TIGERCAT H822 HARVESTER OPERATOR'S MANUAL - PDF DOWNLOAD

OPERATOR'S MANUAL TIGERCAT H822 HARVESTER TABLE OF CONTENTS

ISSUE 1.1, SEPTEMBER 2004

SECTION INTRODUCTION .............................................................................................................. iii NON-APPROVED FIELD PRODUCT CHANGES ........................................................... iv SAFETY ............................................................................................................................ 1 CONTROLS AND OPERATION ........................................................................................ 2 LUBRICATION AND MAINTENANCE ............................................................................... 3

H822-OM00

Tigercat

H822 Harvester Available Literature Operator's Manual, English (this manual) ........... Part No. 23598A Parts Catalog ....................................................... Part No. 23597A Hydraulic Adapters Book ....................................... Part No. 1472A Hydraulic Hose Assemblies Book ......................... Part No. 3707A

®

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

Fax: (519) 442-1855

Tigercat H822 Harvester

Introduction

ii

Tigercat H822 Harvester Tigercat H822 Harvester

Introduction

INTRODUCTION An Operator's manual, Service manual and a Parts catalog are made available by Tigercat to assist the dealer, customer and operator in becoming familiar with the features of the H822 Harvester serial numbers 822H0123 and 82230191 to 82230999.

The operator's manual will assist the operator with the techniques of proper and safe operation of the H822 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, WARNING and CAUTION notices are displayed where necessary, drawing attention to possible hazards when performing certain procedures.

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

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

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

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

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

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

Tigercat Industries Inc.

iii

Tigercat H822 Harvester

Introduction

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

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

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

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

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

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

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

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

Tigercat Industries Inc.

iv

Tigercat H822 Harvester

SECTION 1 - SAFETY AUGUST 2004

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

Read and understand all manuals for any attachment or accessories.

CONTENTS - SECTION 1 BATTERY SAFETY ........................................................................................ 1.8 CAB EXITS .................................................................................................... 1.9 COOLING SYSTEM ..................................................................................... 1.16 EMERGENCY CAB EXITS ............................................................................ 1.9 ENGINE DOORS ......................................................................................... 1.17 ER BOOM SYSTEM PRECAUTIONS .......................................................... 1.16 EXHAUST FUMES ....................................................................................... 1.17 FIRE PREVENTION FIRE PREVENTION GUIDELINES ........................................................... 1.18 WHAT ELSE TO DO BEFORE YOU EXPERIENCE A FIRE .................... 1.19 WHAT TO DO AFTER A FIRE ................................................................. 1.20 WHAT TO DO IN CASE OF A MACHINE FIRE ........................................ 1.19 FLUID LEAKS .............................................................................................. 1.15 HARVESTING ATTACHMENT – GENERAL SAFETY ................................ 1.12 HAZARD ZONE ............................................................................................. 1.5 HYDRAULIC PRESSURE HAZARD ............................................................ 1.15 LOOSE CLOTHING HAZARD ..................................................................... 1.16 PARKING BOOM ......................................................................................... 1.16 PARKING THE MACHINE ........................................................................... 1.13 PROTECTIVE CLOTHING ............................................................................. 1.5 SAFETY INTERLOCK SWITCHES ON CAB DOORS ................................. 1.10 SAFETY PRECAUTIONS, GENERAL ........................................................... 1.5 SAFETY PRECAUTIONS, OPERATING ....................................................... 1.9 SAFETY PRECAUTIONS, SERVICING ....................................................... 1.14 SAFETY SYMBOLS ....................................................................................... 1.4 SIGNAL WORDS ........................................................................................... 1.4 WELDING, PRIOR TO ................................................................................. 1.14 WORKING WITH OIL .................................................................................... 1.6

Tigercat H822 Harvester

Safety

1.2

Tigercat H822 Harvester

Safety

Noise Level Inside Cab dB(A) As per Tigercat test ETR006 Microphone direction: Forward Rear Left Driving max speed (High) 76 77 74 Driving max speed (Low) 75 76 74 Boom opertation 74 78 73

Right 75 74 74

NOISELEVELS.XLS

Vibration Level - Whole-body As per Tigercat test ETR007 & ISO 2631-1 Weighted rms accleleration (m/s2) Seat Seat-back Health Comfort Driving max speed (High) x-axis (back-to-chest) 0.5630 0.2370 y-axis (right-to-left) 0.3200 0.2310 z-axis (buttocks-to-head) 0.2110 0.4660 Σ 0.6571 0.5700 0.4850 Driving max speed (Low) x-axis (back-to-chest) 0.2150 0.1140 y-axis (right-to-left) 0.0977 0.0764 z-axis (buttocks-to-head) 0.0669 0.2170 Σ 0.2890 0.2568 0.1800 Boom opertation 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 Σ 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 accleleration (m/s2) Driving max speed (High) Σ 1.770 Driving max speed (Low) Σ 1.170 Boom opertation Σ 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

Tigercat H822 Harvester

Safety

SAFETY SYMBOLS

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

Understanding Signal Words

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

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

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

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

1.4

Tigercat H822 Harvester

Safety

GENERAL SAFETY PRECAUTIONS

KEEP BACK 500 FEET

Remember that safety is a prime responsibility of all.

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

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

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

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

500 FEET

500 FEET

500 FEET

500 FEET

Follow all instructions from safety inspector and supervisors.

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

LH830-02

HAZARD ZONE

DANGER

Do not let untrained persons operate the machine.

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

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

These safety rules highlight both general and specific measures that the operator should be familiar with and adhere to. More specific measures are illustrated with pictograms which may also be attached to the machine in locations pertinent to their respective message. Keep safety labels in good condition. Repair or replace damaged labels.

1.5

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

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

Tigercat H822 Harvester

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

GENERAL SAFETY PRECAUTIONS continued Use the handrails and steps provided when mounting and dismounting from the machine.

Check windows and door guards for damage.

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

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

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

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

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

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

Do not use the machine foot controls as steps.

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

Check all fluid levels.

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

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

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

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

Some advice which should be observed: • • •

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

• •

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

•

Machine should be washed completely at every major service.

• • •

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

1.6

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.

Don't put oily rags in your pockets.

Oil soiled clothing should be changes as soon as possible.

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

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

Avoid breathing in oil fumes.

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

Tigercat H822 Harvester

Safety 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.

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

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

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

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

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

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

•

If these are found, Do Not Touch!!!

•

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

•

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

•

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

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

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

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

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

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

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

WARNING

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.

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.

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

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

1.7

Tigercat H822 Harvester

Safety

GENERAL SAFETY PRECAUTIONS continued

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

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

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

Wash hands after handling.

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

To avoid backover accidents:

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

• •

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

•

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

•

Do not short out battery terminals for any reason.

Serious burns or an explosion can result.

•

CAUTION

•

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

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

•

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

Keep reverse* warning alarm in working condition.

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

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

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

Keep windows, mirrors and lights in good condition.

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

1.8

Tigercat H822 Harvester

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

OPERATING SAFETY PRECAUTIONS

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

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

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

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

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

Sound the machine horn before starting the machine.

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

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

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

ALWAYS shut OFF engine before using the escape hatch exit.

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

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

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

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

WARNING

1.9

Tigercat H822 Harvester

Safety Secure loose items in the cab.

OPERATING SAFETY PRECAUTIONS continued

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

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

SWITCH

ACTUATOR ON DOOR

••

••

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

Harvesting should only be performed from the operator's seat.

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

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

822-D02

INTERLOCK SWITCH (FRONT DOOR)

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

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

Close the front door and press the PILOT RESET switch.

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

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

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

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

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

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

Use only prearranged and approved signalling practices.

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

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

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

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

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

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

1.10

Tigercat H822 Harvester

Safety

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

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

NEVER travel across a STEEP slope or side hill: •

As a load is added to the attachment the handling and the stability of the machine will change.

•

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

•

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

•

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

1.11

Tigercat H822 Harvester

Safety

OPERATING SAFETY PRECAUTIONS continued HARVESTING ATTACHMENT – GENERAL SAFETY: Improper operation, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any maintenance or repair of this product until you have read and understood the operation and repair information contained in the manuals provided by the attachment manufacturer.

The following are general safety guidelines for harvesting attachments. Note the design, operation, and maintenance of attachments varies among manufacturers. Always follow the specific safety, maintenance, and operating procedures provided by the attachment manufacturer.

The operator of the carrier and harvesting head must be properly trained in the operation of the equipment and its safety requirements.

PRIOR TO STARTING OPERATION:

•

Ensure no one is near the machine where the risk of personal injury is present.

•

Ensure no one is in the line of the chain saw when starting or operating the harvesting head. The hydraulically driven saw chain reaches high speeds and is an extreme hazard if the chain breaks.

•

•

•

•

Never fell trees when there are personnel on the ground within the 150 metres (500 ft) “hazard zone.”

•

During operation do not allow anyone within the hazard zone of at least 150 metres(500 ft) from the machine.

•

Never fell trees in the direction of the operator’s cab.

•

Do not process trees with the saw guide (bar) aligned with the operator’s cab. The hydraulically driven saw chain reaches high speeds and is an extreme hazard if the chain breaks.

