-014

822D-129

A Jumper Cable Connection

822D-128

A DEF Tank Door Latch Pin

NOTE: The aftertreatment system and its related components are applicable to Tier 4f machines only.

Remove the latch pin and swing the door open. Refer to DIESEL EXHAUST FLUID (DEF) TANK for complete information.

The batteries are located at the rear-right side of the engine compartment. This machine employs a special battery booster jumper connector that is used in conjunction with booster cables with matching ends.

Cables are available from the Tigercat parts department.

If standard booster cables are used, the negative connection can be made on any bare metal anywhere on the upper structure, as close to the batteries as possible.

IMPORTANT

24 VOLT ELECTRICAL SYSTEM

2.74

Tigercat H820D Harvester

Controls and Operation

REFUELLING WARNING

DO NOT refuel while smoking or while near an open flame or sparks.

S≤15 mg/kg ULTRA LOW SULFUR FUEL ONLY 36686AUNI R0

Refuelling of the machine is a critical component of proper operation. It is important to follow the proper procedures based on the refuelling options available for your machine. The proper type and grade of fuel must be used in your machine. Refer to REFUELLING PROCEDURE in SECTION 3 for complete details.

2.75

Controls and Operation

Tigercat H820D Harvester

OPERATING THE MACHINE Make sure the appropriate lubrication and maintenance schedule has been performed prior to operating the machine. Refer to SCHEDULED MAINTENANCE in SECTION 3.

A

B

Refer to the engine MANUFACTURER OPERATOR’S MANUAL supplied with the machine.

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

C

PRESTART CHECKS

A

822D-118

A Pressure Gauge (Pointer Must be in Green Zone) B Electrical Actuator C Pressurized Cylinder

B

3. The fire suppression cylinder must be sufficiently charged. Refer to FIRE SUPPRESSION SYSTEM, OPTIONAL in THIS SECTION.

822D-018

A Ignition Key Switch B Attachment Switch

1. Make sure the ignition switch and attachment switch are in the OFF position.

A

A B B

822D-001

A Fuel Level Indicator B DEF Level Indicator

822D-029

A Pressure Gauge (Pointer Must be in Green Zone) B Portable Fire Extinguisher

2. The portable fire extinguisher must be sufficiently charged

4. Turn the ignition switch to the RUN position to check fuel and DEF levels. Turn the switch to the OFF position. Fill fuel and DEF to required levels, if required. Refer to REFUELLING PROCEDURE and FILLING THE DEF TANK in SECTION 3.

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Tigercat H820D Harvester

Controls and Operation A B

A

D B C

800009

A B C D

822D-060

Air Intake Seal Air Intake Area Air Cleaner Air Intake Precleaner

7. Check the air intake precleaner. Remove any blockages or obstructions. Refer to ENGINE AIR PRECLEANER in SECTION 3.

822D-056

A First Sight Gauge (DEF Tank Side of Hydraulic Tank) B Second Sight Gauge (Engine Side of Hydraulic Tank

5. Check the hydraulic oil level.

The level should be between the HIGH and LOW marks on the level gauge. Refer to REFILLING THE HYDRAULIC SYSTEM in SECTION 3.

A B

800010

A Fuel Filter/Water Separator B Fuel Filter A

8. Check the fuel filter/water separator and drain any accumulated water into a bowl and clean up any spills. Refer to Filter/water separator DRAINING PROCEDURE in SECTION 3.

800008

A Engine Oil Dipstick

6. Check the engine oil level.

The level of the oil must be between the ADD and the FULL marks on the dipstick. Refer to the engine OPERATION AND MAINTENANCE MANUAL

2.77

Controls and Operation

Tigercat H820D Harvester A

B

B A

LX830D-001

A Engine Coolant Fill Cap B Engine Coolant Surge Tank

11. Check the engine coolant level. Fill as required.

800011

A Filter Restriction Electronic Sensor B Filter Restriction Mechanical Indicator

WARNING

9. Check the air filter restriction indicator. Refer to FILTER RESTRICTION INDICATOR in SECTION 3.

Turn OFF the engine. Only remove the engine coolant fill cap when cool enough to touch with bare hands. Slowly loosen the fill cap to the first stop to relieve the pressure before removing completely.

B

A A

822D-134

822D-053

A Serpentine Belt B A/C Compressor Belt

10. Check the condition of engine serpentine belt (every 250 hours) and the A/C compressor belt (every 125 hours).

A Debris Screens

12. Clean the cooler package, if required. Refer to CLEANING COOLER PACKAGE in SECTION 3.

Refer to INSPECTION/REPLACEMENT OF SERPENTINE BELT in SECTION 3.

2.78

Tigercat H820D Harvester

Controls and Operation ANTI-STALL

A

B

On the Engine Menu screen ( ) of MD4 Computer display module, there is an Anti-Stall icon ( ). Tap the icon to turn the Anti-Stall ON ( – WHITE) / OFF ( – YELLOW).

E

Tapping Anti-Stall ON 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 ON during normal machine operation and OFF only when performing service checks on the machine.

C C

830-02

A B C D E

D

If engine stalling occurs, check:

Cracking Bent Edge Wear Broken Edge Worn Holes

• The Anti-Stall function is ON. • The relevant 10 A fuse located in the cab fuse and relay panel (fuse is labelled A/C HEAT COMBO UNIT RELAY IGNITION AND FUNCTION PANELS).

13. Check the condition of the track shoes.

• Malfunction of the Anti-Stall system.

B A

C

853ILL8

A Underside of Track Guard B Sag Dimension C Upper Surface of Track Shoe

14. Check the track chain tension by measuring the track sag. Refer to TRACK CHAIN SAG in SECTION 3.

15. Check all exits.

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

17. Inspect all windows daily and immediately after any impacts. Refer to WINDOWS– INSPECTION AND MAINTENANCE in SECTION 3.

18. Unlock all cab doors.

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Controls and Operation

Tigercat H820D Harvester

STARTING ENGINE 1. All prestart checks must be performed and the area must be clear of personnel prior to starting the engine. Refer to OPERATING MACHINE– PRESTART CHECKS in THIS SECTION. 2. Sound horn to warn personnel of machine start-up.

6. Set the engine idle speed switch to LOW and wait three to five minutes before operating with a load.

7. Increase the engine speed (rpm) slowly to provide adequate lubrication to the bearings and allow oil pressure to stabilize.

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

3. Turn the ignition key switch to the RUN position.

The WAIT TO START icon below will appear on the display during the 'key ON' engine preheat time.

Heating elements (grid heater elements) located in the engine air intake manifold are turned ON to heat the intake air when starting the engine. The engine must not be started until this icon turns OFF automatically.

CAUTION Do not attempt to start the engine by shorting across the starter terminals as personal injury could occur. Only start the engine from operator’s seat.

WARNING DO NOT USE ETHER! The engine is equipped with an electrical starting aid. Use of ether may cause an explosion and severe injury.

A 822D-061

IMPORTANT! Allow a cold engine to warm-up at LOW IDLE for at least five minutes before applying any load. Check all measured values on the MD4 Computer display terminal often during the warm-up period.

FUEL HEATER

A WAIT TO START Icon

NOTE: The MD4 Computer will automatically perform a test of the alarm and alarm light when the key is initially turned to the RUN position.

A

4. Turn the ignition key switch to the START position to crank engine.

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

B

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

800012

A Fuel Filter/Water Separator B Fuel Heater (Bottom of Clear Bowl)

The fuel heater is incorporated into the fuel filter/water separator and is controlled electronically by the engine ECU.

2.80

Tigercat H820D Harvester COLD WEATHER STARTING WARNING DO NOT USE ETHER! The engine is equipped with an electrical starting aid. Use of ether may cause an explosion and severe injury.

IMPORTANT! Cold start-ups can result in pump failure. Refer to APPROVED HYDRAULIC OILS in SECTION 3 for recommended oil viscosity and temperature ranges.

Controls and Operation 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.

1. Remove the four bolts securing each cover.

2. Place the bottom cover over the top cover and secure with four bolts removed in Step 1.

3. Replace the remaining four bolts in the weld nuts of the bottom access holes for storage.

IMPORTANT! If the covers are removed, they must be re-installed when operating in warmer outside temperatures otherwise the engine will run at a higher temperature and less horsepower.

NOTE: Cold temperatures require the use of an engine block heater and a hydraulic oil heater. Preheating of hydraulic oil is recommended as standard procedure in cold weather.

Periodically check to ensure the seal on the top of the precleaner is making proper contact with the sealing surface of the inside top of the power roof.

Hot air leakage at this seal will reduce engine power.

A

See SCHEDULED MAINTENANCE – 2000 HOURS in SECTION 3 for required maintenance in this area.

4. Follow the STARTING ENGINE instructions for this COLD WEATHER STARTING procedure, paying attention to the WAIT TO START icon on the MD4 Computer display.

This message will be ON during the key RUN engine preheat time. The engine must not be started until this message turns OFF automatically.

LX830D-004

NOTE: If at any time during the warming procedure, the hydraulic filter bypass message comes on, return the engine speed to LOW IDLE .

A Clean Out Cover

The precleaner receives air via an air intake grill on the right side of the engine power roof and through a passage way fabricated into the power roof. With the door opened, two covers can be removed to allow access behind the engine air intake grill to remove any accumulation of debris.

A

B

5. During the engine warm-up period constantly monitor the engine coolant temperature and the engine oil pressure. Turn OFF the engine if any pressure or temperature does not meet the specification.

6. Continue with MACHINE PREPARATION– SYSTEM TEST AND WARM-UP in THIS SECTION.

LX830D-005

A Bottom Clean Out Cover Removed B Bottom Clean Out Cover Stored Over Top Cover

2.81

Controls and Operation 7. Start the engine and keep speed at LOW IDLE. • DO NOT ACTIVATE THE PILOT SYSTEM. • The hydraulic filter bypass icon must be OFF before proceeding to step 8.

• The engine coolant temperature must reach 60°C (140°F) before proceeding to step 8.

• The hydraulic oil temperature must reach -7°C (20°F) before proceeding to step 8.

• Check the cooling fan is turning before proceeding to step 7.

Tigercat H820D Harvester 16. Increase the engine speed to 1500 rpm, and begin driving to the work area in LOW travel speed. Do not fully depress the foot pedals until the hydraulic oil reaches 32°C (90°F). Harvesting may begin but work very slowly. The machine functions will seem to operate much slower until the systems are warmed up. Avoid operating the boom or tilt functions quickly until the hydraulic oil is above 32°C (90°F). Work the machine for thirty minutes at 1500 rpm.

17. When the hydraulic oil reaches 32°C (90°F) and the machine has been operated for 30 minutes, it is safe to increase the engine speed to HIGH IDLE.

NOTE: At a starting temperature of -18°C (0°F), it will take approximately thirty minutes to complete Step 7.

8. Activate the pilot system and turn ON the saw.

• The hydraulic filter bypass icon must be OFF. • Observe the saw blade rpm has stabilized.

• Operate the saw for approximately five minutes to warm-up the spindle bearings.

9. Turn OFF the saw.

10. Increase the engine speed to 1300 rpm and begin slow boom movements.

• The hydraulic filter bypass icon must be OFF. • Operate the main boom to raise the attachment off the ground.

11. Operate telescopic boom (if applicable) IN and OUT and check that it is operating correctly.

12. Rotate the attachment and check that it is operating correctly.

13. Swing the upper structure 360° to the left, then 360° to the right.

14. Place the travel speed switch in the LOW position and drive the machine forward pressing the foot pedals very gradually. DO NOT exceed ½ pedal position.

15. Watch the hydraulic oil temperature; it must reach 10°C (50°F) before any work may begin.

2.82

Tigercat H820D Harvester RESTARTING AN ENGINE THAT HAS RUN OUT OF FUEL 1. Fill the fuel tank completely.

2. Bleed the system according to the procedures in the engine OPERATION AND MAINTENANCE MANUAL.

Controls and Operation 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. The important benefits are: • Extended life of engine, cooling and exhaust systems.

WARNING DO NOT USE ETHER! The engine is equipped with an electrical starting aid. Use of ether may cause an explosion and severe injury.

• Reduced risk of post shutdown fires.

• Interior of machine cools significantly reducing risk of touching hot surfaces.

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

1. Turn the saw switch to the OFF position and stop the attachment. This should be done before leaving the cutting area.

IMPORTANT! To prevent damage to the starter, do not engage the starter motor for more than 15 to 20 seconds. Wait two minutes between each attempt to start the engine. If the engine fails to start, refer to the engine OPERATION AND MAINTENANCE MANUAL.

2. Find a clear and level area, a least 15 m (50 ft) from any other equipment, to park the machine.

3. Park the machine and lower the saw head onto firm ground.

4. Reduce the engine speed to LOW IDLE , deactivate the pilot system and let the engine run at low idle speed for approximately three minutes (minimum) to allow 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. Press the Open Roof button roof/door.

to open the power

Do not increase the engine speed before turning it OFF. 6. Turn OFF the engine by turning the ignition key switch to the OFF position.

NOTE: Whenever the engine is stopped, all DEF solution is pumped back to tank before the engine power system is turned off. This process takes approximately 90 seconds. Refer to AFTERTREATMENT SYSTEM in SECTION 3 for more information.

7. Perform daily maintenance at the end of the shift (greasing, clean engine compartment, etc.). This allows the machine time to cool down while under the watchful eye of the operator.

8. Press the Close Roof button roof/door.

2.83

to close the power

Controls and Operation

Tigercat H820D Harvester

MACHINE PREPARATION

10. Observe all boom operations. If any operations are not operating as they should, take the necessary steps to correct the problem.

SYSTEM TEST AND WARM-UP Before commencing harvesting operations, follow steps 1 – 15 to accomplish the following:

11. Turn ON the attachment. Refer to attachment manufacturer’s manual and check the attachment for proper operation according to manufacturer’s instructions.

• Warm-up the hydraulic system.

• Test all systems for proper operation.

12. After completion of the warm-up and system testing, turn OFF the attachment and rest it on the ground.

• Inspect for hydraulic oil leaks.

IMPORTANT! 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.

13. Set the swing brake to the ON position.

14. Set the engine idle speed switch to LOW

WARNING

1. Close the cab doors and sound the horn to warn personnel of machine start-up.

DO NOT USE ETHER! The engine is equipped with an electrical starting aid. Use of ether may cause an explosion and severe injury.

2. Start the engine (Refer to STARTING ENGINE in THIS SECTION).

3. Press the Pilot Reset switch

.

15. Leave the cab and visually check hose connections and cylinders for leaks. Check under the machine for oil leaks.

4. Ensure the MD4 Computer Display is indicating normal operating conditions.

5. Check that all personnel are clear of the machine.

6. Increase the engine speed 1300 rpm.

.

WARNING

to approximately

NOTE: The MD4 Computer has a warm-up mode function which limits engine speed and applies the anti-stall during cold starts. Refer to WARM-UP MODE in THIS SECTION for more information.

7. Slowly raise and lower the stick boom and the hoist boom, and check for proper operation.

Never use your bare hand to check for fluid leaks.

8. With the head raised slightly off the ground:

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.

a. Operate the accumulation and clamp arms and check for proper operation. b. Tilt the head forward and back and check that it is operating correctly. c.

Swing the upper structure to the left and right.

9. When cold weather conditions exist, continue the process of warming up the hydraulic system by repeating steps 7 – 8 several times. As the hydraulic system warms up, engine speed can be increased gradually to the HIGH IDLE position. If the FILTER BYPASS message comes ON, decrease the engine speed immediately and continue warming the system.

2.84

Tigercat H820D Harvester

Controls and Operation

TRAVELING (BOOM RAISED)

OPERATING TIPS WITH LOAD SENSING

1. Select the appropriate drive range.

When using the controls on a load sensing system, be aware of what the load sensing 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.

Place the track switch in the LOW or DRIVE position.

When in LOW, the machine moves slower but with increased drive force. LOW should be selected when operating on sloped terrain.

When in DRIVE the machine moves faster but with less drive force. Traveling 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 longer than 10 minutes, take 5 minute breaks, this will help prevent the track drive gearboxes from overheating.

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

3. Move the engine idle speed switch to the HIGH position.

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

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

Refer to SET MARGIN PRESSURE in SECTION 4.

Refer to SET FLOW (FUNCTION SPEED) RATE in the appropriate BOOM, SWING or TRACK DRIVE sections.

ATTACHMENT OPERATING INSTRUCTIONS AND SAFETY PRECAUTIONS 1. Tree harvesting on sloped terrain should be carried out in LOW driving range. Refer to TRACK, LOW/ DRIVE, SWITCH WITH LIGHT in THIS SECTION. 2. Refer to HARVESTING ATTACHMENT – GENERAL SAFETY in SECTION 1.

3. Read and understand the operating and safety instructions found in the attachment manufacturer’s manual for the attachment installed on this machine.

2.85

Controls and Operation

Tigercat H820D Harvester

SPECIAL OPERATING INSTRUCTIONS FOR ER BOOM SYSTEM A

SIDE WINDOW SCREEN

B

A

822D-062

A Window Screen Lever

The side door is equipped with a small sliding window screen to allow outside air to enter the cab.

Squeeze the lever and slide the window open/closed.

800014

A

Normal Horizontal Reach Motion Performance can be Expected in this Area

Operating the Hoist Boom in this Zone with a Full Load Will B Not Allow the Horizontal Reach Motion to Perform as it Should Without Assistance from the Right Joystick

This ER 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 ER 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.

2.86

LUBRICATION AND MAINTENANCE.................................................................................................................3

Tigercat H820D Harvester SECTION 3– LUBRICATION AND MAINTENANCE Always read and understand the entire contents , and all manuals for any attachments or accessories associated with this machine, prior to operating or servicing this equipment.

CONTENT – SECTION 3 A

ISSUE 2.0, FEBRUARY 2017

ACCESS DOOR, UNDERCARRIAGE, SWIVEL......................................................................................................... 3.70 A/C COMPRESSOR BELT.......................................................................................................................................... 3.36 AFTERTREATMENT SYSTEM................................................................................................................................... 3.54 CATALYTIC CONVERTER....................................................................................................................................... 3.67 DENOX 2.2 DOSING SYSTEM............................................................................................................................... 3.62 DIESEL EXHAUST FLUID (DEF) TANK.................................................................................................................. 3.59 DEF QUALITY SENSOR...................................................................................................................................... 3.58 HEATER UNIT...................................................................................................................................................... 3.59 DIESEL OXIDATION CATALYST (DOC).................................................................................................................. 3.64 DOSING MODULE (DEF INJECTOR)..................................................................................................................... 3.67 EXHAUST FLAP...................................................................................................................................................... 3.63 HEATED DEF SUPPLY LINES................................................................................................................................ 3.63 HEATER VALVE / HEATED DEF SUPPLY LINES................................................................................................... 3.62 HUMIDITY AND TEMPERATURE SENSOR........................................................................................................... 3.68 MIXER TUBE........................................................................................................................................................... 3.67 NH3 SENSOR.......................................................................................................................................................... 3.68 NOX SENSOR......................................................................................................................................................... 3.69 SUPPLY MODULE................................................................................................................................................... 3.64 TEMPERATURE SENSORS.................................................................................................................................... 3.68 AIR CLEANER............................................................................................................................................................ 3.50 AIR CONDITIONING SYSTEM................................................................................................................................... 3.36 AIR FILTERS FRESH AIR, A/C UNIT............................................................................................................................................. 3.40 AIR INTAKE SYSTEM................................................................................................................................................. 3.50 AIR CLEANER......................................................................................................................................................... 3.52 AIR INTAKE SEAL................................................................................................................................................... 3.50 CLEAN OUT COVERS............................................................................................................................................. 3.53 ENGINE AIR PRECLEANER................................................................................................................................... 3.50 FILTER RESTRICTION INDICATOR....................................................................................................................... 3.53 IMPROPER SERVICING......................................................................................................................................... 3.52 OVER SERVICING.................................................................................................................................................. 3.52 ANTI-CORROSION SPRAY, REMOVAL, IF APPLICABLE......................................................................................... 3.75 APPROVED ANTI-SEIZE PASTES FOR EXHAUST/AFTERTREATMENT SENSORS............................................. 3.69 B

BELT, A/C COMPRESSOR......................................................................................................................................... 3.36 C

CARE OF THE MACHINE........................................................................................................................................... 3.72 CASE DRAIN STRAINERS......................................................................................................................................... 3.30 CHECKING THE AIR CONDITIONING SYSTEM....................................................................................................... 3.36 CLEANING REMOVAL OF ANTI-CORROSION SPRAY, IF APPLICABLE................................................................................. 3.75 CLEANING COOLER PACKAGE................................................................................................................................ 3.38 CLEAN OUT COVER.................................................................................................................................................. 3.51 COMMERCIAL WOOD– WEIGHTS............................................................................................................................ 3.87 CONTROLS ENGINE COOLANT HEATER.................................................................................................................................. 3.35 COOLER PACKAGE– CLEANING.............................................................................................................................. 3.38 D

DEF (DIESEL EXHAUST FLUID) DRAINING THE TANK............................................................................................................................................. 3.60 HANDLING AND STORAGE.................................................................................................................................... 3.61 TANK........................................................................................................................................................................ 3.58