SERVICING AND REPAIR: Before beginning any service work on the harvesting head, place the machine on level ground, place the attachment on the ground and properly support the boom, refer to PARKING BOOM in THIS SECTION. Stop the machine engine and turn the battery disconnect switch to the OFF position. Install any safety chains or locking parts required by the attachment manufacturer. Ensure that any accumulators on the attachment are completely relieved of hydraulic pressure. Always follow the specific safety, maintenance, and operating procedures provided by the attachment manufacturer.

•

Regularly inspect, check and maintain the saw guide (bar), the saw chain and sprocket, ensuring that all components are secure and not damaged as detailed in the harvesting attachment operator’s manual.

Never place any part of your body between the roll arms or delimbing arms. This area is a crush zone. Keep clear to avoid personal injury or death.

•

Ensure that all safety equipment upgrades available from the attachment manufacturer have been installed.

Never place any part of your body near the rolls. Avoid the risk of entanglement in moving parts. Keep clear to avoid personal injury or death.

•

Never place any part of your body in front of the saw guide (bar). Avoid the risk of dismemberment. Keep clear to avoid personal injury or death.

•

When working in the area of the roll arms, delimbing arms, or rolls and when changing the saw guide (bar) or saw chain the machine must be completely shut down, with the battery disconnect switch to the OFF position.

•

Do not change the pressure settings of any hydraulic valves or make structural modifications to the harvesting head without obtaining authorized instructions from the attachment manufacturer.

Before starting each shift the operator must test ALL functions of the carrier and attachment to ensure that they are in proper working order.

OPERATION: Felling trees with the harvester is very dangerous and should be done only by properly trained and experienced operators.

•

Always fell trees in the direction that they are leaning.

•

Never fell trees close to overhead power lines, vehicles, houses, roads/pathways, etc.

1.12

Tigercat H822 Harvester

Safety

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

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

Stop the attachment before leaving the harvesting area.

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

Before leaving operator's cab, lower the felling attachment onto the ground.

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

When parking the machine: •

Park on level ground only and engage the swing brake.

•

Do not park on a hillside or incline.

•

Lower attachment onto level ground.

•

Stop the engine.

•

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

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.

1.13

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

Tigercat H822 Harvester

Safety Prior to welding on any part of the machine, it should be cleaned and a fire extinguisher should be made available at the welding location.

SERVICING SAFETY PRECAUTIONS

Care must be taken in attaching the welding machine grounding clamp so current does not pass through bearings, especially the swing bearing.

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

This machine is equipped with sensitive electronic control equipment, prior to welding:DISCONNECT THE MULTI-PIN PLUG FROM THE ENGINE ANTI-STALL CONTROLLER

Conduct maintenance inspections at least as frequently as recommended in section 3 of the OPERATOR'S MANUAL. When servicing or repairing equipment, shut the engine down. Turn Battery Disconnect switch OFF.

••

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

822-D03 ENGINE ANT-STALL DISCONNECT Disconnect the multi-pin plug from the engine anti-stall controller located on the rear inside wall of the cab.

DISCONNECT THE TWO MULTI-PIN PLUGS FROM THE ENGINE CPU

••

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

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

QSC AND QSL9 ENGINES ONLY 830-D38

1.14

ENGINE CPU DISCONNECT - LEFT SIDE OF ENGINE

Tigercat H822 Harvester

Safety

SERVICING SAFETY PRECAUTIONS continued

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

DISCONNECT THE TWO MULTI-PIN PLUGS FROM THE ENGINE CPU

•

Never use your bare hand to check for fluid leaks.

Fluid leaks under pressure may not be visible.

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

Wear safety goggles for eye protection.

QSC AND QSL9 ENGINES ONLY

ENGINE CPU DISCONNECT - LEFT SIDE OF ENGINE Disconnect the engine CPU (Central Processing Unit) by unplugging the two multi-pin connectors from the left side of the engine. (Applicable on QSC or QSL9 engines only).

830-D39

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

Pressure can be maintained in a hydraulic system long after the power source and pump have been shut down. Lower the attachment to the ground, stop engine and relieve trapped pressure before performing work on components, or disconnecting any hoses. Refer to PARKING BOOM diagram (fig.5). Accumulators will self drain within 2 minutes of stopping the engine on the H822 MODEL. Also, for earlier machines (822H0123, 82230191 TO 82230349) equipped with pressurized hydraulic tanks, relieve pressure in the hydraulic reservoir by opening hydraulic tank vent valve and waiting until the sound of escaping air stops.

••

APPLIES ONLY TO MACHINES WITH IQAN CONTROL SYSTEM 830-D36

IQAN DISPLAY DISCONNECT

ENGINE ANTI-STALL DISCONNECT PLUG

•• DISCONNECT THE 42 PIN PLUG FROM THE XP MODULE

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

HOIST CYLINDER FULLY COLLAPSED HEAD

IQAN XP MODULE DISCONNECT

••

ROTATOR

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

••

•• TIP OF STICK BOOM FULLY SUPPORTED

LH830-04

1.15

PARKING BOOM FIG.5

NOTE: FULLY RETRACT TELESCOPIC STICK BOOM IF EQUIPPED

Tigercat H822 Harvester

Safety

SERVICING SAFETY PRECAUTIONS continued

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

MACHINE MODELS EQUIPPED WITH AN ER BOOM SYSTEM Pay attention to the following when servicing the ER Boom System: Certain hydraulic circuits on this machine are inter-connected in order to provide level head travel and to recirculate hydraulic oil to reduce heat generation and fuel consumption. As a result, disconnecting hydraulic lines from one cylinder may release pressure in a different cylinder at the same time. Before attempting to disconnect hydraulic hoses or perform work on the boom system, ensure that:-

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

Shut off engine. Only remove coolant filler cap when cool enough to touch with bare hands.

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

(a) The machine is parked on level ground with the head laying flat on the ground. (b) The hoist cylinder fully collapsed. (fig. 5) c) The telescopic boom fully retracted (if equipped) and the tip of the stick boom supported at the rotator pin.

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

Do NOT rely on the harvester attachment to support the boom system during servicing.

Slow leakage in the hydraulic components can cause the attachment to move unexpectedly.

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

HOIST CYLINDER FULLY COLLAPSED HEAD

•

ROTATOR

••

•• TIP OF STICK BOOM FULLY SUPPORTED

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

LH830-04

PARKING BOOM FIG.5

NOTE: FULLY RETRACT TELESCOPIC STICK BOOM IF EQUIPPED

MACHINE MODELS EQUIPPED WITH A TELESCOPIC BOOM SYSTEM On machines equipped with a telescopic stick boom ensure that the telescopic section is fully retracted when parking the boom system as shown in fig.5.

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.

1.16

Tigercat H822 Harvester

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

SERVICING SAFETY PRECAUTIONS continued

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

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

•

Do not use the boom to service other equipment.

•

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

•

Do not modify the boom system.

•

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

•

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

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

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

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

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

Dispose of fluids properly.

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

WARNING Always follow attachment manufacturer's instructions and safety warnings before approaching attachment head to make adjustments.

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

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

WARNING

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

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

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

1.17

Tigercat H822 Harvester

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

FIRE PREVENTION

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

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

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

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.

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

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

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

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

Refer to CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR in SECTION 2 of the OPERATOR’S MANUAL. 4. Blow off all debris and dust accumulated near hot engine exhaust components (turbocharger and exhaust manifold as well as exhaust pipes and muffler) at the completion of each work shift or more frequently depending on logging conditions. Visual inspection after blow off to ensure thorough cleanliness is vital.

Engine exhaust systems provide numerous small pockets where saw dust, small wood chips and other flammable forest debris can gather. Even small accumulations close to hot exhaust components can ignite and smolder. If dislodged by vibration this smoldering debris 1.18

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

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

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

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

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

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

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

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

Tigercat H822 Harvester

Safety WHAT TO DO IN CASE OF A MACHINE FIRE

FIRE PREVENTION continued 16. Before starting repair work, such as welding, the surrounding area should be cleaned and a fire extinguisher should be close by.

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

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

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

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

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

•

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

•

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

•

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

•

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

•

•

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

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

•

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

•

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

•

Shut the engine off.

•

Activate the fire suppression system*

•

Radio or call for help (as appropriate).

•

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

•

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

•

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

•

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

•

Use the PASS method with most extinguishers.

•

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

•

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

•

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

•

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

Continued on page 20

Prevent the fire from happening by ensuring that the machine is cleaned regularly and all systems are well maintained. *NOTE: Dry chemical fire suppression systems are offered by Tigercat as an optional installation on some of the Tigercat product lines. Please disregard any references made to fire suppression systems if not installed on your machine.

1.19

Tigercat H822 Harvester

Safety WHAT TO DO AFTER A FIRE

FIRE PREVENTION continued Continued from page 19

20229A

TYPICAL FIRE EXTINGUISHER ACCESS HOLE

•

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

•

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

•

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

•

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

•

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

1.20

•

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

•

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

•

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

•

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

Tigercat H822 Harvester SECTION 2 - CONTROLS & OPERATION SEPTEMBER 2004

CONTENTS - SECTION 2 AIR CONDITIONER/HEATER CONTROLS ..............................................................

AIR INTAKE CLEAN-OUT COVER PLATE ..............................................................

AIR INTAKE SEAL ....................................................................................................

AM/FM STEREO CASSETTE ...................................................................................

ATTACHMENT OPERATING INSTRUCTIONS ........................................................

AUXILIARY POWER OUTLET ..................................................................................

2.21 2.43 2.43 2.30 2.58 2.23

BATTERY DISCONNECT - SWITCH ........................................................................ 2.36 BOOM CONTROLS ATTACHMENT, ROTATE ........................................................................................ 2.4 BOOM, FORWARD/BACK ...................................................................................... 2.4 BOOM, UP/DOWN .................................................................................................. 2.4 BREATHER/VENT, HYDRAULIC TANK ................................................................... 2.38 CARE OF THE MACHINE ......................................................................................... 2.59 CIGARETTE LIGHTER .............................................................................................. 2.23 CIRCUIT BREAKERS AND FUSES ............................................................................ 2.6 CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR EARLY MACHINE 822H0123 ............................................................................... 2.44 LATER MACHINES 82230191 TO 82230999 ...................................................... 2.46 CLEANING LEXAN WINDOWS ................................................................................ 2.59 CONTROL PANEL .................................................................................................... 2.18 COOLING ASSEMBLY - CLEANING EARLY MACHINE 822H0123 ............................................................................... 2.44 LATER MACHINES 82230191 TO 82230999 ...................................................... 2.46 COOLING FAN - SWITCH ........................................................................................ 2.23 EMERGENCY EXITS ESCAPE HATCH ...................................................................................................

ESCAPE HATCH REMOVAL/REPLACEMENT ....................................................

MAINTENANCE GUIDE ........................................................................................

SIDE DOOR ...........................................................................................................

ENGINE AIR CLEANER ............................................................................................

FILTER RESTRICTION INDICATOR ....................................................................

ENGINE AIR CLEANER UNLOADER VALVE ..........................................................

ENGINE AIR PRECLEANER ....................................................................................

ENGINE ANTI-STALL - SWITCH WITH LIGHT .......................................................

ENGINE COLD START SWITCH (SISU) ..................................................................

ENGINE HOT WATER SHUT OFF VALVES ............................................................

ENGINE RPM ............................................................................................................

ENGINE SHUTDOWN OVERRIDE - SWITCH (SISU) .............................................

ENGINE, STARTING CUMMINS ..............................................................................................................

SISU .......................................................................................................................

ENGINE, STARTING, COLD WEATHER CUMMINS ..............................................................................................................

SISU .......................................................................................................................

FELLING HEAD OPERATING INSTRUCTIONS SAFETY PRECAUTIONS ......................................................................................

FILTER, FRESH AIR - A/C UNIT ..............................................................................

FILTER, HIGH PRESSURE, PILOT SYSTEM ..........................................................

FILTER, RE-CIRCULATING AIR - A/C UNIT ............................................................

FILTERS, HYDRAULIC OIL ......................................................................................

FIRE SUPPRESSION SYSTEM (OPTIONAL) AUTOMATIC OPERATION ...................................................................................

AVOIDING DAMAGE AND FALSE DISCHARGES DURING MACH ...................

COMPONENT LOCATIONS ..................................................................................

DISCHARGE OF THE SYSTEM ...........................................................................

IN CASE OF FIRE .................................................................................................

INSPECTION OF FIRE SUPPRESSION SYSTEM ..............................................

MANUAL OPERATION ..........................................................................................

2.30 2.32 2.32 2.30 2.42 2.42 2.42 2.42 2.18 2.19 2.28 2.19 2.19 2.52 2.54 2.54 2.55 2.58 2.28 2.40 2.28 2.40 2.24 2.27 2.26 2.25 2.25 2.26 2.24

Tigercat H822 Harvester

Controls and operation

FOOT PEDALS, LEFT AND RIGHT TRACK DRIVE .................................................. 2.5 FUEL COOLER ......................................................................................................... 2.38 FUEL SHUT-OFF VALVE .......................................................................................... 2.36 FUEL TANK ............................................................................................................... 2.36 CAPACITY ............................................................................................................. 2.36 FUSES AND CIRCUIT BREAKERS ............................................................................ 2.6 GRAFFITI REMOVAL ................................................................................................ 2.59 HAND FILL PUMP, HYDRAULIC OIL .......................................................................

FILLING HYDRAULIC TANK .................................................................................

HORN, SAFETY ALERT - SWITCH ..........................................................................

HOT WATER SHUT OFF VALVES (ENGINE) .........................................................

HYDRAULIC OIL FILTERS .......................................................................................

HYDRAULIC OIL LEVEL SIGHT GAUGES ..............................................................

HYDRAULIC OIL TANK ............................................................................................

2.41 2.41 2.22 2.28 2.40 2.39 2.38

IGNITION KEY SWITCH ........................................................................................... 2.19 INSTRUCTIONS, VEHICLE MOVING ............................................................... 2.1, 2.60 INSTRUMENT PANEL EARLIER MACHINE 822H0123 .............................................................................. 2.8 BULB TEST SWITCH ......................................................................................... 2.11 COOLANT LOW - WARNING LIGHTAND HORN ............................................ 2.10 DIMMER CONTROL, INSTRUMENT PANEL .................................................... 2.11 ENGINE COOLANT TEMPERATURE - GAUGE AND HORN ............................ 2.9 ENGINE OIL PRESSURE - GAUGE ................................................................... 2.8 ENGINE POWER DOOR - SWITCH .................................................................. 2.8 FILTER BYPASS, HYD. OIL - WARNING LIGHT .............................................. 2.11 FUEL LEVEL - GAUGE ....................................................................................... 2.9 HOUR METER ..................................................................................................... 2.8 HYDRAULIC OIL LOW - LIGHT AND HORN .................................................... 2.10 HYDRAULIC OIL TEMPERATURE GAUGE AND HORN ................................. 2.10 LIGHTS, SERVICE - SWITCH ............................................................................ 2.8 LIGHTS, WORK - SWITCH ................................................................................ 2.11 PILOT SYSTEM "OFF" LIGHT ........................................................................... 2.11 PILOT SYSTEM "ON" LIGHT ............................................................................. 2.11 POWER ENGINE DOOR - SWITCH .................................................................. 2.8 SAW "ON" LIGHT ............................................................................................... 2.11 TACHOMETER .................................................................................................... 2.9 VOLTMETER ....................................................................................................... 2.9 LATER MACHINES 82230191 TO 82230999 ...................................................... 2.12 BULB TEST SWITCH ........................................................................................ 2.16 COOLANT LOW - WARNING LIGHTAND HORN ............................................ 2.15 DIMMER CONTROL, INSTRUMENT PANEL ................................................... 2.16 ENGINE COMPUTER FAULT CODE LIGHTS .................................................. 2.16 ENGINE COOLANT TEMPERATURE - GAUGE AND HORN .......................... 2.13 ENGINE DIAGNOSTICS CONNECTION .......................................................... 2.17 ENGINE DISPLAY AND DIAGNOSTICS MODULE (MDDM) ........................... 2.12 ENGINE OIL PRESSURE - GAUGE ................................................................. 2.13 ENGINE POWER DOOR - SWITCH ................................................................ 2.12 FILTER BYPASS, HYD. OIL - WARNING LIGHT ............................................. 2.15 FUEL LEVEL - GAUGE ..................................................................................... 2.14 HYDRAULIC OIL LOW - LIGHT AND HORN .................................................... 2.15 HYDRAULIC OIL TEMPERATURE GAUGE AND HORN ................................. 2.14 LIGHTS, SERVICE - SWITCH .......................................................................... 2.12 LIGHTS, WORK - SWITCH ............................................................................... 2.16 PILOT SYSTEM "OFF" LIGHT .......................................................................... 2.16 PILOT SYSTEM "ON" LIGHT ............................................................................ 2.16 POWER ENGINE DOOR - SWITCH ................................................................ 2.12 SAW "ON" LIGHT .............................................................................................. 2.15 STOP ENGINE - WARNING LIGHT .................................................................. 2.16 TACHOMETER .................................................................................................. 2.14 VOLTMETER ..................................................................................................... 2.14 WAIT TO START - WARNING LIGHT ............................................................... 2.17

2.2

Tigercat H822 Harvester

Controls and operation

WARNING - WARNING LIGHT ......................................................................... 2.16 WATER IN FUEL - WARNING LIGHT ............................................................... 2.17 INTERIOR LIGHTS .................................................................................................... 2.30 IQAN CONTROL SYSTEM .......................................................................................... 2.7 JOYSTICKS, LEFT AND RIGHT HAND ...................................................................... 2.4 JUMPER BAR CABLE CONNECTION ..................................................................... 2.36 KEY SWITCH ............................................................................................................ 2.19 LIGHTS, INTERIOR ................................................................................................... 2.30 LIGHTS, SERVICE EARLIER MACHINE 822H0123 .............................................................................. 2.8 LATER MACHINES 82230191 TO 82230999 ...................................................... 2.12 LIGHTS, WORKING ........................................................................................ 2.11, 2.16 MACHINE PREPARATION SYSTEM TEST AND WARM-UP .......................................................................... 2.57 MOVING, INSTRUCTIONS ............................................................................... 2.1, 2.60 OPERATING MACHINE ............................................................................................

PRE-START CHECKS ..........................................................................................

STARTING ENGINE CUMMINS ..........................................................................................................

SISU ...................................................................................................................

SYSTEM TEST AND WARM-UP ..........................................................................

OPERATING TIPS WITH LOAD SENSING ..............................................................

OPERATOR’S SEAT (SEATS INC.) ........................................................................