Lubrication and Maintenance

Tigercat H820D Harvester

DIAGNOSTICS CONNECTION, ENGINE................................................................................................................... 3.41 DIFFUSERS CHANGING OR CLEANING.................................................................................................................................... 3.32 DIFFUSERS/STRAINERS– HYDRAULIC OIL RETURN............................................................................................ 3.31 E

EMERGENCY EXITS, CHECK MONTHLY................................................................................................................... 3.8 ENGINE COOLANT HEATER (OPTIONAL)............................................................................................................... 3.35 ENGINE DIAGNOSTICS CONNECTION.................................................................................................................... 3.41 ER BOOM SYSTEM.................................................................................................................................................... 3.22 F

FILTERS A/C HEATER UNIT, CAB.......................................................................................................................................... 3.40 DEF SUPPLY MODULE FILTER.............................................................................................................................. 3.65 DIFFUSERS/STRAINERS– HYDRAULIC OIL RETURN......................................................................................... 3.31 ENGINE OIL............................................................................................................................................................. 3.44 FRESH AIR.............................................................................................................................................................. 3.40 FUEL........................................................................................................................................................................ 3.44 RECIRCULATING AIR............................................................................................................................................. 3.40 REMOVE AND REPLACE, ENGINE........................................................................................................................ 3.44 REMOVE AND REPLACE, HYDRAULIC OIL.......................................................................................................... 3.28 RESTRICTION PRESSURE SWITCH, HYDRAULIC OIL....................................................................................... 3.27 RETURN FILTERS– HYDRAULIC OIL..................................................................................................................... 3.27 FIRE PREVENTION...................................................................................................................................................... 3.9 FIRE SUPPRESSION SYSTEM, OPTIONAL COMPONENT LOCATIONS...................................................................................................................................... 3.9 FUEL, BOTTOM REFUELLING PROCEDURE.......................................................................................................... 3.49 FUEL COOLER........................................................................................................................................................... 3.23 FUEL, REFUELLING PROCEDURE........................................................................................................................... 3.48 FUEL STRAINER........................................................................................................................................................ 3.46 FUEL SYSTEM............................................................................................................................................................ 3.44 STRAINER– CHANGING/CLEANING...................................................................................................................... 3.45 FUEL TANK CAPACITY................................................................................................................................................................ 3.46 COMPONENTS....................................................................................................................................................... 3.46 REFUELLING PROCEDURE................................................................................................................................... 3.48 FUSES AND RELAYS BATTERY COMPARTMENT.................................................................................................................................... 3.43 CAB.......................................................................................................................................................................... 3.41 ENGINE COMPARTMENT....................................................................................................................................... 3.42 GRID HEATER......................................................................................................................................................... 3.43 SIDE PANEL............................................................................................................................................................ 3.42 G

GRAFFITI REMOVAL.................................................................................................................................................. 3.72 H

HEATER CONTROL, ENGINE COOLANT (OPTIONAL)............................................................................................ 3.35 HYDRAULIC OIL FILL PUMP...................................................................................................................................... 3.25 HYDRAULIC OIL LEVEL SIGHT GUIDES.................................................................................................................. 3.24 HYDRAULIC OIL TANK............................................................................................................................................... 3.23 FILTER/BREATHER................................................................................................................................................. 3.24 FILTER RESTRICTION PRESSURE SWITCH........................................................................................................ 3.27 FILTER/STRAINER SERVICE................................................................................................................................. 3.27 HYDRAULIC OIL FILTERS...................................................................................................................................... 3.27 PRESSURIZATION INSTRUCTIONS...................................................................................................................... 3.33 HYDRAULIC SYSTEM................................................................................................................................................ 3.23 FILTER CHANGE PROCEDURE............................................................................................................................. 3.28 REFILLING............................................................................................................................................................... 3.34 M

MACHINE PARAMETERS.......................................................................................................................................... 3.38 3.2

Tigercat H820D Harvester

Lubrication and Maintenance

N

NEW MACHINE MAINTENANCE FIRST 125 HOUR INSPECTION REPORT............................................................................................................... 3.5 INITIAL PRE-DELIVERY INSPECTION..................................................................................................................... 3.5 TIGHTENING POINTS............................................................................................................................................... 3.5 O

OIL ANALYSIS PROGRAM OIL ANALYSIS KITS.................................................................................................................................................. 3.6 OIL LOST FROM LEAKAGE......................................................................................................................................... 3.8 OIL SAMPLING PROGRAM OIL SAMPLE COLLECTION PROCEDURES............................................................................................................ 3.7 P

PRESSURE AND SPEED SETTINGS...........................................................................................3.88, 3.89, 3.90, 3.91 R

REFILLING THE HYDRAULIC SYSTEM.................................................................................................................... 3.34 REFUELLING PROCEDURE...................................................................................................................................... 3.48 RELAYS AND FUSES BATTERY COMPARTMENT.................................................................................................................................... 3.43 CAB.......................................................................................................................................................................... 3.41 ENGINE COMPARTMENT....................................................................................................................................... 3.42 GRID HEATER......................................................................................................................................................... 3.43 SIDE PANEL............................................................................................................................................................ 3.42 ROTARY MANIFOLD SEAL– LUBRICATION............................................................................................................. 3.21 S

SCHEDULED MAINTENANCE 8 HOURS................................................................................................................................................................. 3.10 24 HOURS............................................................................................................................................................... 3.10 125 HOURS............................................................................................................................................................. 3.12 250 HOURS............................................................................................................................................................. 3.13 500 HOURS............................................................................................................................................................. 3.14 1000 HOURS................................................................................................................................................. 3.14, 3.15 2000 HOURS........................................................................................................................................................... 3.15 FREQUENTLY......................................................................................................................................................... 3.10 SERVICE AND LUBRICATION SCHEDULE............................................................................................................... 3.16 STRAINERS, CASE DRAIN........................................................................................................................................ 3.31 SWING DRIVE GEARBOX LUBRICATION OF SWING PINION AND SWING BEARING.................................................................................. 3.19 SWING DRIVE LUBRICATION GEARBOX LOWER BEARINGS.............................................................................................................................. 3.19 GEARBOX UPPER GEARING................................................................................................................................ 3.20 T

TIMED PURGE INTERVAL......................................................................................................................................... 3.38 TORQUE CHART, GENERAL..................................................................................................................................... 3.82 TORQUE, FLUID CONNECTIONS..........................................................................................................3.83, 3.84, 3.85 TRACK COMPONENTS MEASURING TRACK SAG TRACK SAG ADJUSTMENT (FILL COUPLER)................................................................................................... 3.80 TRACK SAG ADJUSTMENT (FILL VALVE).......................................................................................................... 3.79 TRACK CHAIN......................................................................................................................................................... 3.78 TRACK OPERATION AND WEAR PREVENTION...................................................................................................... 3.76 PROTECTING STEEL TRACKS.............................................................................................................................. 3.76 TORQUE PROCEDURE.......................................................................................................................................... 3.78 TRACK CHAIN SAG................................................................................................................................................ 3.78 W

WEIGHTS OF COMMERCIAL WOOD........................................................................................................................ 3.87 WINDOWS CARE OF POLYCARBONATE WINDOWS CAUTIONS........................................................................................................................................................... 3.74 CLEANING INSTRUCTIONS................................................................................................................................ 3.74 CONCEALING HAIRLINE SCRATCHES.............................................................................................................. 3.75 3.3

Lubrication and Maintenance

Tigercat H820D Harvester

FIRE PRECAUTIONS........................................................................................................................................... 3.75 GRAFFITI REMOVAL........................................................................................................................................... 3.75 INSPECTION AND MAINTENANCE.................................................................................................................... 3.73 RESISTANCE TO CHEMICALS........................................................................................................................... 3.73 RESISTANCE TO WATER.................................................................................................................................... 3.73 WOOD, WEIGHTS OF COMMERCIAL WOOD.......................................................................................................... 3.87

3.4

Tigercat H820D Harvester

Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE

Refer to the engine OPERATION AND MAINTENANCE MANUAL and attachment manual for additional required maintenance at this scheduled time period.

NEW MACHINE MAINTENANCE INITIAL PRE-DELIVERY INSPECTION

IMPORTANT! Before driving the machine, the track tension (sag) must be set correctly. Track sag may be set less than specified for shipping purposes. Refer to TRACK SAG ADJUSTMENT in THIS SECTION for the procedure.

Perform the initial pre-delivery inspection using Tigercat form numbers 5341 and 5347: PDI and 125 hour inspection report FIRST 125 HOUR INSPECTION AND SERVICE REPORT With the owner's mechanic present, perform an inspection and service according to the Tigercat form numbers 5341 and 5347: PDI and 125 hour inspection report This must be completed within the first 125 hour time frame.

IMPORTANT! To qualify for continued warranty, this report must be completed and returned to Tigercat Industries Inc. Warranty department.

TIGHTENING POINTS All hydraulic connections Hose clamps All cylinder and boom pin retainers Check swing bearing bolt torque Engine mounting bolts Pump mounting bolts Track shoe bolts Track roller retaining bolts Track sprocket retaining bolts Track drive gearbox mounting bolts Track drive motor mounting bolts Swing gearbox mounting bolts Swing motor mounting bolts Cab securing bolts Any other loose nut, bolt or fitting NOTE: Use of filters other than genuine Tigercat replacement filters is not recommended.

3.5

Lubrication and Maintenance

Tigercat H820D Harvester

TIGERCAT OIL ANALYSIS PROGRAM

TIGERCAT OIL ANALYSIS KITS

Using the Tigercat Advanced Oil Analysis Program on a regular basis is an excellent preventative maintenance tool.

Each kit includes a Prepaid Sample Bottle and Sample Information Form. Preprinted mailing labels are also included to ensure all samples are quickly returned directly to the lab for immediate analysis and results within 24 hours of receipt.

Studies have shown that it is possible to receive a 10 to 1 payback when looking at the amount saved on repair costs in relation to the amount invested in a scheduled oil analysis program. Some of the benefits of a sampling program include:

The same type of sample bottle can be used for all types of oil testing including Hydraulic Circuits, Final Drives, Axles, Gearboxes, Engines, etc.

Each kit includes detailed instructions on how to properly collect, prepare and ship the oil samples to ensure accurate and meaningful results are obtained.

• Detecting problems early and before they become major catastrophic failures.

• Better ability to schedule downtime and forecast cost of repairs.

Contact your Tigercat Dealer Parts Department to order Kits.

• Monitoring maintenance schedules and practices and confirming the required maintenance is being done on time.

• Increase used equipment value by providing proof of proper maintenance.

This Program uses the most modern technology available to analyze all oil samples. Most test results are available within 24 hours after receipt of the sample and are supplied in an easy to understand report, which calls for specific action and makes detailed recommendations.

The report is available as a mailed or faxed hardcopy, sent via e-mail or it can be viewed on the Internet.

This program will provide Tigercat machine owners access to an Advanced Oil Analysis Program for all major machine components including Engines, Hydraulic Circuits, Axles, Final Drives, Gearboxes, etc.

Tigercat Oil Analysis Kits are available from your Tigercat dealer parts department. If required, arrangements can also be made with your Tigercat dealer to supply and perform all of the required follow-up oil samples.

Refer to OIL SAMPLE COLLECTION PROCEDURES in THIS SECTION for sample valve and drain plug locations.

800 Series Models Recommended Testing Schedule Location

First Sample

Follow-up Samples

Hydraulic Oil

125 Hours

Every 1000 Hours or 6 Months

Swing Drive Gearbox (if applicable*)

125 Hours

Every Oil Change (250 Hours or 1.5 Months)

Track Drive Gearboxes

125 Hours

Every 1000 Hours or 6 Months

Pump Drive Gearbox (if applicable)

125 Hours

Every 1000 Hours or 6 Months

* Note that swing drive gearbox oil sampling applies only to machines that use gear oil in the swing drive gearbox.

3.6

Tigercat H820D Harvester

Lubrication and Maintenance

TIGERCAT OIL SAMPLING PROGRAM

Hydraulic Oil Samples:

OIL SAMPLE COLLECTION PROCEDURES

A

Fill out the Sample Information Form (SIF) completely and accurately. When taking multiple oil samples, fill out all of the required SIF`s in their entirety, prior to taking any oil samples. Then, immediately package each completed SIF together with the matching oil sample in the black outer shipping container as each individual sample is taken. This will reduce the possibility of mixing up or incorrectly identifying the SIF`s and oil samples.

Incorrectly identified samples could result in a false warning alarm.

LX830D-028

A Hydraulic Oil Sample Valve

• Hydraulic oil samples should be taken from the circulating oil flow at operating temperature, with no functions actuated, using sample valves that are permanently located on the machine whenever possible.

The accuracy of the lab analysis results is very dependent on the quality of the oil sample taken.

Collection of clean oil samples that are representative of the main body of oil are essential if meaningful lab results are to be obtained. Erroneous readings may result if proper collection, handling, packaging and shipping practices are not followed prior to the sample being tested by the lab. To be able to accurately compare and trend the lab results over time, all followup samples should be consistently taken from the same location using the same techniques as all previous samples.

• Purge the bleed hose before taking a representative oil sample. Drain a minimum of 90-120 ml (3-4 oz) of oil into a separate container and discard this oil using approved recycling methods.

• Remove the bleed hose from the sample valve and replace the dust cover on the sample valve immediately after taking the oil sample and sealing the sample bottle.

Gearbox Samples:

• Ensure that all sample valves and drain plugs are clean and free of debris.

• These samples can be taken during the oil change process.

• Remove the dust cover from the sample valve and attach the bleed hose (supplied with the machine) to the sample valve connection.

• To obtain a representative oil sample, the oil must be warm and must not have settled very long (within 30 minutes of shutdown).

• Remove the sample bottle cap only when ready to obtain the sample. Keep the cap clean – DO NOT put it in your pocket or let it get contaminated in any way.

• Place the required drain container under the machine to capture the used oil to be discarded using approved recycling methods.

• DO NOT allow any airborne dirt, etc., to enter the sample bottle.

• Remove the drain plug and allow approximately 50% of the oil to drain, then place the sample bottle in the stream of draining oil to obtain a representative sample.

• Avoid contamination of the sample – replace the sample bottle cap immediately after filling the bottle to approximately ¾ full.

All samples taken should be immediately forwarded to the lab for processing.

Contact your Tigercat dealer to purchase additional or replacement hydraulic sample valves or drain plugs.

In cases where oil samples must be pumped or otherwise drawn out of a tank or housing, a hand operated oil suction pump is also available from your Tigercat dealer.

3.7

Lubrication and Maintenance

Tigercat H820D Harvester

GENERAL

• Inspect the exhaust system daily for any signs of leakage. Check for worn, cracked, broken, or damaged pipes or muffler. Also check for missing or damaged bolts or clamps. Should any exhaust leaks or defective parts be found, repairs must be made immediately. Engine exhaust leaks can cause fires; DO NOT operate the machine until the exhaust leak is repaired.

CAUTION All handles, steps and platforms must be kept free of grease, oil, fuel, mud, snow, ice and forest debris.

• Always clean around fill caps before checking or adding fluids.

• Always clean around hydraulic fittings before breaking connection. Plug or cap immediately.

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

• Always clean up spills as soon as possible.

• Always have a fire extinguisher at hand.

• Always use clean oil and containers.

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

• Always release pressure in hydraulic tank before breaking a connection. For machines with pressurized tanks.

• Drain dirty oil while still warm.

• Do not exceed recommended fluid levels.

• Always install the door safety struts when working on the machine.

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

• Always clean the fire suppression system sensors.

CHECK EMERGENCY EXITS MONTHLY • Two alternate exit routes are provided: side door emergency exit and roof escape hatch/emergency exit. These are ONLY to be used if the front door cannot be opened.

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

• Always clean up oil spills on walking surfaces in the engine enclosure immediately.

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

• Before welding on the machine, be sure to disconnect all electrical connections and follow all servicing safety precautions as outlined in the PRIOR TO WELDING in SECTION 1 in THIS MANUAL.

• Refer to EMERGENCY EXIT– MAINTENANCE GUIDE in SECTION 2 for the procedure.

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

• Always clean away all branches, bark and chips.

Clean up all traces of oil to avoid fires.

*OIL LOST FROM LEAKAGE LOST OIL (LITRES)

LEAKAGE RATE

PER DAY

PER MONTH PER YEAR

LOST OIL (US GALLONS) PER DAY

PER MONTH PER YEAR

ONE DROP IN TEN SECONDS

0.424

12.72

152.0

0.112

3.36

40.0

ONE DROP IN FIVE SECONDS

0.852

25.6

306.6

0.225

6.75

81.0

ONE DROP PER SECOND

4.26

127.76

1533.1

1.125

33.75

405.0

THREE DROPS PER SECOND

14.2

425.86

5110.31

3.75

112.5

1350.0

DROPS BREAK INTO STREAM

90.83

2725.5

32706.0

24.0

720.0

8640.0

3.8

Tigercat H820D Harvester

Lubrication and Maintenance

FIRE PREVENTION

FIRE SUPPRESSION SYSTEM COMPONENTS

Proper maintenance of your machine will greatly extend its life and reduce your operating costs.

Pay attention to the location of the components of the fire suppression system. 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 an accidental discharge of the system.

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

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

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.

1. When allowed to accumulate, forest debris and fine organic material (twigs, pine needles, branches, bark, leaves, saw dust, small wood chips, etc.) and any other combustible materials form a fuel source that is extremely difficult to extinguish when ignited. 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.

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

If any of the components are damaged, replace them immediately before operating the machine.

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

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

BTL NAB N6

S6

CP

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

Refer to FIRE SUPPRESSION SYSTEM in THIS SECTION.

EMA

S5

N5

N3

4. In case of fire, lower the boom system to the ground and turn OFF the engine before discharging the fire suppression system.

S1 N4 S4

Refer to FIRE PREVENTION in SECTION 1 for additional information.

N1 BTL D

N2

S2

S3

N

DENOTES NOZZLE LOCATION AND SPRAY DIRECTION

BTL

DENOTES BOTTLE LOCATION

EMA

DENOTES ELECTRICAL MANUAL SWITCH

NAB

DENOTES NITROGEN ACTU ATION BUTTOM

D

DENOTES DISTRIBUTION BLOCK LOCATION

S

DENOTES THER MOSTAT LOCATION

CP

DENOTES CONTROL PANEL LOCATION

822D-004

Component Locations

3.9

Lubrication and Maintenance

Tigercat H820D Harvester

SCHEDULED MAINTENANCE

EVERY 8 HOURS PERFORM

IMPORTANT!

• FREQUENTLY maintenance

PRESSURIZED HYDRAULIC TANK 35 KPA (5 PSI) MAXIMUM 7 KPA (1 PSI) NOMINAL

• Drain water from fuel/water separator.

CHECK • Engine coolant level.

• Engine oil level.

• Hydraulic oil level.

• Air intake precleaner operation.

A

• Air intake connections.

B

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

C

• Air intake filter restriction indicator.

LX830D-030

A Air Vent Valve B Open/Close Lever C Pressure Gauge

• Replace primary filter if indicator is in red zone.

• Replace secondary (safety) filter every third primary filter change to guarantee maximum performance and reliability.

Before servicing the hydraulic system, release the air pressure from the tank using the air vent valve.

Eye protection is required. Refer to HYDRAULIC SYSTEM– HYDRAULIC TANK PRESSURIZATION INSTRUCTIONS in THIS SECTION.

• For loose nuts, bolts and fittings.

• Condition and tension of fan belts.

Handle Perpendicular to Valve (shown) = Valve Closed

• Visually check condition of tracks.

Handle Parallel to Valve = Valve Open

• Conduct an overall visual inspection.

After service is completed, close the air vent valve.

• Swing drive gearbox upper gearing gear oil level.

FREQUENTLY

CLEAN • Oil cooler, engine radiator, charge air cooler and enclosure screens.

• Check the engine cooling air intake screens for possible restriction. In broad leaf applications, it may be necessary to reverse the cooling fan as frequently as every 10 minutes.

• Remove potentially damaging limbs or sticks.

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

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

3.10

Tigercat H820D Harvester

Lubrication and Maintenance EVERY 24 HOURS

LUBRICATE • Swing pinion; 1 fitting – 10 shots while swinging.

PERFORM

• Boom joints:*

• FREQUENTLY maintenance

• 13 fittings – purge

• 8 HOURS maintenance LUBRICATE • Swing bearing: 1 fitting – 10 shots while swinging.

A

H822C-005

A Stick Cylinder Fully Extended

Refer to the engine OPERATION AND MAINTENANCE MANUAL and ATTACHMENT MANUAL (when required) for additional required maintenance at this scheduled time period.

• Cylinders; hoist, stick & tilt:* • 8 fittings – purge * Lubricating cylinder pins and boom joints: 1. Ensure the machine is on level ground.

2. Fully retract telescopic stick (if equipped).

3. Lay attachment on ground.

4. Force tip of stick boom onto support.

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.

Refer to the engine OPERATION AND MAINTENANCE MANUAL and ATTACHMENT MANUAL (when required) for additional required maintenance at this scheduled time period.

3.11

Lubrication and Maintenance

Tigercat H820D Harvester

EVERY 125 HOURS

VISUALLY INSPECT FOR • Frayed electrical wiring and hydraulic hoses.

PERFORM

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

• FREQUENTLY maintenance • 8 HOURS maintenance

• Wear in any other components.

• 24 HOURS maintenance

• Signs of cracks beginning in booms and attachments.