2.48 2.48 2.52 2.54 2.57 2.58 2.34

PILOT SYSTEM INTERLOCK SWITCH (FRONT DOOR) .......................................

PILOT SYSTEM "OFF "- PUSH BUTTON SWITCH .................................................

PILOT SYSTEM RESET - PUSH BUTTON SWITCH ...............................................

POWER ENGINE DOOR - SWITCH ................................................................ 2.8, POWER DOOR LATCH ................................................................................ 2.9, PRECLEANER, ENGINE AIR ...................................................................................

2.21 2.21 2.21 2.12 2.13 2.42

RETURN FILTERS ~ HYDRAULIC OIL .................................................................... 2.40 SAW - SWITCH ......................................................................................................... 2.22 SEAT, OPERATOR'S (SEATS INC.) ....................................................................... 2.34 SERVICE LIGHTS ............................................................................................. 2.8, 2.12 STARTING ENGINE CUMMINS .............................................................................................................. 2.52 SISU ....................................................................................................................... 2.54 STEREO CASSETTE AM/FM RADIO ....................................................................... 2.30 STOPPING ENGINE ................................................................................................. 2.59 SWING BRAKE - SWITCH WITH LIGHT ................................................................. 2.18 SWING CONTROL, JOYSTICK .................................................................................. 2.4 SYSTEM CIRCUIT BREAKERS AND FUSES ............................................................ 2.6 THROTTLE SWITCH CUMMINS .............................................................................................................. 2.20 SISU ....................................................................................................................... 2.19 TRACK DRIVE, LEFT AND RIGHT ............................................................................. 2.5 TRACK, LOW/DRIVE - SWITCH WITH LIGHT ........................................................ 2.22 TRAVELLING (BOOM RAISED) ............................................................................... 2.58 VEHICLE MOVING INSTRUCTIONS ........................................................................ 2.60 VENT/BREATHER, HYDRAULIC TANK ................................................................... 2.38 WINDOWS - CLEANING .......................................................................................... 2.59

2.3

Tigercat H822 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.

CONTROLS - CAB 1 2

•

••

H822-02

H822-01

FOOT PEDAL

FOOT PEDAL

22765A R0

22763A R0

1. L.H. JOYSTICK CONTROL LEVER

2. R.H. JOYSTICK CONTROL LEVER

Boom, Forward/Back Move the joystick back to move the boom IN toward the machine.

Boom , Up/Down Move the joystick back to RAISE the boom.

Move the joystick forward to LOWER the boom.

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

Attachment, Rotate Move the joystick right to rotate the attachment clockwise.

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

Move the joystick left to rotate the attachment counterclockwise.

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

Thumb switch Press and hold the right side of the momentary switch to move the telescopic boom IN.

Thumb switch No factory equipped function.

Press and hold the left side of the momentary switch to move the telescopic boom OUT. 2.4

Tigercat H822 Harvester

Controls and operation

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

Depress the foot pedal with the heel to drive backward.

4

•

3

••

FOOT PEDALS 4. LEFT FOOT PEDAL - LEFT TRACK DRIVE 822-D06

Depress the foot pedal with the toe to drive forward.

Depress the foot pedal with the heel to drive backward.

NOTE: Use these drive pedals in conjunction with the TRACK LOW/DRIVE control switch.

See THIS SECTION. Travelling Travel is accomplished by depressing both foot pedals simultaneously. Travel over distances should be done in the forward direction to reduce the wear on track components. Track drive gearboxes are considered to be at the rear of the machine. NOTE: Track component life is severely reduced by driving the machine backwards.

2.5

Tigercat H822 Harvester

Controls and operation

5. SYSTEM CIRCUIT BREAKERS AND FUSES EARLIER MACHINE (822H0123) WITH SISU ENGINE Each major circuit on the vehicle is protected against current overload by a circuit breaker.

The circuit breakers on this machine are arranged on two separate panels. The breakers on the smaller panel numbered 1 to 8 protect all of the external work and service lights, the power door and the cold start circuit.

The breakers on the larger panel numbered 9 to 24 protect the rest of the machine operating circuits. A 2 amp fuse located at the top of the panel protects the engine anti-stall circuit.

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

There is also a 2 x 12 gauge fusible link that is "in-line". The 2 x 12 gauge fusible link protects the engine fuel PULL and HOLD solenoids and also the power cover door motor circuit.

822-D07

SYSTEM CIRCUIT BREAKERS

2 AMP FUSE

•

IQAN FUSES BEHIND THIS COVER

•• LH830-03

FUSES LATER MACHINES

LATER MACHINES (82230191 TO 82230999) Each major circuit on the vehicle is protected against current overload by a circuit breaker or fuse. The main circuit breakers and fuses on this machine are arranged on two separate panels. The breakers on the smaller panel numbered 1 to 8 protect all of the external work and service lights, the power door and the cold start circuit. The fuses on the larger panel protect the rest of the machine circuits.

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

830-D01

SYSTEM CIRCUIT BREAKERS EARLIER MACHINE (822H0123) 2.6

Tigercat H822 Harvester

Controls and operation The three 60 amp fuses are ahead of the system fuses (or circuit breakers) in terms of their location within the circuit and are there to prevent major damage to the electrical systems of the machine in the event of a short circuit in any of the three main battery feed lines.

BATTERIES

2X12 GAUGE FUSIBLE LINK CONNECTIONS

••

FUSIBLE LINKS LATER CUMMINS ENGINE

LH830-26

••

There are also three 2 x 12 gauge fusible links that are "in-line". One 2 x 12 gauge fusible link protects the power cover door motor circuit.

Two others are used for the engine grid heater relays.

ENGINE DIAGNOSTICS CONNECTION BEHIND COVER

APPLIES ONLY TO MACHINES WITH IQAN CONTROL SYSTEM 830-D36

IQAN DISPLAY

•• LH830-05

INSTRUMENT PANEL LATER MACHINES

The engine computer fuses and the engine diagnostics plug are located behind a cover on the left side of the instrument panel. Refer also to ENGINE DIAGNOSTICS CONNECTION in THIS SECTION.

IQAN XP MODULE 6. IQAN CONTROL SYSTEM 830-D37

ALL MACHINES IQAN fuses are located directly below the large fuse (or breaker) panel located in the rear of the cab.

The IQAN control system controls the telescopic boom function. The IQAN display is used by a qualified service technician to adjust the these functions. Do NOT attempt to adjust the IQAN programming without proper training.

822-D10

•• • • •

APPLIES ONLY TO MACHINES WITH IQAN CONTROL SYSTEM

ENGINE BELL HOUSING THREE 60 AMP FUSES

822-D09

MAIN SYSTEM FUSES, ENGINE COMP. There are also three 60 amp fuses that are "inline".

2.7

Tigercat H822 Harvester

Controls and operation POWER DOOR LATCH

•• • ••

1

••

2

RIGHT SIDE ACCESS DOOR OPEN 822-D19

••

enclosure must be open to unlatch power door before opening/closing power door. The power engine door is equipped with a motion alarm.

4

•

2. SERVICE LIGHTS - SWITCH This is a two position switch labelled ON - OFF. Use to turn ON the three service lights located in the engine compartment, pump area and valve area.

5

9

••

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

8

6

•

5. PUMP DRIVE GEARBOX OIL TEMP. GAUGE Not used for this machine configuration.

•

6. ENGINE OIL PRESSURE - GAUGE

7

The oil pressure should be greatest after starting a cold engine. Check oil pressure as soon as engine starts. If gauge does not rise above the minimum oil pressure of 20 psi. within 5 seconds, stop engine and determine cause. Engine should normally operate between 40 and 70 psi. when the engine is running at rated speed and operating temperature. If the gauge registers less than the above range with engine running at full throttle, check the engine oil level. With engine at IDLE, the gauge should read a minimum of 20 psi.

••

•• 10

• 822-D59

POWER DOOR LATCH

INSTRUMENT PANEL EARLIER MACHINE

INSTRUMENT PANEL EARLIER MACHINE (822H0123) 1. POWER ENGINE DOOR - SWITCH This is a three position "momentary" switch labelled OPEN - CLOSE, spring return to center OFF position. Push and hold switch in OPEN position to OPEN door or push and hold in CLOSE position to CLOSE door. NOTE: Engine access door on right side of engine

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

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

CAUTION Watch for personnel in area of power door before opening door 2.8

Tigercat H822 Harvester

Controls and operation 7.

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

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

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8. FUEL LEVEL - GAUGE Capacity when full:Standard fuel tank; 378 L/100 gal (US) High capacity fuel tank; 492 L/130 gal (US)

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

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

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A reading of less than 12 Volts indicates a possible faulty battery, alternator or accessory drive belt failure.

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10. TACHOMETER This meter indicates the engine speed.

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Refer to THROTTLE SWITCH in THIS SECTION for engine speeds.

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• 822-D59

ENGINE COOLANT TEMPERATURE - GAUGE, WARNING LIGHT AND HORN

INSTRUMENT PANEL EARLIER MACHINE

2.9

Tigercat H822 Harvester

10

Controls and operation

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Malfunction of engine Anti-Stall system

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Low hydraulic oil level in reservoir

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

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12. COOLANT LOW - WARNING LIGHT This light will come ON when the coolant level drops below a safe operating level. The sensor (proximity switch) is located in the surge tank.

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

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Malfunction of hydraulic fan drive system

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

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WARNING

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

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13. HYDRAULIC OIL LOW - LIGHT AND HORN

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

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

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

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Malfunction in a hydraulic circuit 2.10

This light will come ON when the oil level falls 10 gal. US (38L) below the FULL mark. The light will stay on and a HORN will sound when the oil level falls 18 gal. US (68L) below the FULL mark. When the light first comes on stop engine and look for signs of broken hoses or other leaks. Repair leaks and refill the tank to FULL mark on the sight gauge. Restart engine and inspect for leaks. When the horn sounds stop the engine immediately. Operating machine with low hydraulic oil can cause hydraulic pumps to fail.

Tigercat H822 Harvester

Controls and operation due to the pilot system not being reset, this will be indicated by the pilot off light being ON. In this case press the PILOT RESET switch* and turn the saw switch OFF and then ON.

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Note: On Harvester Model Machines this saw light indicates power is being supplied to the attachment's control systems.

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18. PILOT "OFF" LIGHT (AMBER) This light comes ON when the pilot system has been de-activated*.

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19. PILOT "ON" LIGHT (GREEN) This light comes ON when the pilot system is activated by the pilot reset switch*.

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*When the ignition key switch is in the RUN position, either the PILOT OFF or the PILOT ON will be lit. If neither are lit then the state of the SAFETY INTERLOCK SYSTEM is unknown and should be checked out immediately.

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

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

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20. BULB TEST SWITCH

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This is a two position "momentary" switch.

Press and hold this switch in the ON position to test the bulbs in the 4 warning lights; Items 11,12, 13 and 14. Replace the bulb in any light that does not come ON. If the light does not come ON after inserting a new bulb, check the fuse or circuit breaker. Bulbs should be tested at the start of each shift.

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• 830-D07

INSTRUMENT PANEL EARLIER MACHINE

14. FILTER BYPASS - WARNING LIGHT

21. WORK LIGHTS - SWITCH

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

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

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

22. DIMMER CONTROL

17. SAW "ON" LIGHT This light is ON when the saw system is activated. It comes ON when the saw switch is turned to the ON position. It is possible that the light will not be on even though the saw switch is in the ON position 2.11

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

Tigercat H822 Harvester

Controls and operation POWER DOOR LATCH

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RIGHT SIDE ACCESS DOOR OPEN

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POWER DOOR LATCH

822-D19

2. SERVICE LIGHTS - SWITCH

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

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PUMP DRIVE GEARBOX OIL TEMP. - GAUGE Not used for this machine configuration.

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ALARM (LED) AMBER

•• DATA, LCD

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SHUTDOWN (LED) RED

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SCROLL UP

•• LH830-30

LH830-05

INSTRUMENT PANEL LATER MACHINES

14

SCROLL DOWN

ENGINE DIAGNOSTICS MODULE

5. ENGINE DISPLAY AND DIAGNOSTICS MODULE (MDDM) This is a multifunction display and fault warning module that enables the operator to view many different engine parameters and engine codes. The module includes a two line eight character backlit LCD, displaying data in either imperial or metric units.

INSTRUMENT PANEL LATER MACHINES (82230191 TO 82230999) 1. POWER ENGINE DOOR - SWITCH This is a three position "momentary" switch labelled OPEN - CLOSE, spring return to center OFF position. Push and hold switch in OPEN position to OPEN door or push and hold in CLOSE position to CLOSE door. NOTE: Engine access door on right side of engine enclosure must be open to unlatch power door before opening/closing power door. The power engine door is equipped with a motion alarm.

Two push button switches (UP and DOWN) are used to scroll through the parameter list or main menu (see below). Two LEDs (amber and red) are used to draw attention to active fault messages received by the module.

To read any of the engine parameters press either the UP or DOWN arrows until the display shows the desired information.

ACTIVE ENGINE SERVICE CODES

CAUTION

When a fault occurs the display will show the message "SrvcCode" every five seconds interrupting the currently displayed parameter.

Watch for personnel in area of power door before opening door 2.12

Tigercat H822 Harvester

Controls and operation explanation of this module and how it should be used.

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The following are some of the engine parameters displayed: 1. Engine hours 2. Engine RPM 3. System voltage 4. % engine load at current RPM 5. Coolant temperature 6. Engine oil pressure 7. Fuel economy 8. Throttle position (N/A) 9. Manifold air temperature 10. Current fuel consumption 11. Active service codes 12. Stored service codes from engine 13. Set Imperial/Metric Units 14. View engine configuration parameters

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6. ENGINE OIL PRESSURE - GAUGE

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This gauge displays information transmitted by the MDDM diagnostics module in the traditional analog format.

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The engine oil pressure should be greatest after starting a cold engine. Check oil pressure as soon as engine starts. If gauge does not rise above minimum oil pressure of 15 psi within 5 seconds, stop engine and determine cause.

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•• LH830-05

When the engine is running at full load rated speed, using SAE 10W30 oil and engine oil at normal operating temperature, the normal operating oil pressure should be between 40 and 70 psi. If the oil pressure gauge registers less than stated above at high idle, check the engine oil level. If pressure drops below 15 psi., shut the machine down immediately.

INSTRUMENT PANEL LATER MACHINES

In addition the amber LED will start to flash during active service code faults and the red LED will be ON during shut-down faults. These warnings will continue until the fault is corrected.

7. ENGINE COOLANT TEMPERATURE - GAUGE

To view the active service codes, select the service code sub-menu by pressing the UP or DOWN arrows until the display shows the message "SrvcCode". Press BOTH the UP and DOWN arrows SIMULTANEOUSLY to access the sub-menu. If the service codes are not available, the display will show the message "SrvcCode - No Code".

A list of "SPN(S)" FAULT CODES for the Cummins engines are enclosed with the machine document package.

Also refer to the enclosed MURPHY OPERATION MANUAL for a more detailed 2.13

This gauge displays information transmitted by the MDDM diagnostics module in the traditional analog format displaying the current engine coolant temperature.

Gauge should normally indicate between 84°C - 91°C (183°F - 196°F). If temperature rises beyond 100°C (212°F), reduce load on engine and check for plugged radiator, oil cooler or A/ C condenser. Unless temperature drops quickly, stop engine and determine cause. Do not continue to operate machine above recommended temperatures.

Tigercat H822 Harvester

Controls and operation 10. TACHOMETER This gauge displays information transmitted by the MDDM diagnostics module in the traditional analog format.

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This meter indicates the engine speed.

Refer to THROTTLE SWITCH in THIS SECTION for engine speeds.

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11. HYDRAULIC OIL TEMPERATURE - GAUGE, WARNING LIGHT AND HORN

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Displays the current hydraulic oil temperature registered in the hydraulic reservoir.

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

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

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Malfunction in a hydraulic circuit

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Malfunction of hydraulic fan drive system

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Malfunction of engine Anti-Stall system

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Low hydraulic oil level in reservoir

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• LH830-05

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

INSTRUMENT PANEL LATER MACHINES

8. FUEL LEVEL - GAUGE Capacity when full:Standard fuel tank; 378 L/100 gal (US) High capacity fuel tank; 492 L/130 gal (US)

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

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

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

A reading of less than 12 Volts indicates a possible faulty battery, alternator or accessory drive belt failure.

2.14

Tigercat H822 Harvester

Controls and operation 13. HYDRAULIC OIL LOW - LIGHT AND HORN

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This light will come ON when the oil level falls 10 gal. US (38L) below the FULL mark. The light will stay on and a HORN will sound when the oil level falls 18 gal. US (68L) below the FULL mark. When the light first comes on stop engine and look for signs of broken hoses or other leaks. Repair leaks and refill the tank to FULL mark on the sight gauge.

Restart engine and inspect for leaks. When the horn sounds stop the engine immediately. Operating machine with low hydraulic oil can cause hydraulic pumps to fail.

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

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

17. SAW "ON" LIGHT

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This light is ON when the saw system is activated. It comes ON when the saw switch is turned to the ON position. It is possible that the light will not be on even though the saw switch is in the ON position due to the pilot system not being reset, this will be indicated by the pilot off light being ON. In this case press the PILOT RESET switch* and turn the saw switch OFF and then ON.

•• 830-D07

INSTRUMENT PANEL LATER MACHINES

12. COOLANT LOW - WARNING LIGHT This light will come ON and when the coolant level drops below a safe operating level. The sensor (proximity switch) is located in the surge tank.

Note: On Harvester Model Machines this saw light indicates power is being supplied to the attachment's control systems.

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

WARNING

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

2.15

Tigercat H822 Harvester

Controls and operation 20. BULB TEST SWITCH

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This is a two position "momentary" switch.

Press and hold this switch in the ON position to test the bulbs in the 4 warning lights; Items 11, 12, 13 and 14. Replace the bulb in any light that does not come ON. If the light does not come ON after inserting a new bulb, check the fuse or circuit breaker. Bulbs should be tested at the start of each shift.

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

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

ENGINE COMPUTER FAULT CODE LIGHTS:

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NOTE: The following items 23 to 27 are associated with the computer control system on Cummins QSL9 or QSC engines. For a more comprehensive explanation of these and other electronic control/ monitoring features, please refer to the OPERATION AND MAINTENANCE MANUAL for the Cummins ENGINE.