• Open both (left side door and cab roof escape hatch) emergency exits to ensure they are fully operational.

• Carry out A/C system inspection. Refer to CHECKING THE AIR CONDITIONING SYSTEM in THIS SECTION. CHECK • Return filter bypass message is NOT displayed on the MD4 Computer with the engine running at high idle with oil flow and oil at operating temperature.

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

Refer to the engine OPERATION AND MAINTENANCE MANUAL and ATTACHMENT MANUAL (when required) for additional required maintenance at this scheduled time period.

• Pilot filter restriction indicator (when fitted) with the engine running at high idle.

• Track gearboxes oil level with the level plug at the nine o’clock and the other plug at the six o’clock position.

• Hydraulic pump and motor securing bolts.

• Torque tightening points as per new machine maintenance.

CLEAN/REPLACE • Inspect for debris buildup on cooler package debris screens. Clean as required.

• Air conditioner re-circulation filter • Cab fresh air filter VISUALLY CHECK FOR DAMAGE TO • The hoist and stick booms • Track components and undercarriage frames • Swing bearing area • Attachment Complete repairs immediately.

3.12

Tigercat H820D Harvester EVERY 250 HOURS

Lubrication and Maintenance REPLACE • Engine oil and filter *

PERFORM • FREQUENTLY maintenance

• Engine fuel filter *

• 8 HOURS maintenance

• Filter in fuel filter/water separator *

• 24 HOURS maintenance

• DEF dosing module filter * (Tier 4f machines only)

• 125 HOURS maintenance

• Swing drive gearbox upper gearing oil. Fill gear oil bottle half full.

CHECK

• Oil in the track drive gearboxes with the drain plug at the six o'clock position and the fill plug at the nine o’clock position.

• Condition and tension of serpentine belt.

• All hydraulic pressures.

CLEAN • Clean and thoroughly inspect all surfaces of the hoist and stick booms for cracks.

Refer to the engine OPERATION AND MAINTENANCE MANUAL and ATTACHMENT MANUAL (when required) for additional required maintenance at this scheduled time period.

All cracks must be properly repaired in their early stages. In most cases, cracks will continue to grow in size and often lead to major structural damage. Failure to regularly inspect for cracks and immediately repair the boom system will void the structural warranty. Contact your Tigercat dealer for specific procedures required to correctly repair any cracks found.

LUBRICATE • Rotary manifold seal: 1 fitting – 2 shots. DO NOT USE POWER GREASE GUN. • Swing drive gearbox lower bearing: 2 fittings – 5 shots each*. DO NOT USE A POWER GREASE GUN. *With the swing gearbox at operating temperature slowly add five shots of lithium based EP2 to each side of the gearbox.

NOTE: During cold weather, 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 the gearbox pinion seal.

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

3.13

Lubrication and Maintenance

Tigercat H820D Harvester

EVERY 500 HOURS

EVERY 1000 HOURS

PERFORM

PERFORM

• FREQUENTLY maintenance

• FREQUENTLY maintenance

• 8 HOURS maintenance

• 8 HOURS maintenance

• 24 HOURS maintenance

• 24 HOURS maintenance

• 125 HOURS maintenance

• 125 HOURS maintenance

• 250 HOURS maintenance

• 250 HOURS maintenance

CHECK

• 500 HOURS maintenance

• Torque on the swing bearing, swing gearbox retaining bolts, track drive gearboxes and the motor mounting bolts.

CHECK

• Track rollers for leakage.

Refer to the engine OPERATION AND MAINTENANCE MANUAL and ATTACHMENT MANUAL (when required) for additional required maintenance at this scheduled time period.

Rollers are considered to be maintenance free. If a lubricant leakage is detected the rollers must be replaced.

• In-tank fuel strainer

• Track idler assembly for leakage.

The bearing is filled with oil and is considered to be maintenance free. If a lubricant leakage is detected, the idler must be replaced.

LUBRICATE • All door hinges and cover: 24 fittings – 1 shot • Engine roof cylinder pins: apply oil liberally REPLACE • Case drain return filter ** • Hydraulic oil return filters ** • Pilot filter * *Refer to FILTERS– REMOVE AND REPLACE in THIS SECTION. Refer to the engine OPERATION AND MAINTENANCE MANUAL and ATTACHMENT MANUAL (when required) for additional required maintenance at this scheduled time period.

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

3.14

Tigercat H820D Harvester

Lubrication and Maintenance

EVERY 1500 HOURS

EVERY 2000 HOURS

PERFORM

PERFORM

• FREQUENTLY maintenance

• FREQUENTLY maintenance

• 8 HOURS maintenance

• 8 HOURS maintenance

• 24 HOURS maintenance

• 24 HOURS maintenance

• 125 HOURS maintenance

• 125 HOURS maintenance

• 250 HOURS maintenance

• 250 HOURS maintenance

• 500 HOURS maintenance

• 500 HOURS maintenance

• 1000 HOURS maintenance

• 1000 HOURS maintenance

REPLACE

• 1500 HOURS maintenance

• Crankcase ventilation filter ** (Tier 4f machines only)

• Drain and refill hydraulic oil tank with recommended hydraulic oil. Refer to APPROVED HYDRAULIC OILS in THIS SECTION. Also refer to HYDRAULIC SYSTEM, REFILLING in THIS SECTION.

Refer to engine OPERATION AND MAINTENANCE MANUAL for replacement instructions.

Refer to the engine OPERATION AND MAINTENANCE MANUAL and ATTACHMENT MANUAL (when required) for additional required maintenance at this scheduled time period.

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

The hydraulic oil type selected in the MD4 Computer program must match the oil type being used.

Adjust oil type if needed. Refer to COMPUTER – ADJUSTMENT MENU – OIL GRADE SELECTION in SECTION 2 or SECTION 6 of the SERVICE MANUAL for selecting hydraulic oil type setting procedure.

CHECK • All air intake tubing and band clamps for signs of wear and leakage.

REPLACE • The hydraulic tank breather.

• All air intake rubber components such as elbows and connectors.

High temperatures in this area can cause the rubber to harden.

NOTE: High-temperature silicone connectors do not need to be replaced unless they are damaged.

Refer to AIR INTAKE SYSTEM– INTAKE TUBING AND JOINTS in THIS SECTION. Refer to the engine OPERATION AND MAINTENANCE MANUAL and ATTACHMENT MANUAL (when required) for additional required maintenance at this scheduled time period.

3.15

Lubrication and Maintenance

Tigercat H820D Harvester

SERVICE AND LUBRICATION SCHEDULE

75661BENG R0

3.16

Tigercat H820D Harvester

Lubrication and Maintenance

75661BENG R0

3.17

Lubrication and Maintenance

Tigercat H820D Harvester

APPROVED HYDRAULIC OILS Use one of the following oils to fill or replenish the hydraulic system:

5168AR05

3.18

Tigercat H820D Harvester SWING DRIVE LUBRICATION LUBRICATION OF SWING DRIVE GEARBOX LOWER BEARINGS

Lubrication and Maintenance LUBRICATION OF SWING BEARING AND SWING PINION

A

B 822D-135

A Swing Bearing Grease Fitting B Swing Pinion Grease Fitting

822C-65

To lubricate the swing bearing, apply 10 shots of grease, while swinging, every 24 hours to the right grease fitting which is located on the seat pedestal in the operator’s cab.

To lubricate the swing pinion (or teeth), apply 10 shots of grease, while swinging, every eight hours to the left grease fitting located on the seat pedestal.

For the lubrication intervals, refer to SCHEDULED MAINTENANCE or SERVICE AND LUBRICATION SCHEDULE in THIS SECTION. A

For additional information refer to SECTION 15.

822D-139

A Gearbox Lower Bearing Lubrication Points

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

The grease fittings are located in the hoist boom saddle area under the rubber belting. Using a hand grease gun and with the gearbox at operating temperature slowly add five shots of lithium based EP2 grease to each side of gearbox every 250 hours. DO NOT OVER GREASE. NOTE: During cold weather applications the swing function must operate for several hours to achieve operating temperature. If machine is not warmed up, the lower seal can be damaged.

IMPORTANT! DO NOT force grease, gearbox failure may result. DO NOT use a power grease gun to lubricate this machine.

Use a hand grease gun only.

For additional information refer to SECTION 15 in the SERVICE MANUAL. 3.19

Lubrication and Maintenance

Tigercat H820D Harvester

LUBRICATION OF SWING DRIVE GEARBOX UPPER GEARING

A

A

822D-139

A Drain Plug

822D-133

A Gear Oil Bottle

The swing drive gearbox upper gearing is filled with gear oil. Check oil level in the bottle every eight hours.

Oil level in the bottle must be kept at the half full mark at all times. Drain and replace the swing drive gearbox upper bearing gear oil according to SCHEDULED MAINTENANCE – EVERY 250 HOURS in THIS SECTION. Use 75W-90 or 80W-140 gear oil.

2. Remove the drain plug from the end of the hose (under the upper structure) and allow the oil to pour into a container capable of holding the entire capacity of the swing drive gearbox and bottle.

3. Replace the plug.

4. Fill the gearbox via the bottle until the level of the bottle is at half.

5. Replace the cap on the bottle.

6. Clean any spillage and dispose of used oil.

For additional information refer to SECTION 15.

Before draining any fluids, know the proper way to dispose of them. Do not pour fluids into the ground, stream, pond or lake.

The gear oil bottle is located directly above the DEF tank in the back-left corner of the hydraulic compartment.

1. Remove the cap on the bottle.

3.20

Tigercat H820D Harvester

Lubrication and Maintenance

ROTARY MANIFOLD SEAL LUBRICATION

A

822D-139

A Rotary Manifold

To lubricate the rotary manifold seal, apply two shots of grease every 250 hours.

To access the lubrication point, the upper structure must be turned 180°: The boom must be over the drive motors.

NOTE: During cold weather applications the swing and machine functions must operate for several hours to achieve operating temperature. Warm the lubricating grease to 22°C (72°F) before lubricating the rotary manifold seal. DO NOT OVER GREASE.

3.21

Lubrication and Maintenance

Tigercat H820D Harvester

ER BOOM SYSTEM

• Before attempting to disconnect any hydraulic hoses or perform work on the boom system:

WARNING This machine is equipped with a non-switchable ER boom system and may behave in an unexpected manner compared to a conventional boom system.

A

B

C FIG. 1

800016

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

D

• The hoist and stick cylinder circuits are connected hydraulically. Disconnecting a hydraulic line to a boom cylinder may cause either boom to move unexpectedly.

800017

• The booms 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 booms and attachment.

A B C D

A

B FIG. 2

Parking the Boom

Stick Cylinder Fully Extended Hoist Boom Fully Retracted Tip of Stick Boom Fully Supported at Rotator Tip of Stick Boom Fully Supported

(a) The machine is parked on level ground with the attachment on the ground (FIG. 1).

Ensure the attachment is properly parked for service (refer to the 'Parking the Boom' illustration) and the engine is turned OFF before disconnecting any hydraulic lines.

(b) The stick cylinders are fully extended (FIG. 1) or the hoist cylinders fully retracted (FIG. 2).

• Some machines are equipped with pressurized hydraulic tanks. Relieve the pressure in the hydraulic tank by opening the hydraulic tank vent valve and waiting until the sound of escaping air stops.

(c) The telescopic boom fully retracted (if equipped) and the tip of the stick boom supported at the rotator pin.

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

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

NOTE: Because of the hydraulic connection between the hoist and stick cylinders, the hoist cylinder can overpower the stick cylinders under certain conditions, causing the stick boom to move unexpectedly. This most often occurs when setting the HOIST BOOM UP relief valve, causing the stick cylinders to extend. 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 there is sufficient overhead clearance for the head to rise before making any adjustments.

3.22

Tigercat H820D Harvester HYDRAULIC SYSTEM

Lubrication and Maintenance HYDRAULIC OIL TANK

HYDRAULIC FILTER SERVICING GUIDELINES IMPORTANT! NEVER PRE-FILL HYDRAULIC FILTERS Tigercat does not recommend the pre-filling of spinon filters due to the risk of damage to the hydraulic system caused by unfiltered oil. Unfiltered oil used to pre-fill filters enters directlyt 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 pre-filtered before use.

A

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.

WARNING 800028

A Hydraulic Oil Tank (Shown with Optional Engine Coolant Heater Components)

WARNING: HOT HYDRAULIC OIL AND HOT MACHINE SURFACES CAN CAUSE SERIOUS BURNS! • Before servicing the machine, allow the engine cooling system, fuel system, exhaust system, hydraulic system and machine surfaces to cool down.

• Use a thermometer to check surface and system temperatures to ensure it is safe to begin service work.

• DO NOT begin service work until the surface or system temperature has cooled down to below 38°C (100°F).

Located at the rear-left of the machine directly behind the operator cab, the hydraulic oil tank has a capacity of 208 L (55 US gal) plus another 23 L (6 US gal) for the suction elbow, suction manifold and fan pump suction hose.

Six full-flow hydraulic oil return filters are connected to the hydraulic oil tank and mounted on three filter heads with built-in bypasses. The filters are located above the hydraulic oil tank.

A temperature sender activates the temperature gauge on the MD4 Computer display. The hydraulic oil temperature icon displays BLUE during the warmup mode and changes to WHITE in normal operating temperature. Should the temperature rise above normal the icon changes to YELLOW. A Critical message is displayed when the oil temperature gauge needle enters the red zone and the icon changes to RED. Stop the machine and resolve the cause of the fault.

3.23

Lubrication and Maintenance

Tigercat H820D Harvester

FILTER/BREATHER, HYDRAULIC TANK

HYDRAULIC OIL LEVEL SIGHT GAUGES

A

A B

LX830D-030

A Hydraulic Oil Tank Filter/Breather

The air space in the top of the hydraulic oil tank is vented to atmosphere via a check valve and spin-on filter/breather. The check valve will open or crack when the pressure in the hydraulic oil tank reaches 34.5 kPa (5 psi) maximum (7 bar (1 psi) nominal). The pressure build-up in the hydraulic oil tank can be due to thermal expansion as the hydraulic oil heats up.

822D-056

A First Sight Gauge (DEF Tank Side) B Second Sight Gauge (Engine Side)

There is a pressure gauge to indicate the pressure inside the hydraulic oil tank and an air vent valve to relieve the pressure when servicing the hydraulic system.

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

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

There is a sight gauge on each side of the tank. Always keep the hydraulic oil level to within 5 cm (2 in) of the HIGH mark on the sight gauge.

An electronic fluid level sending unit is installed in the top of the tank. This unit sends a signal, to the MD4 Computer, which is translated by the MD4 Computer and displayed as a fluid level on the MD4 Display. If the hydraulic oil reaches a low level, an alert message is displayed and the hydraulic oil level icon displays in YELLOW. Also, an audio and visual alarm will turn on and the MD4 Computer will display a message to alert the operator.

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

3.24

Tigercat H820D Harvester

Lubrication and Maintenance

HYDRAULIC OIL FILL PUMP

A

A

C

B

B C

D

D

LX830D-002

E

822D-150

800028

A Fill Hose Sight Gauges – Not Shown (Refer to HYDRAULIC OIL LEVEL SIGHT GAUGES) C Fill Tube D Electric Fill Pump E Pump Switch

C

B

The electric hydraulic oil fill pump, located on the rear left behind the cab, is used for adding oil to the hydraulic oil tank. Hydraulic oil is pumped directly into the hydraulic oil tank via the return filter manifold to ensure any hydraulic oil added is filtered prior to entering the hydraulic tank. Refer to APPROVED HYDRAULIC OILS in THIS SECTION.

C

D LX830D-002

A B C D

D

LX830D-003

Fill Hose Fill Tube Fill Tube Plug Bracket with Hexagon Socket

To add oil to the hydraulic oil tank: 1. Depressurize the hydraulic oil tank.

2. Thoroughly clean the outside surface of the fill tube.

3. Remove the plug with the aid of the bracket with the hexagon socket.

4. Insert the end of fill tube into supply drum.

3.25

Lubrication and Maintenance

Tigercat H820D Harvester

5. Turn ON the pump (press and hold the pump switch).

IMPORTANT! PRESSURIZED HYDRAULIC TANK

Operate the pump using the pump switch located on the side of the pump compartment. The oil is pumped directly into the hydraulic tank via the return filters.

35 KPA (5 PSI) MAXIMUM 7 KPA (1 PSI) NOMINAL

Observe the level gauges on the rear of the tank to determine when to release the switch. The hydraulic oil level should be within 5 cm (2 in) of the HIGH mark on the sight gauge with the boom fully extended.

When the tank is at the desired level: A

6. Release the pump switch.

7. Replace the plug on the fill tube.

B

C

8. Wipe the fill tube and store.

LX830D-030

IMPORTANT! Failure to keep the fill tube clean will significantly reduce the life of the filter elements.

A Air Vent Valve B Open/Close Lever C Pressure Gauge

Before servicing the hydraulic system, release the air pressure from the tank using the air vent valve.

Eye protection is required. Refer to HYDRAULIC SYSTEM– HYDRAULIC TANK PRESSURIZATION INSTRUCTIONS in THIS SECTION.

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

Handle Perpendicular to Valve (shown) = Valve Closed Handle Parallel to Valve = Valve Open After service is completed, close the air vent valve.

3.26

Tigercat H820D Harvester

Lubrication and Maintenance

RETURN FILTERS– HYDRAULIC OIL

IMPORTANT

A

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 THIS SECTION.

D

855C-035 822D-064

A B C D

B

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

C

FILTER RESTRICTION PRESSURE SWITCH

HYDRAULIC OIL FILTERS

Filter Head Filter Manifold Filter Filter Restriction Pressure Switch

The majority of return oil entering the tank passes through six spin-on hydraulic oil filters. One of the filters is a water absorbing filter (blue filter) 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 filters should be checked/changed at the intervals specified in the SERVICE AND LUBRICATION SCHEDULE in THIS SECTION. There is a bypass valve, preset at 1.7 bar (25 psi), built into each filter head, which will open in the event the elements become restricted. Before this valve is activated, a filter restriction pressure switch, will cause the hydraulic oil filter bypass icon on the MD4 Computer Display to illuminate YELLOW. If the icon continues to display YELLOW after the filters have been changed, the return diffusers attached to the base of the return tubes in the hydraulic tank should be examined for possible obstruction.

A 1.4 bar (20 psi) filter restriction pressure switch is installed in the return manifold. When an oil pressure differential in excess of 1.4 bar (20 psi) is encountered at the return filters in the hydraulic tank, this pressure switch closes and the hydraulic oil filter bypass icon displays YELLOW on the MD4 Computer display.

The master alarm will sound and the alarm light flash continuously.

FILTER/DIFFUSER SERVICE NOTE: The filters should be checked/changed when the oil filter bypass icon displays YELLOW on the MD4 Computer display. If the icon continues to display YELLOW after the filters have been changed, the diffusers attached to the base of the return tubes in the hydraulic tank should be examined for possible obstruction.

IMPORTANT! DO NOT use these warnings as a substitute for changing the oil filters at regular intervals as per the SCHEDULED MAINTENANCE in THIS SECTION. This information is assuming that operating conditions and running temperatures are normal.

IMPORTANT

NEVER PRE-FILL

Refer to DIFFUSERS, CHANGING OR CLEANING in THIS SECTION.

HYDRAULIC FILTERS

If the filter bypass icon displays YELLOW between scheduled maintenance intervals, turn off the engine and change these filter elements immediately.

Tigercat does not recommend the pre-filling of spinon 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 pre-filtered before use.

NOTE: The filter bypass icon will display RED when the hydraulic oil temperature is low and the filter restriction switch is activated. Allow the oil to warm to operating temperature and the icon should change to GREY. Refer to MACHINE PREPARATION in SECTION 2.

3.27

Lubrication and Maintenance

Tigercat H820D Harvester

FILTER CHANGE PROCEDURE

9. Drain away any accumulation of oil in the built-in tray (top of hydraulic tank) by using the drain hose routed through the floor to a waste oil container.

IMPORTANT! PRESSURIZED HYDRAULIC TANK

10. 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.

35 KPA (5 PSI) MAXIMUM 7 KPA (1 PSI) NOMINAL

 SQUARE SECTION GASKET

A

B A

C

B FILTR_SEALS 2

A Filter Head B Gasket C Filter Element

C LX830D-030

A Air Vent Valve B Open/Close Lever C Pressure Gauge

a. Remove the used gasket and clean the groove in the head. b. Apply clean oil to new gasket surfaces.

Before servicing the hydraulic system, release the air pressure from the tank using the air vent valve.

Eye protection is required. Refer to HYDRAULIC SYSTEM– HYDRAULIC TANK PRESSURIZATION INSTRUCTIONS in THIS SECTION.

c.

Install the new gasket into the groove in the filter head.

d. Screw on the new filter until the gasket makes contact.

Handle Perpendicular to Valve (shown) = Valve Closed

e. Tighten the filter an additional ¾ turn.

Handle Parallel to Valve = Valve Open

 O-RING GASKET

After service is completed, close the air vent valve.

A

1. Park the machine on level ground with the attachment resting on the ground.

2. Open the engine roof to gain access to the return filters.

B

3. Turn OFF the engine.

FILTR_SEALS 2

4. Turn the BATTERY DISCONNECT SWITCH to the OFF position.

C

A Filter Head B Gasket C Filter Element

5. Wearing eye protection, release air from the hydraulic tank by opening the air vent valve.

NOTE: Air pressure expelling from the vent valve will blow accumulated loose debris in the compartment.