•• 830-D07

INSTRUMENT PANEL LATER MACHINES

18. PILOT "OFF" LIGHT (AMBER) This light comes ON when the pilot system has been de-activated*.

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

*NOTE: These warning lights will come ON when the key switch is first turned to the RUN position.

The warning lights will go OFF when the engine is running normally. The YELLOW 'WARNING' warning light will stay ON if there is a problem with the engine.

23. STOP ENGINE - *warning light When this RED warning light comes ON, the engine must be stopped as soon as it is safe to do so. It is recommended that the engine should remain shut down until the fault can be repaired.

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

24. WARNING - *warning light

WARNING

This YELLOW warning light is incorporated into the engine protection system and will come ON to indicate that there is a problem with one or more of the engine systems. To identify the fault, refer to the engine display and diagnostics module.

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

2.16

Tigercat H822 Harvester

Controls and operation 26. WATER IN FUEL - *warning light

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When this YELLOW warning light comes ON it indicates that the engine fuel/water separator needs to be drained. This task must be performed as soon as possible whenever this warning light is ON.

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27 ENGINE DIAGNOSTICS CONNECTION BEHIND COVER

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LH830-05

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27. ENGINE DIAGNOSTICS CONNECTION (BEHIND COVER ON LEFT SIDE OF INSTRUMENT PANEL) Plug a remote electronic diagnostic device into this connection such as a lap-top computer with appropriate Cummins programming to perform engine performance analysis and tuning. NOTE: This operation can only be performed by a trained service technician.

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•• 830-D07

INSTRUMENT PANEL LATER MACHINES

INSTRUMENT PANEL LATER MACHINES

The fault should be repaired at the first available opportunity, at which point the YELLOW warning light will turn OFF automatically.

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

25. WAIT TO START - *warning light This YELLOW warning light will be ON during the "key ON" engine pre-heat time. Heating elements (grid heater elements) located in the engine air intake manifold are turned ON during cold weather conditions to heat the intake air when starting the engine. The engine must not be started until this light turns OFF automatically.

2.17

Tigercat H822 Harvester 1

Controls and operation

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LH830-06

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

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

2. SWING BRAKE - SWITCH WITH LIGHT

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

IMPORTANT: It should be noted that this anti-stall system will only allow full main pump flow with the engine running at speeds above: Sisu Engine 1950 RPM Cummins QSL9 Engine 1700 RPM Cummins QSC Engine 2000 RPM If BOOM, SWING or TRACK DRIVE functions slow down or stop, check to ensure that the engine speed is above the required level listed above for your machine’s engine.

If engine stalling occurs, check: (a) The ANTI-STALL switch is in the ON position. (b) The 2 amp fuse located in the large fuse (or circuit breaker) panel in the cab. (c) Malfunction of the anti-stall system.

2.18

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

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

CAUTION • Turning ON the swing brake while the boom is moving can damage the gearbox • NEVER operate the tracks with the swing brake ON as boom contact with the ground will damage the swing gearbox

Tigercat H822 Harvester

Controls and operation

3. ENGINE SHUTDOWN OVERRIDE - SWITCH SISU ENGINE ONLY (822H0123)

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This is a two position "momentary" switch.

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

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4. COLD START SWITCH SISU ENGINE ONLY (822H0123) The SISU engine cold start system uses an intake manifold diesel fuel flame burner to preheat the intake air.

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This is a two position "momentary" switch.

With the ignition key in the RUN position, press and hold this switch DOWN to activate the cold start system. For a complete procedure, refer to STARTING IN COLD WEATHER in THIS SECTION. 822-D16

CONTROL PANEL SISU ENGINE ONLY

when the desired decrease in RPM level is reached.

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

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

Maintaining Correct Engine RPM.

5. IGNITION KEY SWITCH This is a three-position switch labelled OFF/ RUN/START.

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

OFF Position - All electrical power through the ignition switch is turned “OFF”

Sisu Engine

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

FULL ....... 2150 to 2200 RPM max. (No Load)

MINIMUM 1000 to 1200 RPM (No Load)

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

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

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

For MINIMUM engine speed press and hold the bottom of the rocker switch, release

2.19

The above values are with the hydraulic and engine oil at normal operating temperatures and no functions activated and without pilot system engaged. Check engine speed regularly with a calibrated hand tachometer.

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

Under no circumstances allow the no load minimum throttle speed to vary below the recommended minimum setting. Lower than recommended speeds will damage the pumps and drive coupling. of the If engine stalls, press the bottom throttle switch for 3 seconds to return the fuel rack to the IDLE position.

Tigercat H822 Harvester 1

Controls and operation

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CONTROL PANEL

LH830-06

6B. THROTTLE SWITCH

Cummins QSC 240 HP Engine

CUMMINS ENGINE

IDLE

900 to 950 RPM (No Load)

This is a three position "momentary" switch connected into the engine CPU circuit to adjust (IDLE) the engine RPM. between the

FULL

2200 to 2250 RPM max (No Load)

and

NOTE: At start-up the engine will always default to IDLE.

(FULL) throttle set points.

PRESS and HOLD this switch in the position to increase engine speed (rpm), release switch at desired rpm. or continue to HOLD to place engine at the correct FULL throttle setting.

PRESS and HOLD this switch in the position to decrease engine speed (rpm), release switch at desired rpm. or continue to HOLD to place engine at the correct MINIMUM throttle setting.

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

Maintaining Correct Engine RPM. It is most important that the IDLE and FULL RPMs. of the engine be correct at all times: Cummins QSL9 280 HP Engine IDLE

900 to 950 RPM (No Load)

FULL

1830 to 1850 RPM max (No Load)

RATED WORKING 2200 RPM

RATED WORKING 1800 RPM

2.20

The above values are with the hydraulic and engine oil at normal operating temperatures and no functions activated and without pilot system engaged. These values are pre-set into the engine CPU (computer) and cannot be adjusted without the proper electronic equipment programming software. Check engine speed regularly with engine diagnostics module.

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

Tigercat H822 Harvester

Controls and operation

7 8 C

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CONTROL PANEL

822-D17

7. AIR CONDITIONER/HEATER

8. PILOT SYSTEM RESET - PUSH BUTTON SWITCH

The three controls on this panel are used to adjust the heating and air conditioning temperature for operator comfort in the operator’s cab.

This is a push ON spring return switch. With the engine running and the front door closed, push this switch to activate the pilot system.

The pilot ON light will be ON and the pilot OFF light will be OFF.

A. A/C SWITCH This is a two position switch labelled ON - OFF. Placing this switch in the ON position will turn ON the A/C compressor for cooling.

NOTE: The front door must be closed to ACTIVATE the pilot system. The side door exit WILL NOT DE-ACTIVATE the pilot system when opened.

B. FAN SPEED - OFF/LOW/MED/HIGH SWITCH

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

ACTUATOR ON DOOR

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

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

822-D02

INTERLOCK SWITCH (FRONT DOOR)

9. PILOT SYSTEM OFF - PUSH BUTTON SWITCH This is a push OFF spring return switch. This switch shuts off the pilot system deactivating all operating functions as well as applying the track drive brake and swing brake. The pilot OFF light will be ON and the pilot ON light will be OFF.

Refer also to CHECKING THE AIR CONDITIONING SYSTEM in SECTION 3 of THIS MANUAL.

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

2.21

Tigercat H822 Harvester

Controls and operation

10. TRACK, LOW/DRIVE - SWITCH WITH LIGHT

11. HORN, SAFETY ALERT - SWITCH

This is a two position switch labelled LOW and DRIVE. IMPORTANT: This switch when in DRIVE provides infinitely variable travel speeds/torque ranges, unlike similar travel range controls on some types of construction equipment.

This is a two position "momentary" switch.

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

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

12. SAW - SWITCH

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

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

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

Place throttle in FULL position before turning saw ON.

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

It should be noted that the available torque when travelling at maximum speed is only half of that in LOW.

NOTE: If the engine has been turned off or the pilot shut off system tripped (Front Door opened) with the saw switch left in the ON position, the saw will not start up when the engine is restarted or the front door closed. In this case press the PILOT RESET button and turn the saw switch OFF and then ON. NOTE ALSO: On Harvester Model Machines this saw switch supplies power to the attachment's control systems.

The DRIVE position will provide a faster travel speed range but with a lower driving force.

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

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

2.22

Tigercat H822 Harvester

Controls and operation

7 8 C

B

9

10

11

12

13

14

15

A

••

••

••

• ••

••

• ••

••

CONTROL PANEL

822-D17

13. COOLING FAN - SWITCH This is a two position "momentary" switch.

Press and hold this switch in the CLEAN (PURGE) position to run the cooling fan in reverse. With this switch in the "normal" position the hydraulically driven cooling fan will be turning and drawing cool air through the debris screen and cooling assembly. The air is expelled to atmosphere through the perforated panels that make up the engine enclosure.

CAUTION Before placing the fan switch in the CLEAN (PURGE) position make sure that there are no personnel on the radiator intake area of the machine where the fan will expel debris.

NOTE: The air flow in the CLEAN (PURGE) mode is substantially less than in the NORMAL (FORWARD) mode. Reduce load on engine whenever placing fan in CLEAN mode.

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

15. CIGARETTE LIGHTER Cigar/Cigarette lighter.

2.23

••

••

Tigercat H822 Harvester

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

16

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.