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

a. Remove the used gasket and clean the gasket seat in the head. b. Apply clean oil to the new gasket surfaces. c.

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

Install the new gasket on the inside lip of the filter.

d. Screw on the new filter until the gasket makes contact.

8. Dispose of old filter and any oil properly.

3.28

Tigercat H820D Harvester

Lubrication and Maintenance

e. Tighten the filter until the top edge makes metal to metal contact with the filter head (Approximately 1½ additional turns after gasket contact.).

17. Clean up any spilled oil.

18. If oil reaches FULL mark before air is completely bled, do the following: a. Close the air vent valve

11. Close the air vent valve.

A

b. Place the ignition switch in the ON position. Do not start the engine.

B

The hydraulic tank pressurization pump will pressurize the tank. Listen for the pump to stop. c.

Place the ignition switch in the OFF position.

d. Attach the bleed hose to the bleed coupler connection on the return manifold while the other end is in the waste container. e. Disconnect the bleed hose when a steady stream of oil is coming out of the bleed hose.

C

f.

LX830D-028

A Return Manifold B Bleed Coupler Connection C Waste Oil Tray

12. Attach the bleed hose (supplied with the machine) to the bleed coupler connection.

Repeat as necessary.

19. Start the engine and check for leaks.

20. Run engine at LOW IDLE speed for at least five minutes to purge any remaining air from the filter system. Then STOP the engine for 15 minutes to allow air bubbles in the hydraulic tank to rise.

A

13. Route hose to a waste oil container.

14. Use fill pump to raise hydraulic oil level up to the FULL line, replacing oil lost during filter change.

C

15. As oil is being pumped into the tank, purge air out the bleed hose from the return manifold until a steady stream of oil is coming from the bleed hose.

B

16. Disconnect bleed hose from the coupling at the return manifold.

822D-056

A Hydraulic Oil Tank B Right Side Sight Gauge (Second Gauge) C Left Side Sight Gauge (First Gauge)

21. Re-check hydraulic oil level – top-up as needed.

3.29

Lubrication and Maintenance

Tigercat H820D Harvester

PILOT FILTER

CASE DRAIN STRAINER B

A C A

822D-065

A Pilot Filter B Pilot Manifold C Pilot Valve

There is a low-pressure hydraulic pilot filter placed between the pilot (pressure reducing/pressure relieving) valve and the pilot manifold to filter the oil before it enters the pilot system.

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

822D-126

A Case Drain Strainer

This machine is equipped with one case drain strainer located in the pump compartment.

IMPORTANT! This element should only be serviced in the event of a pump or motor catastrophic failure or hydraulic oil contamination.

Refer to SERVICE AND LUBRICATION SCHEDULE in THIS SECTION for recommended servicing intervals and filter servicing information.

3.30

Tigercat H820D Harvester

Lubrication and Maintenance

CASE DRAIN RETURN FILTER– SAW

HYDRAULIC OIL RETURN DIFFUSERS

B A B

C A 822D-065

C

A Hydraulic Tank B Return Filters C Case Drain Return Filter

There is a hydraulic case drain return filter (in place of a strainer) placed between the hydraulic tank and the saw motor case drain port. Its primary function is to capture any particles in the event of a saw motor failure and to prevent contamination of the hydraulic tank and oil.

E 822D-012

A B C D E

This same filter is also connected to the case drain of the 340° wrist motors (if equipped).

The check valve is installed at the filter head end of the hose from the hydraulic tank.

Refer to SERVICE AND LUBRICATION SCHEDULE in THIS SECTION for recommended servicing intervals and filter servicing information.

D

Diffusers O-ring Round Access Cover Hydraulic Oil Temperature Sensor Port Drain Plug

There are three reusable diffusers/strainers housed in the hydraulic tank (vertical) on the return tubes.

Inspecting, changing or cleaning the strainers should only be performed in the event of a catastrophic pump or motor failure or hydraulic oil contamination.

3.31

Lubrication and Maintenance

Tigercat H820D Harvester

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

1. Park the machine on level ground with the attachment resting on the ground.

2. Turn OFF the engine.

3. Open the engine roof completely.

4. Wearing face protection, release air from the hydraulic tank by opening the air vent valve. See HYDRAULIC SYSTEM, HYDRAULIC OIL TANK PRESSURIZATION INSTRUCTIONS in THIS SECTION. 5. Turn the BATTERY DISCONNECT SWITCH to the OFF position. Always install a DO NOT START ENGINE sign on the operator’s cab door and in the engine compartment when making repairs to the machine.

6. Drain the hydraulic tank into a suitable container via the environmental drain plug in the bottom of the tank using the environmental drain hose. Remove the hose once the tank is drained.

7. Remove the round access cover plate and o-ring.

8. Before removing the diffusers, clean any debris from the bottom of the tank and wipe it clean.

9. Remove the three hydraulic oil return diffusers.

10. Carefully clean the diffusers (they are easily damaged by rough handling).

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

12. Re-install the diffusers.

NOTE: Repair any burrs created when removing the diffuser before re-installing.

13. Re-install the access cover plate with a new o-ring.

14. Refill the hydraulic tank and check for leaks.

15. Close the air vent valve.

3.32

Tigercat H820D Harvester

Lubrication and Maintenance

HYDRAULIC TANK PRESSURIZATION INSTRUCTIONS

1. Wearing eye protection, release air from the hydraulic tank by opening the air vent valve.

Pull valve handle down 90° to open. Push valve handle up to close.

IMPORTANT! PRESSURIZED HYDRAULIC TANK

NOTE: Expelled air from the vent valve will blow accumulated loose debris in the enclosure.

35 KPA (5 PSI) MAXIMUM 7 KPA (1 PSI) NOMINAL

NOTE: Releasing hydraulic tank pressure in the event of a hose breakage may reduce oil loss.

IMPORTANT! The air vent valve must be opened before changing hydraulic filters and strainers or performing any other service on hydraulic circuits. Do not operate the machine with the air vent valve in the open position.

A

IMPORTANT! During a filter change or return hose replacement, air is able to enter the return hydraulic circuit. It is important to bleed as much of this air as possible out prior to restarting the machine. See HYDRAULIC OIL RETURN FILTERS– FILTER CHANGE procedure for instructions on bleeding air from the return circuit. Air bubbles in the hydraulic system will damage the pumps.

B

C LX830D-030

A Air Vent Valve B Open/Close Lever C Pressure Gauge

Before servicing the hydraulic system, release the air pressure from the tank using the air vent valve.

Eye protection is required. Refer to HYDRAULIC SYSTEM– HYDRAULIC TANK PRESSURIZATION INSTRUCTIONS in THIS SECTION.

2. After service is completed, close the air vent valve.

3. Add air pressure from a clean air source to the hydraulic tank via the Schrader valve. Do not exceed 34.5 kPa (5 psi).

Handle Perpendicular to Valve (shown) = Valve Closed Handle Parallel to Valve = Valve Open After service is completed, close the air vent valve.

3.33

Lubrication and Maintenance

Tigercat H820D Harvester

REFILLING THE HYDRAULIC SYSTEM When filters are replaced, there is a nominal amount of oil loss through leakage and oil contained in the filters.

This requires a hydraulic system top-up or refill.

First, check the MD4 Computer to verify which oil type is selected to ensure the same type and grade of oil is used to refill the system. This will allow the program to optimize the cooling and warning functions to best suite the oil type. Refer to OIL GRADE SELECTION in SECTION 2 or SECTION 6 for selecting hydraulic oil type setting procedure.

A 822D-104

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

See HYDRAULIC SYSTEM/HYDRAULIC OIL FILL PUMP in THIS SECTION to add oil to the tank.

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

B 822D-103

A Pump Plugs/ Fittings – Open to vent B Cooling Fan Motor and Valve Assembly Fittings – Open to vent

When refilling the hydraulic system, vent pumps, motors and valves of air by opening a plug or hose fitting located near or on top of the pumps, motors and valves until oil free of air is seen flowing out of the plug or hose fitting.

Failure to vent air from the hydraulic system could cause serious damage to hydraulic components. Tighten plugs or fittings and clean up any spilled oil when completed.

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

3.34

Tigercat H820D Harvester

Lubrication and Maintenance

ENGINE COOLANT HEATER (OPTIONAL) This heater, heats and circulates the engine coolant through the engine, the hydraulic tank, and the cab.

A

B D

C 800161

Control Panel (Upper Right) B C

A

D

800005

A B C D

D F

E LS855D-015

A B C D E F

ON/OFF Button Rotary Knob LCD Screen Status Indicator Light(s) Micro USB Service Port Selection Button

This digital control panel is used on machines equipped with the optional diesel-operated engine coolant heater.

There is a solenoid valve controlling the flow of coolant to the hydraulic tank heater. This solenoid valve is controlled directly by the heater unit. The programming of the heater unit in the cab determines when the heater is ON and OFF. Consult the MANUFACTURER INSTRUCTION MANUAL for additional information.

3.35

Engine Coolant Heater Components

Engine Coolant Heater Heater Fuel Level Gauge Heater Fuel Tank Heater Exhaust

Lubrication and Maintenance AIR CONDITIONING SYSTEM All service work must be performed by a certified A/C technician. The system should be charged with R134a refrigerant only. Polyalkylene Glycol (PAG) oil should be present in the system and must be used on o-rings and fittings during assembly.

Tigercat H820D Harvester 3. Check the evaporator coil, located inside the A/Cheater unit, for dirt and debris. Also check the inside of the A/C-heater unit. Clean as required.

B

A/C SYSTEM TOTAL CAPACITIES R134a REFRIGERANT

2.72 kg (6 lb)

PAG Oil

207 ml (7 oz)

The compressor and charge valves are accessed from the upper-right side of the engine above the alternator.

The receiver dryer is mounted to the back of the cooler package on the left side of the compartment.

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

1. Check re-circulating and fresh air filters in the operator cab. Refer to SECTION 2.

2. Check the condenser core for dirt and debris.

Clean as required. Refer to CHECKING THE AIR CONDITIONING SYSTEM in THIS SECTION.

822D-053

A Serpentine Belt B A/C Compressor Belt

4. With the engine turned OFF, check the compressor belt tension and condition.

NOTE: Belt tension specifications are 55±2 kgf (121 ± 5 lbf).

A

5. Check all A/C hoses for kinks*.

6. Run the air conditioning system for three to five minutes.

822D-134

7. Check the air temperature exiting vents in the cab.

A Debris Screens

CAUTION If using pressurized water or compressed air for cleaning, use at 2 bar (30 psi) or less. Always use personal protective equipment (safety glasses) to guard against flying debris.

3.36

Tigercat H820D Harvester

Lubrication and Maintenance

8. Listen to the compressor and blower motor for abnormal noises*.

b. Evacuate the system. c.

9. Verify that the compressor clutch engages*. *There repairs must only be carried out by a certified A/C technician.

B A

Recharge the system with both refrigerant and PAG oil*.

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

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

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

The A/C circuit uses a binary switch (located on the top of the receiver/dryer) on the high pressure side. The switch has two settings: • The high pressure protection triggers at 391 PSIG for rising pressure and 304 PSIG for falling pressure.

C

• The low pressure protection triggers at 29 PSIG for falling pressure and 30 PSIG for rising pressure.

822D-136

A Sight Glass (Indicates Condition of Charge) B High-Pressure Switch C Moisture Indicator

10. Inspect the sight glass on the receiver/dryer with the A/C ON. A constant stream of bubbles indicates the system requires charging*.

11. Check the color in the moisture indicator: BLUE is OK; PINK indicates desiccant material in dryer is saturated with moisture.

In the latter situation: a. Replace the receiver/dryer.

3.37

Lubrication and Maintenance CLEANING COOLER PACKAGE The cooler package is mounted at the rear of the upper structure. A two-piece debris screen is used to protect the cooler package (charge air cooler/radiator/A/C condenser/oil cooler). The hydraulically driven fan draws air through the screen, through the cooler package.

Tigercat H820D Harvester 6. When the units have been cleaned return all cooling components to their operating position.

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

The cooler package 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.

CLEANING PROCEDURE: 1. Turn OFF the engine as per instructions in STOPPING ENGINE in SECTION 2.

Always follow proper engine shutdown procedures.

The important benefits are: • Extended life of engine, cooling and exhaust systems.

• Reduced risk of post shutdown fires.

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

2. Open the rear engine roof.

3. Lift each debris screen up to disengage the screen from the bottom clip and then out from the bottom.

4. Slide the screen down to release the top tab from the slot at the top of the cooler package.

5. Remove any accumulated debris.

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

NOTE: The cooler package must be checked daily and may have to be thoroughly cleaned on a daily, weekly or monthly basis, depending on operating conditions.

Use personal protective equipment (eye wear) to guard against flying debris. Use compressed air for cleaning only when the machine is cold to avoid the risk of fire caused by debris contacting hot surfaces. Care must be taken not to set the pressure too high otherwise damage to the components could result.

Pay particular attention to cleaning in the corners of the cooler as these areas usually plug deeply. Reversing the fan at least once per hour will help reduce the dust accumulation in the cooler cores, see SYSTEM COOLING FAN SWITCH– CLEAN in SECTION 2 to manually reverse fan or see TIMED PURGE INTERVAL in the MD4 COMPUTER – ADJUST MENU – MACHINE PARAMETERS for resetting the MD4 Computer to change cooling fan purge interval to program the fan to reverse every hour automatically.

For more information on fire prevention refer to FIRE PREVENTION in SECTION 1.

If an oil leak occurs in this area it should be thoroughly power-washed with a mild soap to ensure all of the oil is removed. The presence of oil causes dust and dirt to cling to surfaces which will impair the reversible fan’s ability to remove dust and dirt particles.

If using compressed air for cleaning, use at 2 bar (30 psi) or less.

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

3.38

Tigercat H820D Harvester

Lubrication and Maintenance G

J

I

F E D H

B

C

A 822D-033

A B C D E

Fan Drive Motor Engine Coolant Surge Tank Fan Finger Guard Cooling Fan Cooling Fan Shroud

Cooler Package Components F G H I J

3.39

Charge Air Cooler Radiator Oil Cooler Debris Screens A/C Condenser

Lubrication and Maintenance

Tigercat H820D Harvester

FILTER, FRESH AIR – A/C UNIT

FILTER, RECIRCULATING AIR – A/C UNIT

B

A

A

822D-023

A Recirculating Air Filter 822D-102

A Fresh Air Filter B Side Door

Outside air is continuously drawn into the cab air conditioning unit through this filter and mixed with interior air from the cab. The filter is located at the bottom of the side emergency exit door and can be serviced from the outside by removing the cover grill. The filter should be inspected on a regular basis and cleaned/replaced when dirty or when wet. Never operate the air conditioner without a filter installed.

Air in the cab is drawn into the A/C-heater unit via this filter and recirculated. The filter should be inspected and cleaned on a regular basis. The A/C will not cool efficiently if this filter become dirty or clogged.

3.40

Tigercat H820D Harvester

Lubrication and Maintenance

FUSES AND RELAYS Each circuit on the machine is protected against current overload by individual circuit fuses.

FUSES AND RELAYS– CAB The cab electrical controls, the primary fuse and relay panel (A), the XS2 module and system fuses, are located in the cab on the right-rear side panel behind the operator’s seat.

ENGINE DIAGNOSTIC CONNECTOR The engine diagnostics connection is located near the bottom of the cab fuse and relay panel. A remote electronic diagnostic device, such as a laptop with appropriate engine manufacturer's programming, can be plugged into this connection to perform engine performance analysis and tuning.

B

A

IMPORTANT! This operation can only be performed by a trained service technician.

822D-013

A Primary Fuse and Relay Panel B Engine Diagnostics Connection

68370BENG R0

3.41

Lubrication and Maintenance

Tigercat H820D Harvester

FUSES AND RELAYS– SIDE PANEL

FUSES – ENGINE COMPARTMENT A

B

C

D

A

B

822D-015

A 125 A Door Pump Relay Fuse B Door Pump Relay

822D-026

A B C D

FUSES 125A

24.

27.

1.

7.5A

2.

7.5A

3.

4.

8.

28.

20A

9.

20A

20A

10.

15A

10A

11.

15A

12.

20A

5.

10A

6.

7.5A

7.

7.5A

29.

34.

REPLACE FUSES WITH SAME VALUE AS INDICATED

13.

14.

1. SERVICE LIGHTS #1 2. SERVICE LIGHTS #2 3. ENGINE PRE-HEAT (OPTIONAL) 4. BATTERY DISCONNECT 5. PUMP AREA WORK LIGHTS #1 6. PUMP AREA WORK LIGHTS #2 7. ENCLOSURE WORK LIGHTS 8. ATS SENSOR POWER 9. EXHAUST FLAP POWER 10. PRE FUEL FILTER HEATER 11. PRIMARY FUEL FILTER HEATER (OPTIONAL) 12. DEF LINE HEATERS 13. SPARE 14. ENGINE ECU POWER 15. SPARE CANBUS (OPTIONAL) 16. BOTTOM FUELING 17. TELEMATICS (OPTIONAL) 18. SPARE 19. SPARE 20. SPARE 21. SPARE 22. START RELAY POWER 23. SPARE 24. POWER ROOF

35.

30A

30.

23.

32.

15.

5A

16.

5A

17.

10A

18.

25.

**

19.

31.

26.

33.

20.

21.

1.

2.

3.

4.

60A

60A

60A

60A

FUSES REPLACE FUSES WITH SAME VALUE AS INDICATED 1.

2.

3.

4.

KEY SWITCH RUN/ACC CAB SWITCHED POWER CAB WORK LIGHTS HYDRAULIC FILL PUMP

45756AENG R0

45756AENG R0

Located in the engine compartment directly behind the side Fuse and Relay Panel.

JUNCTION

25. ENGINE ECU POWER 26. SPARE

RELAYS

40A 22.

60A Fuse – Key Switch RUN/ACC 60A Fuse – Cab Switched Power 60A Fuse – Cab Work Lights 60A Fuse – Electrical Hydraulic Fill Pump

Four 60 A fuses are installed ahead of the system circuit fuses to prevent major damage to the electrical systems of the machine in the event of a short circuit in any of these switched power feed lines.

27. POWER ROOF 28. SERVICE LIGHT 29. WORK LIGHT 30. START ** 31. ENGINE ECU 32. DEF LINE HEATERS 33. AFTER RUN 34. ENGINE ATS 35. FUEL HEATER ** MUST ONLY USE AM1530 90 SECOND DELAY OFF RELAY IN THIS POSITION 68247BENG R0

68247BENG R0

The upper structure electrical box is located in the engine compartment behind the right side access door.

This electrical box also includes a 125 A fuse and a relay to operate the engine compartment roof and side door.

3.42

Tigercat H820D Harvester

Lubrication and Maintenance

FUSES– BATTERY COMPARTMENT A

RELAY – GRID HEATER B

A

C

822D-014

A Master Disconnect Relay B 10A Fuse– Fire Suppression System C 60A Fuse (QTY 2) – Electrical Box Unswitched Power

UNSWITCHED POWER FUSES

REPLACE FUSES WITH SAME VALUE AS INDICATED

60A 60A 45757AENG R0

800020

A Grid Heater Relay

This relay is energized by a voltage controlled by the ECU when the key is turned to the RUN position. This activates the heating elements (grid heater elements) located in the engine air intake manifold to heat the intake air when starting the engine. This activity works in conjunction with the WAIT TO START function. See STARTING ENGINE and COLD WEATHER STARTING in SECTION 2.

45757AENG R0

Two 60A fuses provide unswitched power for the battery disconnect relay, service lights, Engine Pre-Heat (Optional), Engine ECU, DEF Line Heaters and Telematics.

A 10 A in-line fuse protects the fire suppression system.

This fuse is located in the fire suppression power lead from the battery.

If a fuse blows, it should be replaced with a fuse of the same amperage rating. If the fuse blows again, the circuit in question must be inspected for a possible short circuit.

3.43

Lubrication and Maintenance

Tigercat H820D Harvester

ENGINE FILTERS– REMOVE AND REPLACE

These engines use filters with a very fine micron rating.

If the fuel supply is dirty, the fuel filter must be replaced more frequently than recommended in the owner’s manual. Operating the machine with a clogged fuel filter will result in low engine power. It is also recommended the fuel/water separator bowl be drained daily.

IMPORTANT! Failure to service and replace engine filters at the proper intervals specified in the engine OPERATION AND MAINTENANCE MANUAL, could cause damage to the machine and result in the product warranty becoming null and void. Check the Tigercat parts catalogue for replacement filters.

When installing a new fuel filter, DO NOT pre-fill with diesel fuel as this will result in fuel pump damage.

This type of failure is not warrantable by the engine manufacturer.

Refer to the appropriate engine OPERATION AND MAINTENANCE MANUAL for the oil and fuel filter replacement procedure. Read and understand the SAFETY section in each of these manuals.

To prolong the operating life of the fuel filter, the fuel supply storage tank must be clean and free of water and the fuel must be pre-filtered prior to adding it to the machine.