••

SHUTDOWN RESET" BUTTON

"SYSTEM OK" LIGHT

•

••

••

FIRE SUPPRESSION SYSTEM

822-D19

•

16. AMEREX FIRE SUPPRESSION SYSTEM (OPTIONAL) The machine leaves the factory with the AMEREX fire suppression system fully activated. The system is not certified for use and certification must be performed by a local AMEREX approved dealer.

376-24A

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 AMEREX FIRE SUPPRESSION SYSTEM AND PORTABLE EXTINGUISHERS in THIS SECTION.

SYSTEM CONTROL PANEL

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

RED FIRE BUTTON

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

•

The fire suppression system installed on this machine uses a dry chemical powder which is stored in a 50 lbs. pressurized cylinder. It is discharged through 6 nozzles strategically placed in the engine compartment and hydraulic areas.

DISCHARGE HOSE

822-D19

To manually operate the system: 1. Safely lower the boom to the ground.

PRESSURE GAUGE

••

2. Pull locking pin.

•

3. Press red FIRE button.

PRESSURIZED CYLINDER

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

•• • 822-D20

MANUAL ACTUATION SWITCH

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

ELECTRICAL ACTUATOR

•

"PUSH TO TEST" BUTTON

PRESSURIZED CYLINDER CHECK GAUGE DAILY 2.24

Tigercat H822 Harvester

Controls and operation

DISCHARGE OF THE SYSTEM When an electrical signal (automatic or manual) is received by the control panel it sends a discharge signal to the electrical actuator located on top of the pressurized cylinder. When activated the electrical actuator extends a control shaft which mechanically opens the agent cylinder valve. This releases the dry chemical in the discharge area protected by the system. At the same time the control panel will also automatically shut down the engine.

The automatic engine shutdown feature will either shutdown the engine immediately the fire suppression system is discharged (non levelling machines) OR will delay the shutdown for a period of between 10 to 15 seconds for levelling machines. The time delay period is a factory setting. This delay feature allows the operator to lower the load or move the machine to a safer location before the engine shuts down. The operator can extend the delay by pressing the SHUTDOWN RESET button on the control panel to repeat the preset delay period. This button can be pressed repeatedly until the operator has brought the machine to a safe stop. The SHUTDOWN RESET button does not delay the discharge of the fire suppression system.

RED FIRE BUTTON

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

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

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

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

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

CAUTION Wear protective clothing and masks when cleaning up after a discharge Before cleaning up after a discharge, read the AMEREX 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.

••

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

822-D19

1. Safely lower the boom to the ground.

2. Pull locking pin.

3. Press red FIRE button.

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

There will be a cloud of dry chemical dispersed in the discharge area. The engine will automatically shutdown either immediately or 2.25

Tigercat H822 Harvester

Controls and operation

INSPECTION OF THE AMEREX FIRE SUPPRESSION SYSTEM AND PORTABLE EXTINGUISHERS: DISCHARGE HOSE

ELECTRICAL ACTUATOR

•

•

All chemical delivery hoses and nozzles are connected and tight.

•

Check fire suppression electrical network.

•

Ensure thermostats are clean.

PRESSURE GAUGE

•• ••

PRESSURIZED CYLINDER

• TYPICAL THERMOSTAT

378-19A

••

• PRESSURIZED CYLINDER CHECK GAUGE DAILY

822-D20

DAILY: •

•

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

Proper pressurization is indicated when the pointer is in the green zone.

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

SHUTDOWN RESET" BUTTON

"SYSTEM OK" LIGHT

••

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

••

"PUSH TO TEST" BUTTON

•• PRESSURE GAUGE 376-24A

•

••

SYSTEM CONTROL PANEL Check the manual actuation switch to ensure that all tamper indicators are in place, operating instructions are visible and access is unobstructed.

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

BI-YEARLY •

822-D21

PORTABLE FIRE EXTINGUISHER CHECK CHARGE GAUGE DAILY

WEEKLY: •

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

•

All components are in place and unobstructed.

2.26

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

Tigercat H822 Harvester

Controls and operation

AVOIDING DAMAGE AND FALSE DISCHARGES DURING MACHINE SERVICE: 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 lead to burnt wiring or an accidental discharge of the system.

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

If any of the components are damaged replace them immediately.

822-03

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

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

2.27

COMPONENT LOCATIONS

Tigercat H822 Harvester

Controls and operation

17. FILTER, RE-CIRCULATING AIR - A/C UNIT

19. HOT WATER SHUT OFF VALVES (ENGINE)

Air in the cab is drawn into the A/C-HEATER unit via this filter and re-circulated. The filter should be inspected and cleaned on a regular basis. The A/C will not cool efficiently if these filters become dirty or plugged.

A

•• 17

LOCATED ON THE LEFT SIDE OF THE ENGINE

••

409-08

HOT WATER SHUT OFF VALVE SISU ENGINE B

822-D22

••

RE-CIRCULATING AIR FILTER

18. FILTER, FRESH AIR - A/C UNIT Outside air is continuously drawn into the cab air conditioning unit through this filter and mixed with interior air from the cab. The filter is LOCATED BESIDE THE MAIN BOOM 18 822-D24

••

822-D23

FRESH AIR FILTER

located on the right side of cab and can be serviced from the outside by removing the two fasteners holding the hinged cover. The filter should be inspected on a regular basis and cleaned/replaced when dirty or when wet.

NEVER operate air conditioning without a filter installed.

2.28

HOT WATER SHUT OFF VALVE SISU ENGINE

SISU ENGINE To maximize the efficiency of the air conditioning, the heat control (C) on the A/C heater control panel must be rotated to the MAX COLD position. During times when cab heating is not required close the hot water shut off valve (A) on the left side of the engine and hot water shut off valve (B) located beside the main boom, this will prevent hot water from seeping through the A/C unit and thereby reducing the effectiveness of the cooling system.

Tigercat H822 Harvester

Controls and operation SHUT-OFF VALVES FOR USE WHEN CHANGING COOLANT FILTER ELEMENT

••

HOSE TO A/C HEATER UNIT

••

•• •• ••

19 SHUT-OFF VALVES COOLANT FILTER ELEMENT

LH830-D18

••

••

HOSE FROM A/C HEATER UNIT

HOT WATER SHUT OFF VALVE (CUMMINS ENGINE)

CUMMINS ENGINE To maximize the efficiency of the air conditioning, the heat control (C) on the A/C heater control panel must be rotated to the MAX COLD position. During times when cab heating is not required close both of the HOT WATER SHUT OFF VALVES on the engine block, this will prevent hot water from seeping through the A/C unit and thereby reducing the effectiveness of the cooling system.

2.29

Tigercat H822 Harvester

Controls and operation 20

•• 21

•

22

•

•

It should be noted that the escape hatch on this machine can only be opened from inside the operator's cab.

••

23

•• 822-D25

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

••

• •

INTERIOR LIGHTS, EMERGENCY EXITS

••

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

21. AM/FM STEREO CASSETTE/CD With dual front mounted speakers. Refer to stereo manufacturer’s manual for operation and safety warnings.

••

RETAINING KNOB AND CLAMP BRACKET

23

21

••

••

ESCAPE HATCH, EMERGENCY EXIT For more information refer to ESCAPE HATCH AND SIDE DOOR EMERGENCY EXIT MAINTENANCE GUIDE in THIS SECTION.

822-D26

822-D27

AM/FM STEREO CASSETTE/CD

22. SIDE DOOR EMERGENCY EXIT This side door serves as one of two emergency exit routes from the cab. Opening the side door WILL NOT DE-ACTIVATE the pilot system, for this reason only use this door in an emergency. In the event that it cannot be used, use the emergency escape hatch in the roof of the cab.

22

••

822-D29

SIDE DOOR EMERGENCY EXIT 2.30

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

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

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

Tigercat H822 Harvester

Controls and operation

2.31

Tigercat H822 Harvester SIDE DOOR AND ESCAPE HATCH EMERGENCY EXIT MAINTENANCE GUIDE

Controls and operation REMOVAL FOR MAINTENANCE OR REPAIR and ESCAPE HATCH REPLACEMENT in THIS SECTION.

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

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

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

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

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

REMOVE BOTH CLAMP BRACKETS

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

••

822-D31

822-D29

INTERIOR HANDLE

822-D28

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.

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

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

CHECKING PROCEDURE FOR ESCAPE HATCH: UNSCREW RETAINING KNOB FOUR COMPLETE TURNS

CLAMP BRACKET

ESCAPE HATCH REMOVAL

`

••

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

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

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

••

822-D30

WARNING

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

CHECK ESCAPE HATCH

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

2. Disengage clamp brackets from slot on cab roof attachment bracket, the escape hatch should move without using excessive force.

If the escape hatch does not move without excessive force refer to ESCAPE HATCH 2.32

Tigercat H822 Harvester

Controls and operation

ESCAPE HATCH REPLACEMENT:

FOAM SEAL

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

••

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

APPLY GREASE TO TOP SURFACE OF FOAM SEAL BETWEEN SEAL AND ESCAPE HATCH

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

•

LH830-06

•

CAB ROOF

• • CROSS SECTION OF ESCAPE HATCH SEAL

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

SKY LIGHT

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

•• CAB

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

••

822-01

'C' CHANNEL RUBBER

APPLY GREASE TO 'C' CHANNEL RUBBER BETWEEN CHANNEL AND CAB ROOF

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

NYLON INSERT

ESCAPE HATCH

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

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

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

NYLON STUD REPLACEMENT

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

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

2.33

Tigercat H822 Harvester OPERATOR’S SEAT (SEATS INC.)