ENGINE OIL FILTER

FUEL FILTER/WATER SEPARATOR DRAINING PROCEDURE A

B

C

I

A

800019

A Oil Filter, Engine (Left Side of Engine)

E

When installing a new oil filter, DO NOT pre-fill with engine oil as this may result in engine damage. This type of failure is not warrantable by the engine manufacturer.

H

A B C D E F G H I

FUEL FILTERS

B

800010

A Fuel Filter/Water Separator B Fuel Filter

F G

822D-025

Refer to the SERVICE AND LUBRICATION SCHEDULE in THIS SECTION for the proper filter replacement procedure.

A

D

O-ring Hand Primer Pump Vent Plug Filter Head Fuel Filter Harness (Heater Element not shown) Sensor, Water in Fuel Heater Knob with Hose Barb Separator Bowl Drain

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 the Tigercat parts catalogue for replacement filters.

Refer to the appropriate manufacturer’s operation and maintenance manual for correct procedures and time intervals when servicing the fuel filters. Read and understand the SAFETY section in each of these manuals.

3.44

Tigercat H820D Harvester

Lubrication and Maintenance

These engines use filters with a very fine micron rating.

If the fuel supply is dirty, the fuel filter must be replaced more frequently than recommended in the owner’s manual. Operating the machine with a clogged fuel filter will result in low engine power. It is also recommended the fuel/water separator bowl be drained daily.

13. Remove the filter cartridge from the filter head (pressure fit) and discard properly.

When installing a new fuel filter, DO NOT pre-fill with diesel fuel, or engine fuel pump damage will result.

This type of failure is not warrantable by the engine manufacturer.

16. Install (screw) separator bowl onto the filter head, hand tight, then turn an additional 3/4 turn only.

14. Place the new filter into position on the filter head.

15. Lubricate the new O-ring with clean engine oil and install at the top of the separator bowl.

17. Reconnect the fuel heater and 'water in fuel' sensor to their respective wiring harness.

To prolong the operating life of the fuel filter, the fuel supply storage tank must be clean and free of water and the fuel must be pre-filtered prior to adding it to the machine.

18. Turn the ignition key to the ON position to energize the fuel supply shut-off solenoid valve.

19. Prime the filter by operating the hand primer pump until fuel spills out the metal vent plug.

CHANGING THE FUEL FILTER/WATER SEPARATOR Refer to SCHEDULED MAINTENANCE and SERVICE AND LUBRICATION SCHEDULE in THIS SECTION for filter replacement intervals.

1. Park the machine on level ground.

2. Lower the attachment to the ground.

3. Turn OFF the engine.

The engine must be off and cool to the touch for installation.

Do not smoke or allow open flames near installation.

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

20. Close the vent plug.

21. Start the engine and check for leaks.

22. Clean up any spilled fuel before returning machine to operation.

5. Disconnect the fuel heater and 'water in fuel' sensor from the respective wiring harnesses.

WARNING

6. Place a drain pan under the separator bowl.

To lower the risk of causing accidental fires, DO NOT leave fuel or oil soaked rags laying around.

7. Loosen the metal vent plug on the filter head.

8. Turn the drain valve open on the separator bowl to allow the fuel to drain completely from the separator bowl into a suitable container.

WARNING

NOTE: A drain hose can be attached to the drain valve if required.

Drain fuel filter into a container and dispose of all fluids properly.

9. Close the drain valve.

10. Use a strap wrench to remove the water separator bowl from the filter head. An optional wrench (Tigercat Part Number: BH814) is also available from your dealer.

11. Remove and discard the O-ring from the top of the separator bowl.

12. Clean the separator bowl.

3.45

Lubrication and Maintenance

Tigercat H820D Harvester

FUEL TANK COMPONENTS

6. Disconnect the fuel supply and return hoses at the fuel tank.

When a connection is made to the bottom refuelling quick disconnect and the bottom refuelling activation button is pulled, the fuel tank fill solenoid is opened to allow fuel to flow into the fuel tank. At the same time, the tank vent solenoid is also opened to allow air pressure to evacuate as the fuel tank is filled. Once the tank is filled, the fuel level switch will close the tank fill solenoid and the tank vent solenoid to stop any more fuel from entering the fuel tank. The tank can also be manually filled using the manual fill opening. This cannot be used when the roof is closed as the latch is prevented from being opened in the vertical position.

7. Remove the clean-out cover and the O-ring.

8. Before removing the fuel strainer, clean any debris from the inside-bottom of the tank and wipe clean.

9. Remove the fuel strainer. Carefully clean the strainer.

NOTE: Rough handling can cause damage.

10. Check for a buildup of foreign material where the fuel strainer screws onto the pipe.

11. Re-install the fuel strainer.

When the machine is in operation, the fuel supply solenoid opens and fuel is supplied to the engine via the fuel filter (not shown). The amount of fuel supplied to the engine is more than required as the fuel is also used to cool some of the fuel system parts (injectors, etc.). The unused fuel is pumped back to the fuel tank via the fuel return line. If the pressure in the tank, during operation, exceeds 34.5 kPa (5 psi), the pressurized relief valve will open and the air will evacuate via the tank breather.

12. Re-install the fuel tank clean-out cover with a new O-ring.

13. Re-install fuel supply and return hoses.

14. Replace the drain plug, refuel the machine and check for leaks.

15. Turn the battery disconnect switch ON and start the engine.

The tank also has a fuel level sender for the operator to indicate the amount of fuel remaining.

16. Check for leaks again.

The fuel tank is incorporated as part of the engine roof and is located at the rear-left corner behind the operators cab next to the DEF and hydraulic tanks.

17. Clean up any spilled fuel before returning the machine to operation.

The fuel tank has a total capacity of 568 L (150 US gal).

WARNING To lower the risk of causing accidental fires, DO NOT leave fuel or oil soaked rags laying around.

FUEL STRAINER A 150 micron stainless steel fuel strainer is screwed onto the end of the fuel supply pipe located inside the fuel tank.

CHANGING/CLEANING THE STRAINER NOTE: This should only be required if there is an excessive build-up of foreign material inside the tank.

1. Park the machine on level ground with the attachment resting on the ground and the engine compartment roof closed.

2. Turn OFF the engine.

3. Turn the battery disconnect switch to the OFF position.

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

5. Remove the drain plug and drain the fuel into a suitable container large enough to accommodate the entire contents of the fuel tank.

3.46

Tigercat H820D Harvester B

Lubrication and Maintenance C

D

F

G

H

E P

I

N

J

K

N

M

L

O

822D-017

A B C D E F G H

Fuel Level Switch Pressurized Relief Valve Tank Valve Solenoid Tank Breather Fuel Level Sender Fuel Fill Cap Fuel Fill Strainer (Under Feul Cap) Manual Fuel Fill Flange

Fuel Tank Components I J K L M N O P

3.47

Bottom Refuelling Activation Button and Indicator Light Bottom Refuelling Quick Disconnect Drain Plug Fuel Tank Fill Solenoid Clean Out Cover Fuel Supply Solenoid Fuel Strainer (In-tank) Fuel Tank

Lubrication and Maintenance REFUELLING PROCEDURES

WARNING

Tigercat H820D Harvester REFUELLING VIA THE BOTTOM QUICK DISCONNECT 1. Turn OFF the engine and allow the machine to cool.

B

DO NOT refuel while smoking or while near an open flame or sparks.

A

C

NOTICE 822D-123

A Quick Disconnect B In-use Indicator Light C ON/OFF Button

S≤15 mg/kg ULTRA LOW SULFUR FUEL ONLY 36686AUNI R0

Use only Ultra Low Sulfur Diesel (ULSD) fuel in Tigercat FPT engines equipped with Tier 4 aftertreatment systems. Using fuel with sulfur levels greater than 15 ppm (S≤15 mg/kg) maximum will permanently damage the engine and aftertreatment system within a short period of time.

2. Remove the dust cap from the quick disconnect ends and attach the fuel truck supply line to the machine intake connector.

3. Attach a grounding strap to an unpainted metal surface on the machine if the refuelling tank or nozzle is so equipped.

4. Turn ON the fuel transfer pump (on the fuel supply truck or tank).

5. Pull the fuel fill ON/OFF switch. The amber signal light will indicate the fuel fill valve is open.

6. When the tank is full, the fuel fill valve will close and the amber light will turn OFF. 7. Turn OFF the fuel transfer pump.

8. Disconnect the lines.

9. Wipe off any fuel residue on the connector.

10. Return the dust cap to the quick disconnect end.

3.48

Tigercat H820D Harvester

Lubrication and Maintenance

B

A 800018

A Fuel Switch B Fuel Level Sender

NOTE: The fuel fill valve can be closed at any time during the filling procedure by pushing the ON/OFF button.

NOTE: A vent at the top of the tank opens when filling.

Regularly inspect and repair all fuel fill system components to reduce the risk of spillage or fire.

CAUTION Never leave the machine unattended during the fuelling process.

NOTE: Before restarting the machine, check that no other personnel have moved into the hazardous area and sound the horn.

The bottom refuelling system includes: • A dry break quick disconnect • A solenoid operated fuel filling shut-off valve • An interior mounted fuel switch to activate the shut-off valve when the tank is full • An ON/OFF switch box with an indicator light.

NOTE: This method can be reached from ground level and does not require the engine compartment roof to be opened.

NOTE: This method relies on a remote fuel transfer pump mounted on the fuel supply truck or tank. There is no fuel transfer pump mounted on this machine. Park the machine with the upper structure level.

3.49

Lubrication and Maintenance REFUELLING VIA THE FUEL CAP

Tigercat H820D Harvester AIR INTAKE SYSTEM ENGINE AIR PRECLEANER

A

A 822D-060 800018

A Air Precleaner

A Fuel Fill Cap

NOTE: The fuel fill cap is an optional kit for machines 82213012 – 82214000. The instructions below apply to these machines also.

1. Park the machine on level ground.

2. Turn OFF the engine and allow machine to cool.

3. DO NOT refuel while smoking or near an open flame or sparks.

4. Clear all obstructions from the steps and handles needed to access the fuel tank.

5. Open the engine compartment roof.

6. Clear any debris from around the fuel cap.

7. Remove the fuel cap slowly to allow pressure to escape from tank.

8. Inspect the fuel cap gasket (replace if required).

9. Inspect the fuel fill strainer (located under the fuel cap) for debris or damage.

10. Attach a grounding strap to an unpainted metal surface on the machine if the refuelling tank or nozzle is so equipped.

11. Fill the tank until the fuel level reaches the fuel strainer or the full mark on the sight gauge (if equipped). Do not leave the nozzle unattended or spillage may occur.

12. Remove the nozzle and ground strap (if applicable).

13. Install the fuel cap, hand tight.

NOTE: Before restarting the machine, check that no other personnel have moved into the hazardous area and sound the horn.

845C-070

PRECLEANER OPERATION

The precleaner receives air via two air intake grills on the right side of the engine roof, behind the clean-out covers and through a passageway fabricated into the roof. With the roof open, the clean-out covers can be removed to allow access behind the engine air intake grill to remove any debris. Refer to CLEAN-OUT COVERS in THIS SECTION. HOW IT WORKS 1. Air enters the underside of the dome through screened louvres, which prevents clogging by blocking any particles larger than the ejection slot from entering the unit.

2. Curved particle accelerator blades slam air and dirt up against the sidewall.

3. Angled fins along the interior surface move heavierthan air debris towards the ejection slot.

4. Clean air continues to swirl down into the engine air inlet pipe.

The engine air precleaner should be checked daily to ensure that foreign materials have not plugged the intake area or the exhaust port area of the precleaner.

3.50

Tigercat H820D Harvester

Lubrication and Maintenance CLEAN-OUT COVERS

AIR INTAKE SEAL

A

A

822D-060

A Clean Out Covers (Closed)

800009

A 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.

INTAKE TUBING AND JOINTS

The precleaner receives air via an air intake grill on the right side of the engine power door, behind the clean-out cover and through a passageway fabricated into the power door. With the door opened, the clean-out cover can be removed to allow access behind the engine air intake grill to remove any accumulation of debris.

A

B

A

800021 LX830D-005

Air Intake Cold Weather Configuration

A

A Bottom Clean Out (Cover Removed) B Bottom Clean Out Cover Stored Over Top of the Top Cover

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.

800022

A Rubber Elbows and Tubing

Check all air intake system components, rubber elbows, connector hoses, tubes and clamps for damage, hardening, wear, cracks, leaks, loose clamps or loose hanger bracket hardware and repair or replace immediately.

Replace all air intake rubber components such as elbows and connectors every 2000 hours. High temperatures in this area can cause the rubber to harden.

1. Remove the four bolts securing each cover.

2. Place the bottom cover over the top cover and secure with four bolts removed in step 1.

3. Replace the remaining four bolts in the weld nuts of the bottom access holes for storage.

IMPORTANT! If the covers are removed, they must be re-installed when operating in warmer outside temperatures otherwise the engine will run at a higher temperature and less horsepower.

3.51

Lubrication and Maintenance

Tigercat H820D Harvester

AIR CLEANER

OVER SERVICING A

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

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

IMPROPER SERVICING

822D-066

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

A Air Cleaner

• 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.

B

IMPORTANT STEPS TO FOLLOW WHEN CHANGING FILTER ELEMENTS • Release the six over-centre latches and lift cover/ dust bowl off of air cleaner.

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

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

• Always clean the inside of the outlet tube.

A

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

470-04

A Primary Element B Safety Element

Air Filter Elements

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.

The air cleaner uses two filter elements: a primary element and a safety element. The elements must be serviced correctly and at proper servicing intervals to ensure maximum engine protection.

• Inspect the new filter for damage.

In addition to the SERVICE AND LUBRICATION SCHEDULE outlined in this section, the following instructions should also be noted.

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

• Check connections and ducts for an air tight fit.

Ensure that all clamps, bolts and connections are tight. Check rubber elbows intake tubing and joints for hardening cracks, splits or wear points and replace as needed. Leaks in these locations send dust directly to the engine.

NOTE: The safety element needs to be replaced on every third primary element change.

The most common and most damaging air intake servicing problems are over servicing and improper servicing.

3.52

Tigercat H820D Harvester FILTER RESTRICTION INDICATOR

Lubrication and Maintenance Refer to AIR CLEANER, OVER SERVICING and IMPROPER SERVICING in THIS SECTION. Refer to MD4 COMPUTER DISPLAY MESSAGES in SECTION 2.

B A

800011

A Filter Restriction Electronic Sensor B Filter Restriction Mechanical 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 the reset button on the end of the indicator.

A

MD4-003

A Engine Air Intake Filter Restriction Icon

The machine is also equipped with an engine air filter restriction sensor which sends a signal to the MD4 Computer in the event of filter restriction. The engine air intake pressure icon turns YELLOW when service to the filter is required and turns RED, along with an ALERT message, when service to the air filter has reached a critical state.

3.53

Lubrication and Maintenance

Tigercat H820D Harvester

THE AFTERTREATMENT SYSTEM AND ITS RELATED COMPONENTS ARE APPLICABLE TO TIER 4F ENGINES ONLY.

NOTICE

AFTERTREATMENT SYSTEM The engine on this machine is equipped with a combination Diesel Oxidation Catalyst (DOC) and high-efficiency Selective Catalytic Reduction (SCR) aftertreatment system to limit the nitrogen oxide exhaust gas values (NOx) to meet Tier 4 Final emission standard requirements with low fuel consumption. This process is electronically controlled by the DENOX 2.2 system.

The Diesel Oxidation Catalyst (DOC) uses oxidation at high temperatures to convert carbon monoxide (CO), hydrocarbons (HC) and the soluble organic fraction (SOF) of diesel particulates into inert compounds, carbon dioxide (CO2) and water vapour (H2O). In addition, the DOC converts nitrogen oxide (NO) into nitrogen dioxide (NO2). Increased NO2 levels enhance the performance of the SCR catalyst at low temperatures and increase the effectiveness of the DOC/SCR aftertreatment system as a whole.

The high-efficiency SCR process is based on a series of chemical reactions which involve the reaction of ammonia with the oxygen in the exhaust gas to reduce nitrogen oxides (NOx) in the exhaust gas by transforming it into inert compounds: free nitrogen (N2) and water vapour (H2O). In addition, the high-efficiency catalytic converter includes a clean up catalyst (CUC) which reduces any excess ammonia (NH3), which may result from the SCR process.

• DO NOT IDLE THIS ENGINE FOR MORE THAN 9 HOURS. • DAMAGE TO EMISSION CONTROL SYSTEM WILL RESULT.

63281BENG R0

IMPORTANT! The engine should not idle longer than 9 consecutive hours. Damage to the emission control system will result. When this machine idles for an extended period, excess hydrocarbon buildup is created in the DOC/SCR aftertreatment system. Burn off of excess hydrocarbon, at full load, immediately after a long idle period, generates excess heat which causes damage to emission control system components.

IMPORTANT! When cleaning the machine with pressurized water it is important to avoid getting water directly or indirectly into the exhaust tube. Water in the exhaust tube will damage sensors and SCR system components and affect the proper operation of the aftertreatment system and the engine.

3.54

Tigercat H820D Harvester A

B

Lubrication and Maintenance E

C

D

E

F

G

H

I

J

K

N M

L

800236

DOC/SCR Aftertreatment Components A B C D E F G

ECU, NH3 Sensor Catalytic Converter (SCR, CUC) Outlet NH3 Sensor (3) Outlet NOx Sensor ECU, NOx Sensors Diesel Oxidation Catalyst (DOC) Dosing Module (DEF Injector)

H I J K L M N

3.55

Supply Module DEF Heater Unit DEF Tank DEF Tank Fill Cap DeNOx 2.2 Control System (incorporated into the engine ECU) Air Filter Heater Valve (DEF Supply Lines)

Lubrication and Maintenance D

Tigercat H820D Harvester E

F

G

H

I

J

C

B K

A L M N

R Q P

O

800237

DOC/SCR Aftertreatment Components A B C D E F G H I J

Exhaust Flap on outlet of Turbocharger Dosing Module (DEF Injector) DOC Inlet NOx Sensor Diesel Oxidation Catalyst (DOC) DOC Inlet Temperature Sensor SCR Outlet Temperature Outlet NOx Sensor SRC Inlet Temperature Sensor Catalytic Converter (SCR, CUC) Air Filter Restriction Indicator

K L M N O P Q R

3.56

Heater Valve (DEF Supply Lines) Air Filter Humidity and Temperature Sensor Air Filter Restriction Sensor Supply Module DEF Tank DEF Tank Fill Cap DEF Heater Unit Mixer Tube (DOC outlet) (not shown)

Tigercat H820D Harvester

Lubrication and Maintenance HC NOx CO NH3 N2 H2O CO2

A B

HC

S T

N

O

C

NOx

R

CO

Q

P

U

- HYDROCARBONS - NITROGEN OXIDES - CARBON MONOXIDE - AMMONIA - FREE NITROGEN - WATER - CARBON DIOXIDE

D

E

J

G F

H2O

N2

NH3

CO2 M

630E-276

L

K

EXHAUST GAS FLOW DIRECTION

H I

COOLANT LINE

DEF LINE

DOC/SCR Aftertreatment System A B C D E F G H I J K

Humidity Sensor Air Filter Supply Module DEF Quality Sensor DEF Level Sensor DEF Tank Heater Valve (Circulating Engine Coolant) Dosing Module Mixer Tube DOC SRC

The DOC/SCR aftertreatment system is electronically managed by the DENOX 2.2 system incorporated into the engine electronic control unit (ECU). The ECU calculates and adjusts the flow rate of the DEF solution into the system based on current engine speed, torque delivered, exhaust temperature, amount of nitrogen oxides and ammonia present.

The exhaust passes through the DOC which uses oxidation at high temperatures to convert carbon monoxide (CO), hydrocarbons (HC) and the soluble organic fraction (SOF) of diesel particulates into inert compounds, carbon dioxide (CO2) and water vapour (H2O). It also converts nitrogen oxide (NO) into nitrogen dioxide (NO2) which enhances the performance of the SCR catalyst.

The supply module pump picks up the DEF solution from the tank and sends it under pressure to the dosing module (DEF injector) to be injected into the exhaust at the outlet of the DOC and pass through the mixer tube upstream of the catalytic converter.

L M N O P Q R S T U

Catalytic Converter CUC NOx Sensor NH3 Sensor Engine Temperature Sensors NOx Sensor Engine ECU Exhaust Flap DEF Dosing Module Filter

The first phase of the SCR process takes place in the pipe between the DOC and Catalytic converter. High temperature exhaust gas evaporates the DEF solution instantly and, by hydrolysis, converts it into ammonia (2NH3) and carbon dioxide (CO2).

Evaporation of the solution lowers exhaust gas temperature, bringing it closer to the optimum temperature required by the process.

The exhaust gases and ammonia, at the proper reaction temperature, are introduced into the catalytic converter, where the second phase of the process takes place. The ammonia is converted into free nitrogen (N2) and water vapour (H2O) by reacting with the oxygen in the exhaust gases.

Finally the high-efficiency catalytic converter incorporates a clean up catalyst (CUC) which reduces any excess ammonia (NH3) resulting from the SCR process.

3.57

Lubrication and Maintenance

Tigercat H820D Harvester

DIESEL EXHAUST FLUID (DEF) TANK

B

The DEF tank is located in the service compartment in the rear of the machine immediately behind the cab.

A C

41581AUNI R0

H845D-133

A

D

E

H845D-134

A B C D E

800028

A DEF Tank Fill Cap

Fill Inlet with Cap Heater Unit DEF Tank DEF Quality Sensor Drain Plug

The DEF fill cap can be accessed through the hinged side door. The fill point is equipped with a filter to prevent contaminants from entering the tank.

The DEF tank includes a fill inlet with cap, a heater unit, a DEF quality sensor and a drain plug.

The DEF tank capacity is 80 L (21.1 US gal). DO NOT overfill the tank. The tank is equipped with an expansion capacity of 7% required to allow for the expansion of DEF in cold temperature conditions. DEF freezes at -11°C (12°F).

The DEF tank and DEF supply lines are heated when temperatures are low. The system will thaw DEF within 30 minutes of engine start for proper operation of the diesel oxidation catalyst /selective catalytic reduction (DOC/SCR) aftertreatment system.

A DEF level indicator is shown on the main menu of the MD4 Computer Display, below the fuel gauge.

When a problem with DEF levels or quality is detected, information messages are shown on the MD4 Display.

The strainer may be the cause and can be visually inspected for debris. Clean or replace, as required.

NOTE: Extremely low DEF levels or quality problems, may result in derating of engine performance to meet exhaust emission requirements. Action to correct DEF levels or quality problems should be taken immediately to avoid affecting engine performance and damage to the DOC/SCR aftertreatment system components.

Refer to MD4 COMPUTER DISPLAY MESSAGES in SECTION 2.

3.58

Tigercat H820D Harvester

Lubrication and Maintenance

A B

WARNING Use only Diesel Exhaust Fluid (DEF) which meets ISO 22241 specifications. NEVER fill the DEF tank with any other fluid.

D C

DEF is injected into the exhaust gas stream during normal operation of the Selective Catalytic Reduction (SCR) aftertreatment system.

620E-082

A B C D

Coolant Heater Coil Level Sensor Strainer Temperature Sensor

The heater unit incorporates a heater coil, heating system inlet/outlet connections, DEF inlet/outlet connections, a breather, a level sensor, a temperature sensor and a strainer.

DIESEL EXHAUST FLUID (DEF) DEF is used by the DOC/SCR aftertreatment system to lower the concentration of nitrogen oxides from the diesel engine exhaust.

DEF is an aqueous urea solution with 32.5% high purity urea and 67.5% deionized water.

Use of other fluids may cause component damage, or a fire risk which could result in death or serious injury.

NOTE: Whenever the engine is stopped, all DEF is pumped back to tank before the engine power system is turned OFF. This process takes approximately 90 seconds. Refer to AFTERTREATMENT SYSTEM in THIS SECTION. Refer to AFTERTREATMENT SYSTEM in THIS SECTION for more information regarding the use of DEF and its function in the DOC/SCR aftertreatment system.

NOTE: DEF may also be referred to as AUS32 or AdBlue®. All DEF must be American Petroleum Institute (API) Certified DEF or meet ISO 22241 specifications.

IMPORTANT! DEF should be stored between -11°C (12°F) and 30°C (86°F) and out of direct sunlight to maximize shelf life and to avoid DEF quality problems caused by improper storage.

It is important to avoid contamination of the DEF when filling the tank as this may cause costly damage to the aftertreatment system components and affect the proper operation of the aftertreatment system and the engine.

NOTE: DEF quality problems may result in derating of engine performance to meet emission standard requirements. Action to correct DEF quality problems should be taken immediately to avoid affecting engine performance and damage to the DOC/SCR aftertreatment system components.

Refer to MD4 COMPUTER DISPLAY MESSAGES in THIS SECTION. 3.59

Lubrication and Maintenance

Tigercat H820D Harvester

DRAINING DIESEL EXHAUST FLUID TANK

FILLING THE DEF TANK Always clean the area around the DEF fill cap and avoid introducing contaminants into the DEF tank when filling.

1. Fill the tank with new DEF. 2. Observe the DEF level indicator to ensure the tank is not overfilled causing spillage.

A

B

822D-050

A DEF Quality Sensor B DEF Tank Drain Plug

NOTE: To avoid contamination and ensure clean fluid, do not re-use DEF. Re-fill the tank with new DEF only.

See previous page regarding DEF specifications.

IMPORTANT! It is important to avoid contamination of DEF when performing maintenance on the system as this may cause costly damage to SCR system components and affect the proper operation of the aftertreatment system and the engine.

Draining the DEF tank is recommended in the case of DEF quality concerns and/or known contamination.

The DEF tank must be completely drained and all contaminants must be removed before refilling. The DEF tank is equipped with a drain plug on the bottom of the tank.

Use the DEF level indicator on the MD4 Computer Display to estimate the container capacity required to properly drain the DEF solution.

1. Remove the cover from the bottom of the upper structure to expose the drain plug.

2. Remove the DEF tank fill cap for venting purposes during draining.

3. Remove the drain plug and drain the DEF solution into a suitable container.

4. Once the fluid has been drained, clean the inside of the tank with DEF or distilled/demineralized water only if required. Thoroughly drain the tank after cleaning.

5. Replace the drain plug and fill cap.

6. If any DEF has spilled, rinse well with water.

7. Replace the access cover.

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Tigercat H820D Harvester

Lubrication and Maintenance

DIESEL EXHAUST FLUID (DEF) HANDLING AND STORAGE

WARNING

DEF is an aqueous urea solution with 32.5% high purity urea and 67.5% deionized water.

Use only diesel exhaust fluid (DEF) which meets ISO 22241 specifications. NEVER fill the DEF tank with any other fluid.

NOTE: DEF may also be referred to as AUS32 or AdBlue and should meet ISO 22241 specifications. Use only DEF meeting this standard.

DEF is injected into the exhaust gas stream during normal operation of the of the Selective Catalytic Reduction (SCR) aftertreatment system.

It is important to avoid contamination of DEF as this may cause costly damage to SCR system components and affect the proper operation of the SCR system and the engine.

When a problem with DEF quality is detected information messages will be shown on the computer display.

NOTE: DEF quality problems may result in derating of engine performance to meet emission standard requirements. Action to correct DEF quality problems should be taken immediately to avoid affecting engine performance and damage to SCR aftertreatment system components.

Use of other fluids may cause component damage, or a fire risk which could result in death or serious injury.

Use Of Proper Storage Containers • To prevent contaminants from affecting DEF quality, it should be handled only in storage, transport and filling containers intended exclusively for that purpose.

• Polyethylene or stainless steel containers are recommended. Refer to DEF manufacturer's recommendations.

Refer to MD4 COMPUTER AND DISPLAY MESSAGES in SECTION 2 or SECTION 6 of the SERVICE MANUAL. For safety information refer to DIESEL EXHAUST FLUID (DEF) in SECTION 1.

• DEF is corrosive to metals other than stainless steel.

Transport in metal containers other than stainless steel will result in contamination.

Most DEF quality problems can be avoided entirely with a little care and proper handling of DEF.

Proper Storage Conditions To Maximize Shelf Life

Filling The Def Tank

• DEF should be stored between -11°C (12°F) and 30°C (86°F) and out of direct sunlight to maximize shelf life and to avoid DEF quality problems caused by improper storage.

• Always clean the area around the fill cap and avoid introducing contaminants into the DEF tank when filling.

• Always use only DEF that meets ISO 22241 specifications. Use of any other fluid will contaminate the aftertreatment system and may pose a safety hazard.

• DEF quality problems can often be avoided with proper storage and handling practices to maximize shelf life.

• DEF storage areas should always be out of direct sunlight and away from heat sources to avoid reducing shelf life.

• DEF shelf life is limited. It should be consumed on a first in first out basis, within manufacturer's recommended shelf life limits. DEF beyond manufacturer's recommended shelf life limits may not meet ISO 22241 specifications.

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Lubrication and Maintenance

Tigercat H820D Harvester

HEATER VALVE / HEATED DEF SUPPLY LINES

Heating is switched OFF when: • DEF tank temperature >16°C (61°F) • Supply module temperature >10°C (50°F) • Ambient air temperature >-4°C (25°F) Heating is switched ON when:

A

• DEF tank temperature < -15°C (-59°F) • Supply module temperature< -8°C (-46°F) • Ambient air temperature< -5°C (23°F) When conditions require heating, the system will thaw DEF within 30 minutes of engine start for proper operation of the aftertreatment system.

LX830D-031

NOTE: Whenever the engine is stopped, all DEF is pumped back to tank before the engine power system is turned OFF. This process takes approximately 90 seconds.

B

C

E

D 630E-265

A B C D E

DEF Heater Valve Connector Coolant Bypass Coolant Outlet Coolant Inlet

The heater valve is located on a bracket mounted to the top-left corner of the fan shroud in the engine compartment.

The heater valve controls the flow of engine coolant through the DEF tank heater coil and the supply module when heating of the DEF is required. The heater valve also controls the constant flow of engine coolant to the dosing module for cooling purposes. This machine is equipped with electrically heated DEF supply lines. DEF freezes at -11°C (12°F).

Temperature sensor signals control the operation of both the electrically heated DEF supply lines and the heater valve which, depending on the temperature, opens or closes the flow of hot engine coolant to the heater coil in the DEF tank and supply module.

3.62

Tigercat H820D Harvester HEATED DEF SUPPLY LINES

Lubrication and Maintenance DENOX 2.2 DOSING SYSTEM

The DEF supply lines to the DOC and DEF tank require heating along the entire path. The three supply lines are each heated by an electrical wire element.

Heating is switched on when ambient temperature is < 0°C (32°F).

A

T250D-117

A

B

24V Heated Def Line

A DEF line B Male Electrical Connector

800023

The DEF supply line from the supply module to the DOC is 24 V and is characterized by the male electrical connector located at the supply module.

A

T250D-118

B

12V Heated Def Line

A DEF Line B Female Electrical Connector

The two DEF supply lines from the supply module to the DEF tank are 12 V and are characterized by female electrical connectors located at the supply module.

These two elements are connected electrically in series.

If one of the elements fail, the element in the other line will not function.

A Engine ECU

The DENOX 2.2 control system is incorporated into the engine electronic control unit (ECU).

The DOC/SCR aftertreatment system is electronically managed by the DENOX 2.2 control system. The ECU calculates and adjusts the flow rate of the DEF solution into the system based on current engine speed, torque delivered, exhaust temperature, amount of nitrogen oxides and ammonia present and the humidity levels in incoming air.

EXHAUST FLAP

A

Refer to ELECTRICAL SCHEMATICS in SECTION 6 of the SERVICE MANUAL for complete machine electrical schematics.

800022

A Exhaust Flap

An exhaust flap is located at the exhaust outlet from the engine. The MD4 Computer controls the exhaust flap to automatically regulate the temperature of the exhaust entering the diesel oxidation catalyst (DOC) to optimum levels for proper operation of the aftertreatment system.

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Lubrication and Maintenance

Tigercat H820D Harvester

DIESEL OXIDATION CATALYST (DOC)

DEF SUPPLY MODULE

A

A

800024

A Diesel Oxidation Catalyst

The diesel oxidation catalyst (DOC) uses oxidation at high temperatures to convert carbon monoxide (CO), hydrocarbons (HC) and the soluble organic fraction (SOF) of diesel particulates into inert compounds, carbon dioxide (CO2) and water vapour (H2O).

800028 H845D-038

A DEF Supply Module

In addition the DOC converts nitrogen oxide (NO) into nitrogen dioxide (NO2). Increased NO2 levels enhance the performance of the SCR catalyst at low temperatures and increase the effectiveness of the DOC/SCR aftertreatment system as a whole.

The DOC is located upstream of the catalytic converter (SCR & CUC) and at its outlet incorporates the mixer tube and the mounting for the dosing module.

The supply module pump picks up the DEF solution from the tank and sends it, under pressure, to the dosing module, mounted on the DOC. DEF is injected into the exhaust at the outlet of the diesel oxidation catalyst and upstream of the catalytic converter.

The supply module is equipped with a filter. Refer to SERVICE AND LUBRICATION SCHEDULE in this section for details.

3.64

Tigercat H820D Harvester THE AFTERTREATMENT SYSTEM AND ITS RELATED COMPONENTS ARE APPLICABLE TO TIER 4F ENGINES ONLY.

Lubrication and Maintenance REMOVE DEF DOSING MODULE FILTER 1. Park the machine on level ground with the attachment resting firmly on the ground. Refer to PARKING THE MACHINE in SECTION 1.

DEF DOSING MODULE FILTER

2. Make sure the engine is at operating temperature.

The DEF dosing module filter should be replaced as part of scheduled maintenance every 250 hours.

3. Turn OFF the engine.

If DEF and/or aftertreatment fault codes have occurred then Tigercat recommends performing a DEF flushing test and Urea Dosing System Test (UDST) at every DEF dosing module filter change to ensure proper operation of the DEF supply module.

If no DEF and/or aftertreatment fault codes have occurred then only the DEF dosing module filter replacement is required.

4. Remove the ignition key.

5. Wipe clean the area around the supply module and filter including the supply module ports with particular attention to the inlet port and filter cap to avoid introducing contamination into the filter housing while performing this procedure.

6. Place container below to catch the spills.

CHANGING DEF DOSING MODULE FILTER, DEF FLUSHING TEST AND UDST (UREA DOSING SYSTEM TEST) TOOLS REQUIRED • 27 mm (1 1⁄16 in) wrench • Container to catch DEF and flushing water • Clean distilled/demineralized water • 1 litre (0.25 US gal) plastic water bottle with hose attached* • Laptop computer with Tigercat by FPT E.A.SY. engine diagnostic software to run UDST test*

630E-281

7. Turn the filter cover counterclockwise to remove from the supply module. Use a 27 mm (1 1⁄16 in) wrench.

• PT-Box* IMPORTANT! Do not contaminate the DEF when performing maintenance on the system as this may cause costly damage to SCR system components and affect the proper operation of the aftertreatment system and the engine. *Items required if performing a DEF flushing test and UDST.

630E-282

8. Remove the equalizing element and note the colour of the filter inside (black or grey).

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Lubrication and Maintenance

Tigercat H820D Harvester

THE AFTERTREATMENT SYSTEM AND ITS RELATED COMPONENTS ARE APPLICABLE TO TIER 4F ENGINES ONLY.

630E-285

9. Find the filter removal tool provided with the replacement parts select the correct edge BLACK (B) for black filters or GREY (G) for grey filters.

630E-287

12. Clean surfaces with distilled/demineralized water only to avoid DEF contamination.

Check the area around the filter for cracks. If cracks are found the supply module must be replaced.

13. Thoroughly clean the filter cover to avoid introducing contamination.

DEF FLUSHING TEST A

630E-284

10. Insert the tool edge completely until a click is felt or heard.

630E-333

A Inlet Port 630E-286

11. Pull out the filter, using a tool in the slot on the filter removal tool if required.

14. Disconnect the DEF hose from the inlet port of DEF supply module.

15. Fill the plastic bottle with distilled/demineralized water.

3.66

Tigercat H820D Harvester

Lubrication and Maintenance A

630E-331

630E-332

A Inlet Port

20. Distilled water will be drawn from the bottle and flushed through the DEF supply module. Suction may begin to collapse the bottle and water flow out the bottom of the module will increase.

16. Connect the water bottle hose to the inlet port of the DEF supply module.

630E-328

21. The results of the UDST will show a flat line for DEF pressure (red line) because the pump cannot build pressure without the filter in place.

22. Repeat the UDST test a second time to ensure the supply module is thoroughly flushed and working correctly.

630E-334

17. Raise the water bottle above the DEF supply module.

23. When the UDST flushing procedure has been performed twice successfully remove the bottle and hose.

18. A small amount of water will flow through the supply module and out the bottom where the filter has been removed.

19. With the aid of an assistant run a UDST test from the laptop computer. Refer to PT Box Manual for UDST test information.

24. Reinstall the DEF module inlet hose.

3.67

Lubrication and Maintenance

Tigercat H820D Harvester 29. Insert the ignition key and turn to the RUN position.

THE AFTERTREATMENT SYSTEM AND ITS RELATED COMPONENTS ARE APPLICABLE TO TIER 4F ENGINES ONLY.

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

31. Start the engine.

32. Check for leaks.

REPLACE FILTER

33. Turn OFF the engine.

IMPORTANT! Do not contaminate the DEF when performing maintenance on the system as this may cause costly damage to SCR system components and affect the proper operation of the aftertreatment system and the engine.

WARNING Use only diesel exhaust fluid (DEF) which meets ISO 22241 specifications. NEVER fill the DEF tank with any other fluid.

630E-288

25. Install the new filter. Lubricate the o-rings on the filter with clean DEF solution for easy installation.

DEF is injected into the exhaust gas stream during normal operation of the Selective Catalytic Reduction (SCR) aftertreatment system.

Use of other fluids may cause component damage, or a fire risk which could result in death or serious injury.

UDST (UREA DOSING SYSTEM TEST)

630E-289

34. With the aid of an assistant run a UDST test from the laptop computer. Refer to PT Box Manual for UDST test information.

26. Install the new equalizing element.

NOTE: The equalizing element must be replaced with each filter change.

630E-327

630E-290

35. If the supply module is functioning correctly the test should show a characteristic curve as shown above, DEF pressure (red line).

27. Reinstall the clean filter cover, tighten to 20 Nm (15 lbf-ft). Use a 27 mm (1 1⁄16 in) wrench.

28. Check that all personnel are clear of the machine before starting the engine.

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Tigercat H820D Harvester

Lubrication and Maintenance

36. A confirmation screen will indicate System is OK if the supply module is functioning correctly.

37. Repeat the UDST test a second time to confirm results.

630E-330

38. If the UDST test passes twice the supply module is OK.

630E-329

39. If the UDST test fails twice note the error mode(s) and contact customer service.

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Lubrication and Maintenance

Tigercat H820D Harvester

DOSING MODULE (DEF INJECTOR)

CATALYTIC CONVERTER A

A

875-175

800021

A Dosing Module

A Catalytic Converter

The dosing module is mounted on the DOC outlet upstream of the catalytic converter. The dosing module injects DEF into the exhaust stream.

The dosing module is cooled by a constant flow of engine coolant supplied by the heater valve to maintain optimum temperature for the aftertreatment process.

MIXER TUBE

A

The catalytic converter is located above the engine.

Chemical reactions inside the catalytic converter reduce nitrogen oxides (NOx) in the exhaust gas.

The catalytic converter is equipped with soundproofing material and replaces the exhaust silencer. It incorporates both the selective catalytic reduction (SCR) and the cleanup catalyst (CUC) components of the aftertreatment system.

The first phase of the SCR process takes place between the DOC and the SCR. High temperature exhaust gas evaporates the DEF solution instantly and, by hydrolysis, converts it into ammonia (2NH3) and carbon dioxide (CO2).

Evaporation of the solution lowers exhaust gas temperature, bringing it closer to the optimum temperature required by the process.

630E-275

A Mixer Tube

The mixer tube is incorporated into the outlet of the DOC upstream from the catalytic converter.

The exhaust gases and ammonia, at the proper reaction temperature, are introduced into the SCR, where the second phase of the process takes place. By reacting with the oxygen in the exhaust gases, the ammonia is converted into free nitrogen (N2) and water vapour (H2O).

Finally the high-efficiency catalytic converter incorporates a clean up catalyst (CUC) which reduces any excess ammonia (NH3) which may result from the SCR process.

The high-turbulence mixer tube is used to mix the DEF solution and exhaust gases together before they enter the catalytic converter.

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Tigercat H820D Harvester

Lubrication and Maintenance

HUMIDITY AND TEMPERATURE SENSOR

NH3 SENSOR A

B

630E-264

620E-089

A Electronic Control Unit B Sensor

The humidity sensor is located on the air intake just past the air cleaner. This sensor monitors the temperature and humidity of intake air sending signals to the DENOX 2.2 control system. This information is used to calculate the amount of DEF to be injected into the system.

The NH3 sensor is mounted at the outlet of the catalytic converter. The NH3 sensors detect and send information about the NH3 levels in the exhaust. This information is used to calculate the amount of DEF to be injected into the system and to monitor DOC/SCR aftertreatment system operation.

TEMPERATURE SENSORS

Refer to APPROVED ANTI-SEIZE PASTES FOR EXHAUST / AFTERTREATMENT SENSORS (TIGERCAT FPT TIER 4F ENGINES) in THIS SECTION.

620E-087

Temperature sensors are mounted at the inlet of the diesel oxidation catalyst, the inlet of the catalytic converter and the outlet of the catalytic converter. These three sensors send exhaust temperature signals to the DENOX 2.2 control system. The control system uses this information to calculate the amount of DEF to be injected into the system.

NOTE: All three temperature sensors are identical, however location should be noted for analysis purposes when replacing a temperature sensor.

3.71

Lubrication and Maintenance NOx SENSOR

Tigercat H820D Harvester APPROVED ANTI-SEIZE PASTES FOR EXHAUST / AFTERTREATMENT SENSORS (TIGERCAT FPT TIER 4F ENGINES)

A

If replacement of these components is necessary in the field, NOx sensors and NH3 sensors are pre-coated at the factory with the required anti-seize paste. The application of anti-seize should not be required.

In the event anti-seize must be re-applied, only the following approved products should be used: • NOx sensors – Weicon High Tech Anti-seize only B

• NH3 sensor – Loctite X203 Dry Film Moly Anti-Seize

620E-088

A Electronic Control Unit B Sensor

The inlet NOx sensor is mounted upstream of the diesel oxidation catalyst. The outlet NOx sensor is mounted at the outlet of the catalytic converter. The NOx sensors detect and send information about the dosing of DEF solution and the efficiency of the catalytic converter to the DENOX 2.2 control system. This information is used to calculate the amount of DEF to be injected into the system and to monitor DOC/SCR aftertreatment system operation.

Each NOx sensor consists of a ceramic sensor and an electronic control unit linked by a cable. The sensor detects the concentration of nitrogen oxides in the exhaust. The sensor, cable and control unit are considered to be one part for service/replacement purposes.

NOTE: Cable length cannot be changed as this will affect the proper operation of the sensor.

IMPORTANT! When checking or replacing any sensor or plug in the exhaust or the aftertreatment system, it is important to use only approved anti-seize as specified by Tigercat.

Use of non-approved compounds can affect the operation of the NOx and NH3 sensors and cause a malfunction of the aftertreatment system. This may result in poisoning of the SCR catalyst and require replacement of expensive aftertreatment system components.

3.72

Tigercat H820D Harvester

Lubrication and Maintenance

UNDERCARRIAGE BOTTOM ACCESS COVERS

DANGER Do not fully remove the access door swivel bolt.

A falling access door could cause serious injury or death.

SWIVEL ACCESS DOOR A

ENGINE OIL PAN ACCESS COVER B A

830-D45

A

B 822D-049

A B

Engine Oil Pan Access Cover Engine Oil Drain Plug Access Cover

The Oil Pan Access Cover allows access to the entire oil pan. When performing an engine oil change, only the oil drain plug access cover needs to be removed.

830-D44

A Notch to Indicate Position of Pivot Point B Swivel Bolt (Loosen Only Enough to Allow Door to Swivel Freely)

The notch in the door indicates the position of the bolt at the swivel point. The bolt at the swivel point is longer and is equipped with a clamp to prevent it from being fully removed from the undercarriage.

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

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Lubrication and Maintenance

Tigercat H820D Harvester

UPPER STRUCTURE BOTTOM ACCESS

PUMP ACCESS

There are three removable cover plates located on the underside of the upper structure. These cover plates are bolted in place and only require removal when a major clean up, service or inspection is to be performed.

A

NOTE: DEF, Main Valve and Pump Access covers have been removed for clarity.

There is a swivel access cover on the undercarriage. It only requires removal when a major clean up, service or inspection is to be performed.

822C-197

DEF BOTTOM ACCESS

A

Pump Compartment (Main Pump)

The Pump Access provides access to the bottom of the pump assembly.

A

B

822D-050

A B

DEF Quality Sensor DEF Tank Drain Plug

The DEF Tank Access provides access to the DEF tank drain plug and quality sensor.

MAIN VALVE ACCESS

A

822D-054

A

Main Control Valve

The Main Valve Access provides access to the main valve sections for adjustments or to access the ports on the lower part of the valve.

3.74

Tigercat H820D Harvester CARE OF THE MACHINE • Ensure that all fluid levels are always at the proper level. Refer to the LUBRICATION AND MAINTENANCE SCHEDULE in THIS SECTION. • Lubricate all grease points at the required intervals as specified in the LUBRICATION AND MAINTENANCE SCHEDULE in THIS SECTION. • Follow proper procedure for cleaning windows described in THIS SECTION. • Close and secure all doors and access panels before running the machine.

• Ensure the cab emergency exits are in working order by following the EMERGENCY EXIT MAINTENANCE GUIDE in THIS SECTION. • 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 a day all debris must be remove from the machine interior.

• DO NOT apply load to a cold engine.

• Always harvest trees in LOW driving range.

• Never park machine with head raised off the ground.

Be sure the head is resting on the ground before servicing or parking the machine. Refer to PARKING BOOM in SECTION 1 for complete instructions.

Lubrication and Maintenance CARE OF POLYCARBONATE WINDOWS IN CAB Some windows used in the cab are made from a polycarbonate resin thermoplastic. This material is a replacement for glass when improved strength, durability and safety is required.

Polycarbonate material is expected to resist heavy impact and to absorb high levels of energy when contacted by high velocity thrown objects such as wood chips, cutter tools or stones.

The extreme operating environment seen in logging applications heightens the need to regularly inspect and properly maintain polycarbonate cab windows.

Polycarbonate windows are an essential piece of operator protective equipment and should be maintained as such. It is important to note that cracks, chips, notches or scarring anywhere on the viewing surface or edges of the window will decrease ability to resist heavy impacts and therefore compromise effectiveness as operator safety protective equipment. Windows with these defects must be replaced immediately.

Refer to the next section for detailed information regarding inspection and maintenance of polycarbonate windows.

• SAFETY FIRST! Follow all safety rules and regulations as outlined in SECTION 1.

IMPORTANT! When cleaning the machine with pressurized water it is important to avoid getting water directly or indirectly into the exhaust tube. Water in the exhaust tube will damage sensors and SCR system components and affect the proper operation of the aftertreatment system and the engine.

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Lubrication and Maintenance

Tigercat H820D Harvester

INSPECTION AND MAINTENANCE

RESISTANCE TO CHEMICALS

Daily inspection and maintenance is essential to confirm the window’s ability to protect the operator has not been compromised.

The resistance of polycarbonate material to chemical exposure varies widely. Fortunately, polycarbonate materials have good resistance to diesel fuel, grease, hydraulic oil, kerosene and engine oil.

• Inspect all windows daily and immediately after any impacts.

• Check for any damage to the window material or steel structure in the area of the window mounting.

• The edges of the polycarbonate window must be evenly and fully supported on a flat surface around the entire window opening at all times. Bent or dented skylight structures must be replaced immediately. Bent or dented cab structures must be evaluated immediately for possible repair or replacement.

Other chemicals however can seriously weaken the polycarbonate.

Do not permit any of the following chemicals to come into contact with polycarbonate windows: • Acetone • Air Conditioning Refrigerant • Ammonia • Antifreeze • Benzene

• The edges of the polycarbonate window must be free from cracks, chips, notches or scarring and must not be pinched or stressed. These defects will decrease ability to resist heavy impacts. Windows with these defects must be replaced immediately.

• Brake Fluid • Carbon Tetrachloride • Cutting Oils

• Cracks, chips, notches or scarring anywhere on the viewing surface of the window will decrease ability to resist heavy impacts. Windows with these defects must be replaced immediately.

• Gasoline • Lacquer Thinner • Toluene

• Bent, dented or missing window retaining parts must be replaced immediately.

• Rubber materials used in mounting the window must be maintained in good condition.

• Identification of the polycarbonate originally used by Tigercat is hot stamped in a corner of the window to identify its composition. Do not use any replacement window without proof of its material composition. Do not substitute with any other materials.

• Skylights, cab structures, windows and window retaining parts must not be modified or replaced with components that are not approved by Tigercat.

• Turpentine • Xylene

RESISTANCE TO WATER Polycarbonate material has good resistance to water up to approximately 65°C (150°F). Above this temperature the effect of water is time-temperature related. This means the higher the water temperature, the shorter the time before the polycarbonate is adversely affected.

Exposing polycarbonate to repeated steam cleaning or high temperature pressure washing may result in crazing, a phenomenon that causes clouding of the surface. Crazing can ultimately result in a loss of physical strength and may precede a fracture.

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Tigercat H820D Harvester

Lubrication and Maintenance

CLEANING INSTRUCTIONS

CAUTIONS

The viewing surfaces of polycarbonate cab windows are specially treated with a hard coating to provide enhanced resistance to abrasion and ultra-violet (UV) radiation.

Failure to follow these cleaning instructions will shorten the service life of polycarbonate and may cause visual hazing, loss of light transmission and delamination of the polycarbonate hard surface coating.

The following instructions are provided to prolong the life of this protective hard coating.

• DO NOT use abusive cleaning procedures either by hand or pressure washing on polycarbonate windows.

1. Rinse the window thoroughly with lukewarm water.

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

• DO NOT use brushes, razor blades, scrapers, squeegees or other sharp tools on polycarbonate windows.

• DO NOT clean polycarbonate windows when the daytime temperature is high or in direct sunlight.

Brand name soaps and detergents recommended for cleaning polycarbonate are:

• DO NOT use abrasive or highly alkaline cleaners on polycarbonate windows.

• Fantastik • Formula 409

• DO NOT use glass cleaners in either aerosol or non aerosol containers to clean polycarbonate windows.

• Hexcel F.O. 554 • Joy • Lysol • Mr. Clean • Neleco-Placer • Pine-Sol • Top Job 3. Rinse the window thoroughly with lukewarm water.

4. Dry the window with a moist soft cloth, cellulose sponge or chamois to prevent water spotting.

5. To remove grease or oil, first rub lightly with a good grade of VM&P Naphtha or Isopropyl alcohol followed by the same rinse, wash, rinse and dry procedure described in steps 1 – 4.

Refer to RESISTANCE TO CHEMICALS in THIS SECTION for a list of chemicals which should not be permitted to come into contact with polycarbonate windows.

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Tigercat H820D Harvester

CONCEALING HAIRLINE SCRATCHES

GRAFFITI REMOVAL

The appearance of scratches and minor abrasions on the surfaces of polycarbonate windows can be minimized by using a mild automotive polish such as:

• For removal of paints, marking pen inks, etc., the use of Butyl Cellosolve is generally effective. The use of masking tape, adhesive tape or lint removal tools works well for lifting off old weathered paints.

• Johnson’s Paste Wax

• 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.

• Novus Plastic Polish #1 and #2 • Mirror Glaze Plastic Polish Be certain to clean the polycarbonate window as outlined prior to application of an automotive polish. Refer to CLEANING INSTRUCTIONS in THIS SECTION.

Refer to RESISTANCE TO CHEMICALS in THIS SECTION for a list of chemicals which should not be permitted to come into contact with polycarbonate windows.

FIRE PRECAUTIONS Polycarbonate window material will ignite when exposed to an ignition source in excess of 427°C (800°F). When working around polycarbonate windows, observe similar fire precautions to those in place for wood.

REMOVAL OF ANTI-CORROSION SPRAY (IF APPLICABLE) Some machines, particularly machines shipped outside North America, are shipped with an optional anticorrosion spray to protect the machine from corrosion during shipment.

This anti-corrosion spray should be removed when the machine reaches it’s destination as it may cause debris to stick to the treated surfaces of the machine.

The anti-corrosion spray can be removed with a pressure washer, a sponge and soap.

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Tigercat H820D Harvester

Lubrication and Maintenance

TRACK OPERATION AND WEAR PREVENTION

Alternate turning directions.

If you're always turning in the same direction, the undercarriage components on one side of the machine will wear at a different rate than those on the other side.

To ensure even wear, pay attention to the way you're turning and change directions whenever possible.

Make gradual turns instead of counter-rotations.

Counter-rotating accelerates wear on the tracks and other undercarriage components. Don't use that technique unless job conditions demand it. Instead, turn the machine gradually while slowly moving forward or reverse. Gradual turns minimize cuts, tears and excessive wear in the undercarriage. They also reduce damage to soft or sensitive work surfaces.

R7150L2-7

NOTE: The following illustrations are presented for illustrative purposes only and may not necessarily depict your machine or model.

PROTECTING STEEL TRACKS Steel tracks are designed to perform in tough underfoot conditions. Take these steps to maximize service life and reduce operating costs.

Start every shift with a clean undercarriage.

When mud and debris build up on the lower part of your machine, components wear at a faster rate. Do not begin work until the undercarriage area is clean.

Inspect the undercarriage before you start working.

In the event a counter rotation is required some operators will carefully push the boom and attachment down against a suitable obstacle and lift the forward or rear sections of the track off the ground. The operator will then counter rotate the tracks while swinging the upper structure. This will disengage most of the track length from the ground during the counter rotation resulting in less site damage and potentially less track wear. This is a complex maneuver and should only be completed by fully trained and experienced operators working in stable ground conditions.

In addition to ensuring the undercarriage is clean, spend a couple of minutes on a visual inspection. Check for loose bolts, leaky seals and abnormal wear patterns.

When you spot potential problems early, you can often prevent them from turning into bigger issues that reduce component life significantly or cause expensive unscheduled downtime.

Don't spin the tracks.

Track spinning reduces production, it increases fuel consumption, without a corresponding increase in productivity, and it accelerates undercarriage wear, so your costs escalate. Grouser bars are especially prone to wear problems associated with track slippage.

Watch your speed.

There are times when a job requires higher speed operation, but the fact is, wear accelerates as speed increases. Links, rollers and idlers are particularly vulnerable. Keep them working longer by controlling your speed.

Work up or down a slope whenever possible.

Working across a slope can shorten undercarriage component life, so try to structure the job with minimal cross-slope activity.

Avoid unnecessary reverse operation.

Operating in reverse, even at slow speeds, compounds bushing and sprocket wear as the track tension loads are applied to the top side of the chain. So avoid an unproductive reverse operation.

3.79

Lubrication and Maintenance

Tigercat H820D Harvester

Watch transition areas.

Try to minimize travel over transition obstacles as this accelerates undercarriage wear. If you must go across a transition, position the machine 90° to the transition.

Without ground support, the undercarriage is subjected to side stresses that can result in rapid, excessive wear.

Other factors:

Configuration refers to the way your machine is equipped and is therefore something you can control. To minimize undercarriage wear on steel-track machines, always use the narrowest track shoe possible that meets your flotation requirements. If you work in very sticky materials, consider using centre-punched track shoes to reduce material packing in the undercarriage area.

Maintenance discipline plays a big role in undercarriage component life. One of the most critical maintenance practices is track adjustment. Tight track is the numberone 'track killer'. But whether your track is too loose or too tight, improper adjustment accelerates wear which can increase downtime and repair costs. Follow the manufacturer's recommendations for track adjustment, and always perform the adjustment in the machine's working environment. A second important maintenance process is cleaning the undercarriage. To maximize wear life, remove mud and debris at the end of every shift, or more frequently if necessary.

Application refers to the type of work you do. Bunching, loading, grading, digging and trenching are a few examples. This factor is largely beyond your control, but generally speaking, the more you work in high horsepower, high-torque applications, the faster your undercarriage will wear.

Talk to the experts:

Material type is another key contributor to undercarriage wear that is outside your control, the more abrasive the material, the more rapid the wear rate.

Terrain, a third uncontrollable factor, describes the contours and slopes at your job site. The more time you spend in rugged, sloped areas, the faster your undercarriage will wear out.

Undercarriage components are expensive! To get long life and maximum value from your investment, consult with a dealer or factory rep that really knows the undercarriage business. Ask for advice on operating techniques. Explore relevant application, material and terrain issues. Fine-tune your maintenance processes.

Working together with an undercarriage expert, you can manage your equipment investment over the long term.

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Tigercat H820D Harvester

Lubrication and Maintenance

TRACK CHAIN

NOTE: If track sag is less than specified, track chain wear will be accelerated. If track sag is excessive, it is possible for the track to jump off the sprocket.

TRACK CHAIN SAG Track chains that are too tight significantly shorten the bushing OD wear life.

MEASURING TRACK SAG

H822C-I01

A

Lift Left Track

1. Position attachment head in vertical position and swing boom to side of machine.

860C-320

TRQUE PROCEDURE, TRACK SHOE

2. Use a jack of suitable design and capacity to safely lift the left track clear of the ground.

Refer to serial number plate for machine weight (less attachment).

A

Refer to attachment manufacturer's manual for correct attachment weight information.

3. Rotate track in forward and reverse several times.

Stop the track while in reverse. Do not clean the track.

860C-333

A

B

Torque Procedure

• Incorrect bolt torque is the leading cause of shoe loosening.

A

• Torque + turn is the shoe bolts assembly method.

C

• Provides a controlled stretch of the bolt of about 0.3 mm (0.012 in). It is the stretch that prevents the bolt from coming loose.

853ILL8

A Underside of Track Guard B Sag Dimension C Upper Surface of Track Shoe

• Provides up to 25% more clamp load than straight torque.

• It is not influenced by friction / condition of mating components.

4. Turn OFF the engine.

5. Measure distance between upper surface of track shoe at centre of lower surface of track guard.

• The method is also used on other critical joints, such as sprockets, master sections, final drives. Refer to TORQUE SPECIFICATIONS in SECTION 11.

6. This dimension should be between 102 – 152 mm (4 – 6 in) for normal operations.

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Lubrication and Maintenance

Tigercat H820D Harvester

TRACK SAG ADJUSTMENT (FILL VALVE)

TIGHTEN TRACK

Filling procedures for track sag adjustment depend on which undercarriage your vehicle is equipped with.

2. Add grease until the track sag dimension is within recommended limits.

1. Connect a grease gun to the grease fitting.

Refer to MEASURING TRACK SAG in THIS SECTION for recommended limits.

A

3. Remove the grease gun from the fitting.

LOOSEN TRACK NOTE: The track sag fill valve is mechanically restricted from being removed completely.

1. Slowly loosen the valve body until the grease begins to escape via a relief passage in the valve body housing.

Grease will be seen escaping from around the valve body threads.

Remove grease until the track sag dimension is within recommended limits. Refer to MEASURING TRACK SAG in THIS SECTION for recommended limits.

880-303

2. Tighten the valve body when the track sag is correct.

845C-002

A Fill Valve

CAUTION The grease is under very high pressure. DO NOT REMOVE the adjustment fitting valve body from the idler adjusting cylinder.

3.82

Tigercat H820D Harvester TRACK SAG ADJUSTMENT (FILL COUPLER)

Lubrication and Maintenance TIGHTEN TRACK 1. Attach the coupler onto the fill valve.

2. Connect a grease gun to the grease fitting on the coupler.

3. Add grease until the track sag dimension is within recommended limits.

B

Refer to MEASURING TRACK SAG in SECTION 11 of the SERVICE MANUAL for recommended limits.

A

4. Remove the grease gun from the coupler fitting.

5. Store the coupler in a safe place.

LOOSEN TRACK 1. Slowly loosen the fill valve until grease begins to escape through the vent passage in the valve body housing.

Grease will vent around the valve body threads.

Remove grease until the track sag dimension is within recommended limits.

880-303

Refer to MEASURING TRACK SAG in SECTION 11 of the SERVICE MANUAL for recommended limits.

2. Tighten the valve body when the track sag is correct.

NOTE: The track sag fill valve is not mechanically restricted from being removed completely.

845C-003

A Fill Valve (DO NOT REMOVE) B Valve Coupler

CAUTION The grease is under very high pressure. DO NOT REMOVE the adjustment fitting valve body from the idler adjusting cylinder.

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Lubrication and Maintenance

Tigercat H820D Harvester

TORQUE CHART LOCATION

THREAD DIAMETER

Cylinder, Hoist, 130 mm (55529B) Piston nut Cylinder end cap bolts Cylinder, Hoist, 140 mm (65591B) Piston nut Cylinder end cap bolts Cylinder, Stick, 110 mm (55479B & 55480B) Piston nut Cylinder end cap bolts Cylinder pin retaining bolts Boom pin retaining bolts** (Use BLUE Loctite on lower MAIN boom joint) Cab securing bolts Swing Swing bearing bolts Swing gearbox mounting bolts Swing motor mounting bolts Engine mounting Bolts, bracket/mount to chassis rear Bolts, bracket/mount to chassis front Bolts, bracket to engine, front Bolts, bracket to engine, rear Pump Drive Torsional drive coupler mounting** Pump Mounting Main Pump mounting bolts Harvester Pump mounting bolts Fan Pump mounting bolts Rotatary Manifold mounting bolts** Rotatary Manifold tie rod mounting bolts Undercarriage Track shoe bolts (D6) Track shoe bolts (FH400) Track shoe bolts (F8) Idler bolts (R6152-5) Roller mounting bolts (R6152-5) Roller mounting bolts (R7150) (R7163L) Sprocket bolts Gearbox mounting bolts Drive motor mounting bolts (R6152-5) (R7150) Drive motor mounting bolts (R7163L)** Leveller, fore/aft pivot shaft and housing bolts

TORQUE (LUBRICATED) lbf•ft N•m

M75 M18

5008 270

7690 367

M75 M18

5827 270

7900 367

M58 M14 M20 M20

2419 126 380 400

3280 171 515 530

1" UNC

400

542

7/8" UNC M20 M16

500 400 160

678 542 217

M24 M24 M12 M12

560 560 75 80

759 759 102 108

M10

34

46

M20 M20 M12 M16 3/4" UNC / M20

400 400 80 200 290

542 542 108 271 393

3/4" UNF M24 X 12.9 M20 X 12.9 M16 7/8" UNC 1" UNC M20 M20 M20 M12 M24

T/T* T/T* T/T* 175 450 750 380 380 380 80 675

T/T* T/T* T/T* 240 600 1000 515 515 515 108 925

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. **Use BLUE Loctite 242 Torque values pertaining to the engine and attachment are provided in the service manuals applicable to those major components.

H80D TORQUE CHART R1

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Tigercat H820D Harvester

Lubrication and Maintenance

GENERAL TORQUE SPECIFICATIONS

The torque values listed below are for general use only.

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

IMPERIAL GRADE 8 BOLTS

GRADE 5 BOLTS

IMPERIAL BOLT TORQUE SPECIFICATIONS GRADE 8 BOLTS GRADE 5 BOLTS LUBRICATED lbf-ft Nm 8 - 10 11 - 13 20 - 28 27 - 38 33 - 36 45 - 49 52 - 57 71 - 77 80 - 88 109 - 119 115 - 127 156 - 172 159 - 175 216 - 237 282 - 310 393 - 420 455 - 501 617 - 679 682 - 750 925 - 1016 966 - 1062 1310 - 1441 1360 - 1496 1844 - 2027 LUBRICATED lbf-ft Nm 10 - 13 14 - 17 18 - 25 25 - 33 37 - 41 50 - 55 58 - 64 79 - 86 90 - 99 122 - 134 128 - 141 174 - 191 180 - 198 244 - 268 315 - 347 427 - 470 501 - 550 679 - 745 746 - 821 1012 - 1113 1083 - 1191 1469 - 1613 1509 - 1660 2046 - 2250 8.8

10.9

8.8

10.9

12.9

8.8

10.9

12.9

10

10

10

METRIC

10

DRY LUBRICATED COARSE THREAD lbf-ft Nm lbf-ft Nm 1/4" - 20 7- 8 10 - 11 8 - 10 11 - 13 5/16" - 18 14 - 18 19 - 24 10 - 15 13 - 20 3/8" - 16 31 - 34 42 - 46 23 - 25 31 - 34 7/16" - 14 49 - 54 66 - 73 37 - 41 50 - 55 1/2" - 13 75 - 83 102 - 112 57 - 63 77 - 85 9/16" - 12 109 - 120 148 - 162 82 - 90 111 - 122 5/8" - 11 150 - 165 204 - 223 113 - 124 152 - 168 3/4" - 10 266 - 293 360 - 397 200 - 220 271 - 298 7/8" - 9 394 - 433 535 - 586 296 - 326 402 - 441 1" - 8 591 - 649 802 - 879 443 - 489 601 - 663 1 1/8" - 7 794 - 873 1077 - 1183 596 - 656 808 - 889 1 1/4" - 7 1120 - 1232 1519 - 1670 840 - 924 1139 - 1252 FINE DRY LUBRICATED lbf-ft Nm lbf-ft Nm THREAD 1/4" - 28 9 - 10 12 - 13 9 - 10 12 - 13 5/16" - 24 17 - 22 23 - 29 16 - 20 21 - 27 3/8" - 24 35 - 39 48 - 53 26 - 29 35 - 39 7/16" - 20 55 - 61 75 - 83 41 - 45 56 - 61 1/2" - 20 85 - 94 116 - 127 64 - 70 87 - 95 9/16" - 18 121 - 133 164 - 180 91 - 100 124 - 135 5/8" - 18 170 - 187 231 - 253 128 - 141 174 - 191 3/4" - 16 297 - 327 403 - 443 223 - 245 303 - 332 7/8" - 14 434 - 477 589 - 646 326 - 359 442 - 486 1" - 12 646 - 711 876 - 965 484 - 534 657 - 724 1 1/8" - 12 891 - 980 1208 - 1328 668 - 735 906 - 996 1 1/4" - 12 1240 - 1364 1682 - 1849 931 - 1024 1262 - 1387 12.9

10

12.9

12.9

12

12

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

10

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

12

METRIC BOLT TORQUE SPECIFICATIONS CLASS 8.8

SIZE PITCH LUBRICATED mm Nm lbf-ft M6 1 8-9 6-7 M8 1.25 20 - 22 15 - 16 M10 1.5 39 - 43 29 - 32 M12 1.75 68 - 75 50 - 55 M14 2 109 - 120 80 - 89 M16 2 169 - 186 125 - 137 M18 2.5 234 - 257 172 - 190 M20 2.5 330 - 364 244 - 268 M22 2.5 451 - 496 332 - 366 M24 3 571 - 628 421 - 463 M27 3 837 - 921 618 - 679 M30 3.5 1135 - 1249 837 - 921 M33 3.5 1545 - 1699 1139 - 1253 M36 4 1985 - 2183 1464 - 1610

CLASS 10.9 LUBRICATED DRY Nm lbf-ft Nm lbf-ft Nm lbf-ft 11 - 12 8-9 11 - 12 8-9 15 - 17 11 - 12 26 - 29 19 - 21 27 - 30 20 - 22 36 - 40 27 - 30 52 - 57 38 - 42 54 - 60 40 - 44 72 - 79 53 - 59 91 - 100 67 - 74 94 - 104 70 - 77 126 - 138 93 - 102 145 - 160 107 - 118 151 - 166 111 - 122 201 - 221 148 - 163 226 - 248 166 - 183 234 - 257 173 - 190 312 - 343 230 - 253 312 - 343 230 - 253 324 - 356 239 - 262 431 - 474 318 - 350 441 - 485 325 - 357 457 - 503 337 - 371 610 - 670 450 - 495 601 - 661 443 - 487 623 - 686 460 - 506 831 - 914 613 - 674 761 - 838 562 - 618 790 - 869 583 - 641 1053 - 1159 777 - 855 1116 - 1228 823 - 906 1158 - 1274 854 - 940 1544 - 1699 1139 - 1253 1514 - 1665 1116 - 1228 1570 - 1727 1158 - 1274 2094 - 2303 1544 - 1699 2060 - 2266 1519 - 1671 2137 - 2351 1576 - 1734 2849 - 3134 2102 - 2312 2646 - 2911 1952 - 2147 2745 - 3020 2025 - 2227 3661 - 4027 2700 - 2970 DRY

3.85

CLASS 12.9 LUBRICATED DRY Nm lbf-ft Nm lbf-ft 13 - 14 10 - 11 18 - 19 13 - 14 32 - 35 24 - 26 43 - 47 31 - 35 63 - 70 47 - 51 84 - 93 62 - 68 110 - 121 81 - 90 147 - 162 109 - 119 176 - 194 130 - 143 235 - 259 173 - 191 274 - 301 202 - 222 365 - 401 269 - 296 378 - 416 279 - 307 504 - 554 372 - 409 534 - 588 394 - 433 712 - 784 525 - 578 728 - 801 537 - 591 971 - 1068 716 - 788 923 - 1016 681 - 749 1231 - 1354 908 - 999 1354 - 1489 998 - 1098 1805 - 1985 1331 - 1464 1835 - 2019 1354 - 1489 2447 - 2692 1805 - 1985 2498 - 2747 1842 - 2026 3330 - 3663 2456 - 2702 3208 - 3529 2366 - 2603 4278 - 4706 3155 - 3471

Lubrication and Maintenance

Tigercat H820D Harvester

Parker

Assembly Torque The four-bolt port is simply a circular opening (flow passage) surrounded by four tapped holes in a certain pattern for acceptance of the flange clamping bolts. The flat surface of the port compresses the O-ring contained in the groove in the flange head when the clamp bolts are torqued. In some instances, the groove is in the port and not in the flange head. The bolts, through the clamp halves, clamp down the flange head onto the flat surface of the port compressing and trapping the O-ring in the groove and leaving no gap for it to extrude under pressure. The hydraulic pressure is thus sealed by the compressed O-ring as long as the bolts are tightened enough to maintain solid metal to metal contact between the flange head at the outside diameter of the O-ring and the top of the port.

A B C

D E F

Flange Port Assembly The steps to properly assemble the flange port clamping bolts are:

FLANGE.JPG

A B C D E F

4-Bolt Split Flange Components

1. Make sure sealing surfaces are free of burrs, nicks, scratches or any foreign particles.

Washers Bolts Flange Clamp Flange Head O-Ring Tapped Holes

2. Lubricate the O-ring.

3. Position flange and clamp halves.

4. Place lock washers on bolts and insert through clamp halves.

• The 4-Bolt Split Flange consists of four main components:

5. Hand tighten bolts.

• A body (flange head) • An O-ring • One captive or two split flange clamps • Four bolts and washers Dash Size

Flange Size

Inch Bolt (J518)

Torque lbf-ft

Metric Bolt (ISO 6162)

Torque Nm

8 12 16 20 24 32 40 48 56 64 80

1/2 3/4 1 1-1/4 1-1/2 2 2-1/2 3 3-1/2 4 5

5/16-18 3/8-16 3/8-16 7/16-14 1/2-13 1/2-13 1/2-13 5/8-11 5/8-11 5/8-11 5/8-11

17 +/- 2 25 +/- 3.5 31 +/- 4.5 41 +/- 5 52 +/- 6 60 +/- 6 85 +/- 9 144 +/- 15 125 +/- 8 125 +/- 8 125 +/- 8

M8 M10 M10 M12 M12 M12 M12 M16 M16 M16 M16

25 49 49 85 85 135 95 220 220 220 220

FLANGE2.JPG

A

Flange Bolt Tightening Sequence

6. Torque bolts in diagonal sequence in small increments to the appropriate torque level listed in Table T6 or Table T7 on this page.

Table T6– Code 61 Flange Recommended Bolt Torque

NOTE: Does not meet ISO 6162 specification.

Dash Size

Flange Size

Inch Bolt (J518)

Torque lbf-ft

Metric Bolt (ISO 6162)

Torque N-m

8 12 16 20 24 32

1/2 3/4 1 1 1/4 1 1/2 2

5/16-18 3/8-16 7/16-14 1/2-13 5/8-11 3/4-10

17 +/- 2 30 +/- 4.5 46 +/- 4.5 69 +/- 6 125 +/- 8 208 +/- 20

M8 M10 M12 M14 M16 M20

25 49 85 135 210 425

Table T7– Code 62 Flange Recommended Bolt Torque

NOTE: Does not meet ISO 6162 specification.

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Tigercat H820D Harvester

Lubrication and Maintenance

Parker

Assembly Torque JIC 37 Degree Flare

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

Thread Size

NPTF

Tube Connection Swivel or Hose Connection FFWR FFWR

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

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

SAE Dash Size

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

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

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

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

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

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

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

BSPT

Tube Connection Swivel or Hose Connection FFWR FFWR NA NA 1/4 TO 1/2 NA 1/4 TO 1/2 1/4 TO 1/2 1/4 TO 1/2 1/4 TO 1/2 NA 1/4 TO 1/2 1/4 TO 1/2 1/4 TO 1/2 NA NA

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

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

O'ring Face Seal / Seal-Lok SAE Dash Size

Tube Connection Swivel or Hose Connection TFFT TFFT

Thread Size

SAE Dash Size

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

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

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

Thread Size

Tube Connection Swivel or Hose Connection TFFT TFFT

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

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

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

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

SAE J1926 Straight Thread Port Assembly Torques ASSEMBLY TORQUE = 10 % -0 SAE DASH SIZE

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

THREAD SIZE

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

SEAL-LOK lbf-ft (lbf-in) (310) (310) (310) (360) (420) 60 100 135 175 200 250 305 375

Nm 20 20 20 40 46 80 135 185 235 270 340 415 510

TRIPLE-LOK FERULOK PIPE FITTINGS lbf-ft Nm (lbf-in) (85) 10 (155) 18 (260) 29 (280) 32 (350) 40 (620) 70 85 115 135 183 175 237 200 271 250 339 305 414 375 509

PLUGS

ADJUSTABLE

NON-ADJUSTABLE

SEAL-LOK lbf-ft (lbf-in) (310) (310) (310) (360) (420) 60 100 135 175 200 250 305 375

3.87

Nm 20 20 20 40 46 80 135 185 235 270 340 415 510

TRIPLE-LOK FERULOK PIPE FITTINGS lbf-ft Nm (lbf-in) (60) 7 (100) 11 (180) 20 (250) 28 (350) 40 (620) 70 85 115 135 183 175 237 200 271 250 339 305 414 375 509

HOLLOW HEX

HEX HEAD

HP5ON-S

P5ON-S

lbf-ft (lbf-in) (30) (55) (120) (170) (410) 60 100 135 175 200 250 305 375

Nm 3.5 6 13.5 19 46 80 135 185 235 270 340 415 510

lbf-ft (lbf-in) (85) (155) (260) (280) (350) (620) 85 135 175 200 250 305 375

Nm 10 18 29 32 40 70 115 183 237 271 339 414 509

Lubrication and Maintenance

Tigercat H820D Harvester

Assembly Torque

EATON Aeroquip Recommended Parallel Connection Assembly torque

Eaton recommends that a Torque wrench be used to assure proper fitting assembly of these connections.

Straight Thread O-Ring Boss Low Pressure with 37º (SAEJ514)

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

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

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

The values listed are for steel connections. Contact Teaton for torque values for other materials.

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

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

ORS

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

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

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

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

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

SAE 37º (JIC) Thread Size (inches) 9/16-18 11/16-20 13/16-16 1-14 1 3/16-12 1 7/16-12 1 11/16-12 2-12

Swivel Nut Torque lb.-ft.

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

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

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

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

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

Swivel Nut Torque lb.-ft.

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

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

BSPP Straight Adapter or Locknut Torque lb.-ft.

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

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

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

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

3.88

Tigercat H820D Harvester

Lubrication and Maintenance Common Conversions

To Convert...

Into...

Multiply By

To Convert...

Into...

Multiply By

BAR �������������������������

PSI ���������������������������

14.5

in3 �����������������������������

cm3 ���������������������������

16.39

cm ���������������������������

in �����������������������������

0.06102

°F �����������������������������

°C ����������������������������

(°F– 32) / 1.8

°C ����������������������������

°F �����������������������������

(°C x 9/5) + 32

US Gal ���������������������

L �������������������������������

3.785

kg �����������������������������

lb ������������������������������

2.205

hp ����������������������������

kW ���������������������������

0.7457

kW ���������������������������

hp ����������������������������

1.341

in ������������������������������

mm ���������������������������

25.4

L �������������������������������

US Gal ���������������������

0.2642

lb ������������������������������

kg �����������������������������

0.4535

mm ���������������������������

in ������������������������������

0.03937

lbf•ft �������������������������

Nm ���������������������������

1.356

Nm ���������������������������

lbf•ft �������������������������

0.7375

psi ����������������������������

par ���������������������������

0.06896

N ������������������������������

lbf �����������������������������

0.22481

in Hg ������������������������

psi ����������������������������

0.4912

in H2O ���������������������

psi ����������������������������

0.03613

lb ������������������������������

N ������������������������������

4.4482

3

3

3.89

Lubrication and Maintenance

Tigercat H820D Harvester

WEIGHTS OF COMMERCIAL WOOD

Alder, Red

SPECIES

Ash, White Aspen, Quaking Bald Cypress Basswood, American Beech, American Birch, Paper Birch, Yellow Cedar, Alaska Cedar, Incense Cedar, Northern White Cedar, Port-Orford Cedar, Western Red Cherry, Black Cottonwood, Eastern Douglas Fir, Coast Douglas Fir, Inland North Elm, American Fir, Alpine Fir, Balsam Fir, Nobel Fir, Red Fir, Silver Fir, White Gum, Black Gum, Blue Gum, Red Gum, Tupelo Hemlock, Eastern Hemlock, Western Hickory, Pecan Hickory, True Larch, Western Locust, Black Magnolia, Cucumber

KG/M3 LB/FT3 737 769 689 817 673 865 801 929 577 721 449 897 433 721 785 881 577 865 449 721 481 769 577 753 721 1121 801 897 801 657 993 1009 769 929 785

SPECIES

Maple, Big Leaf Maple, Black Maple, Red Maple, Silver Maple, Sugar Oak, Black Oak, Chestnut Oak, Red Oak, Red, Swamp Oak, Swamp Chestnut Oak, White Oak, White, Swamp Pine, Jack Pine, Loblolly Pine, Lodgepole Pine, Long Leaf Pine, Norway, Red Pine, Short Leaf Pine, Slash Pine, Sugar Pine, Western Yellow Pine, White-Western Pine, White-Eastern Poplar, Yellow Redwood Spruce, Black Spruce, Engleman Spruce, Red Spruce, Sitka Spruce, White Sweetgum Sycamore, American Tamarack Walnut, Black Willow, Black

46 48 43 51 42 54 50 58 36 45 28 36 57 45 49 55 36 54 28 45 30 48 36 47 45 70 50 56 50 41 62 63 48 58 49

NOTE: The values shown here are green weights.

3.90

KG/M3 LB/FT3 753 865 801 721 897 1009 977 1009 1073 1041 993 1105 801 993 625 993 673 993 993 817 721 561 577 609 801 513 625 545 529 545 801 833 753 929 801

47 54 50 45 56 63 61 63 67 65 62 69 50 62 39 62 42 62 62 51 45 35 36 38 50 32 39 34 33 34 50 52 47 58 50

Tigercat H820D Harvester

Lubrication and Maintenance

PRESSURE AND SPEED SETTINGS HYDRAULIC OIL TEMPERATURE (Check appropriate box) Mult-Weight Oil 60° C (140° F) Summer Oil 60° C (140° F)

Winter Oil Spec.

ENGINE RPM High Idle, no load maximum Low idle, no load Rated working PILOT SUPPLY Pilot supply pressure; low idle, no function Pilot supply pressure; high idle, no function Pilot supply pressure; high idle, swing with brake on

SWING Speed Crossline reliefs Swing torque curve Swing POR *Pilot pressure @ 12 bar (175 psi)

Actual

RPM

2100 rpm 950 rpm 2100 rpm

High Low

31 bar (450 psi) 31 bar (450 psi) 31 bar (450 psi)

Low High High

MAIN PUMP Margin pressure 16 bar (230 psi) To set Margin pressure: Set Head Rotate speed as below, set Head Rotate to 1,500psi, adjust Margin Pressure while holding Head Rotate lever.

Re-check / re-adjust Head Rotate speed as required to settings listed below.

MAIN VALVE Main Relief Load sense relief Boom port reliefs Stick port reliefs Rotate port reliefs Pump 2 port relief Warm-Up Valve port relief

43° C (110° F)

High

Non - Adjustable 310 bar (4500 psi) 338 bar (4900 psi) 338 bar (4900 psi) 103 bar (1500 psi) 338 bar (4900 psi) 138 bar (2000 psi)

High Low Low Low Low High

**Set speed before pressures** 7 rpm Full Flow @ 'LS' port 276 bar (4000 psi) (measured at 'LS' port*) 228 bar (3300 psi) (measured at 'LS' port) 255 bar (3700 psi)

High High High High

(measured at 'P' port) Cracking Pressure @ 'P' port Cracking Pressure @ 'P' port Full Flow @ 'P' port Cracking Pressure @ 'P' port Full Flow @ 'P' port

3.91

Lubrication and Maintenance

Tigercat H820D Harvester

FINAL DRIVE SET UP ACCORDING TO 870C SERVICE MANUAL 39183AENG L.H. Final Drive SECTION 11 "TYPE B MOTOR" Crossline relief 345 bar (5000 psi) Motor Start of regulation Rexroth 248 bar (3600 psi) @ Mb port Brake release (pilot pressure) Speed

Non-Adjustable 28 - 34 bar (400 - 500 psi)

Low

13 rpm MAX. 28 rpm MAX.

High High

822D (Rexroth Motors)

Low High

SET UP ACCORDING TO 870C SERVICE MANUAL 39183AENG R.H. Final Drive SECTION 11 "TYPE B MOTOR" Crossline relief 345 bar (5000 psi) Motor Start of regulation Rexroth 248 bar (3600 psi) @ Ma port Brake release (pilot pressure) Speed

Low Low

Low Low

Non-Adjustable 28 - 35 bar (400 - 500 psi)

Low

13 rpm MAX. 28 rpm MAX.

High High

822D (Rexroth Motors)

Low High

3.92

Tigercat H820D Harvester

Lubrication and Maintenance

PUMP 1 Pressure override 310 bar (4500 psi) Displacement (Max Displacement) Note : Max displacement is the point where the max displacement screw loses contact with the actuator.

Pump 1 CONTROL VALVE Main relief HARVESTER FLOWS

(Set at 2500 psi) No Head Always (MAX 60 Pump 1 Displacement)

Pump 1 + Pump 2

(Turn all the way in) 338 bar (4900 psi) TH570 60

TH575 60

GPM

75 GPM 94 94 **Check total flow at ZERO load, 138 bar (2000 psi), 241 bar (3500 psi).**

FAN PUMP Speed - Fan Full On Speed - Fan Purge

(+/- 25 RPM) (+/- 25 RPM)

DOOR/ROOF PUMP Main Relief

2000 rpm 1700 rpm

207 bar (3000 psi)

NOTE: All hydraulic settings to be done with hydraulic oil at operating temperatures as per oil selection choice at top of sheet.

3.93

Low

Low

High

High

High High

Lubrication and Maintenance BOOM SPEED SETTINGS ER Boom w/Head Main Boom Cylinder UP 1.5 turns DOWN 3.5 turns Stick Boom Cylinder OUT 4.5 Sec IN 5.0 Sec Rotate CW CCW

Tigercat H820D Harvester

Non-ER Boom w/Head

Time w/Head

Time No Head

1.5 turns 3.5 turns

5.0 Sec 8.0 Sec

5.0 Sec 12.0 Sec

Time Only Time Only Time Only Time Only

6.0 Sec 6.0 Sec

Set Flow Set Flow

9.0GPM 9.0GPM

Leveling Valve (if Applicable) Level Fore 8.0 Sec Level Aft 8.0 Sec

Time Only via IQAN Time Only via IQAN

NOTE: All settings to be done with hydraulic oil at operating temperatures as per oil selection choice at top of sheet - Engine RPM at HIGH.

3.94