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

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

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

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

To Raise Firmly lift up on the height adjustment lever.

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

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

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

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

To Lower Firmly lift up on the height adjustment lever.

When the lever releases, partially apply operator body weight to the seat until the seat is at the desired height. FIRMLY PUSH DOWN on the lever. Hold lever down until the seat locks into position (a click should be heard).

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

•• ••

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

•• ARMREST ADJUSTMENT

SEAT ADJUSTMENTS

332-6 4-WAY LUMBAR VERTICAL ADJUSTMENT

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

•

4-WAY LUMBAR HORIZONTAL ADJUSTMENT

PROBLEMS AND CORRECTIVE ACTION

BACK ANGLE ADJUSTMENT KNOB

•• RIDE ADJUSTMENT KNOB 332-1B

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

Refer to height adjustment.

•

•

•• ••

VIEW FROM RIGHT REAR OF SEAT

HEIGHT ADJUSTMENT LEVER FORE/AFT SLIDE LEVER

2.34

Tigercat H822 Harvester

Controls and operation

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

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

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

2.35

Tigercat H822 Harvester

Controls and operation

ENGINE COMPARTMENT

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

Use this valve to shut off the fuel supply when working on the engine. The fuel tank has a standard capacity of 100 gal. U.S. (378 l). A high capacity tank 130 gal. U.S. (492 l) is also available as an option.

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

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

3

••

1

•• 822-D34

822-D32

FUEL SHUT-OFF VALVE

••

BATTERY DISCONNECT SWITCH

2. JUMPER BAR CABLE CONNECTION This machine employs a special JUMPER CONNECTOR that is used in conjunction with jumper cables with matching ends. If standard jumper cables are used the NEGATIVE connection can be made anywhere on the upper frame, as close to the batteries as possible on bare metal.

•• FUEL FILLER CAP

822-D48

FUEL LEVEL SENDER

FUEL FILLER CAP AND FUEL LEVEL SENDER

The filler cap incorporates a fine mesh strainer. The fuel level sender is adjacent to the fuel filler cap in the right side tank.

2

OPTIONAL BOTTOM FUELLING SYSTEM The bottom fuelling system includes a "dry break" quick disconnect which can be reached from ground level, a solenoid operated fuel filling shut off valve, an interior mounted fuel float switch to activate the shut off valve when the tank is full and an ON/OFF switch box with an indicator light. (Note: Some machines converted in the field may be equipped with an exterior mounted fuel float switch.)

••

LH830-29

JUMPER BAR CABLE CONNECTION

Note: This system relies on a remote fuel transfer pump mounted on the fuel supply truck or tank. There is no fuel transfer pump mounted on the machine.

2.36

Tigercat H822 Harvester

Controls and operation CAUTION

INDICATOR LIGHT

••

•• •

QUICK DISCONNECT

LH830-20

ON/OFF SWITCH

CAUTION

BOTTOM FUELLING OPTION

FUEL FILLING PROCEDURE LABEL

BOTTOM FUELLING OPTION FUEL FILLING INSTRUCTIONS 1. Park machine with the upper level.

••

2. Turn service lights on (switch located In top right of cab).

3. Remove dust cap from quick disconnect ends and attach fuel truck supply line to machine.

FUEL FILLING PROCEDURE LABEL

LH830-21

4. Turn on fuel transfer pump (on fuel supply truck or tank).

5. “Pull” fuel fill switch located on hydraulic tank.

SOLENOID OPERATED SHUT OF VALVE

6. The amber signal light will indicate the fuel fill valve is open.

••

7. When the tank is full the fuel fill valve will close and the amber light will turn off.

8. Turn off fuel transfer pump.

9. Disconnect lines and return dust caps to quick disconnects.

LH830-19

10. Turn off service lights.

FUEL FILLING SHUT OFF VALVE

11. The fuel fill valve can be closed at any time during the filling procedure by pushing the mushroom head switch.

12. Caution: Never leave the machine unattended during the fuel filling process.

•• FUEL FILLER CAP

LH830-22

FUEL LEVEL SENDER

13. Regularly inspect and repair all fuel fill system components to reduce the risk of spillage or fire.

•• •• FUEL FLOAT SWTICH

FUEL FILLER CAP AND FUEL LEVEL SENDER - BOTTOM FUELING 2.37

Tigercat H822 Harvester

Controls and operation 4. HYDRAULIC OIL TANK Located at the rear left corner of the machine beside the fuel tank, the hydraulic tank has a capacity of 35 gal. U.S. (134 L) with a total machine dry fill capacity of 66 gal. U.S. (250L).

RETURN MANIFOLD

FILTER GROUP

HYDRAULIC TANK PRESSURE GAUGE

••

••

••

••

• •• WATER ABSORBING ELEMENT (COLOUR BLUE)

DRIP TRAY

•• 4

•• •• 830-D46

FUEL COOLER BYPASS VALVE SHOWN OPEN

FUEL COOLER

422-07

4. FUEL COOLER (IF EQUIPPED) The fuel cooler, located on the rear pump area doors, is used when fuel temperatures rise above the recommended maximum fuel temperature. The fuel cooler is equipped with a bypass valve.

NOTE: High fuel temperatures can cause the engine to de-rate or send fault codes related to fuel temperature.

The bypass valve should be placed in the OPEN position when high ambient air temperatures or operating conditions cause fuel temperatures to rise above the recommended maximum fuel temperature.

HYDRAULIC OIL TANK

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

5A. VENT/BREATHER, HYDRAULIC TANK EARLIER MACHINES (822H0123,82230191 TO 82230349) The air space in the top of the hydraulic tank is vented to atmosphere via a check valve and spin-on filter. The check valve will open or "crack" when the pressure in the hydraulic tank reaches 10 psi. The pressure build-up in the tank can be due to thermal expansion as the hydraulic oil heats up.

The bypass valve should be placed in the BYPASSED position when ambient air temperatures are low to prevent fuel gelling.

••

Recommended Maximum Fuel Temperatures Cummins QSC 140°F (60°C) Cummins QSL9 160°F (71°C)

••

Fuel temperatures can be viewed on the engine display and diagnostics module in the cab.

Refer to INSTRUMENT PANEL ~ ENGINE DISPLAY AND DIAGNOSTICS MODULE (MDDM) in THIS SECTION.

AIR VENT VALVE

822-D35

2.38

AIR VENT FILTER

HYDRAULIC OIL TANK (EARLIER MACHINES)

Tigercat H822 Harvester AIR VENT FILTER CONNECTION TO PRESSURE GAUGE

•• CHECK VALVE 10 PSI. 822-D41

6. OIL LEVEL SIGHT GAUGES

SOME COMPONENTS REMOVED FOR CLARITY

AIR VENT VALVE

•

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

TOP OF HYDRAULIC TANK

••

•

SECOND SIGHT GAUGE

••

VENT, HYDRAULIC TANK EARLIER MACHINES

••

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

••

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

IMPORTANT Direct contact with oil implies a risk of skin complaints. Oil on skin should be washed off immediately with soap and water. Refer also to WORKING WITH OIL in SECTION 1 of THIS MANUAL. 5B. BREATHER, HYDRAULIC TANK LATER MACHINES (82230350 AND UP) The air space in the top of the hydraulic tank is vented to atmosphere via a spin-on filter. The hydraulic tanks on later machines are not pressurized.

SOME COMPONENTS REMOVED FOR CLARITY BREATHER FILTER

•

TEMPERATURE GAUGE (EARLIER MACHINES ONLY)

422-05

LOW LEVEL SENDING UNIT, FOR WARNING LIGHT

•• ••

LOW LEVEL SENDING UNIT, FOR WARNING BUZZER

HYDRAULIC OIL LEVEL SIGHT GAUGES

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

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

TOP OF HYDRAULIC TANK

•• H822-03

FIRST SIGHT GAUGE

BREATHER, HYDRAULIC TANK LATER MACHINES

2.39

Tigercat H822 Harvester

Controls and operation

7. RETURN FILTERS ~ HYDRAULIC OIL

CLOG INDICATOR SIGHT GLASS (IF EQUIPPED)

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

HYDRAULIC TANK PRESSURE GAUGE

RETURN MANIFOLD

5 - HYDRAULIC RETURN FILTERS

•• 822-D47

••

•• •• ••

•• 422-07

•• ••

HIGH PRESSURE PILOT FILTER

8. HIGH PRESSURE PILOT FILTER There is a hydraulic high pressure pilot filter placed ahead of the pilot supply valve (pressure reducing/pressure relieving valve) to filter the oil before it enters the pilot system.

1 - WATER ABSORBING RETURN FILTER (COLOUR BLUE)

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

HYDRAULIC OIL FILTERS

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

The pressures stated are for normal operating conditions and temperatures.

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

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

EARLIER MACHINES ONLY

FILTER SERVICE NOTE

On earlier machines this filter incorporates a clog indicator.

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

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

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

10. HYDRAULIC HAND FILL PUMP The hydraulic hand fill pump, on the rear left door, is used for adding oil to the hydraulic tank. A male quick disconnect port is provided on the return filter manifold and mates with a 2.40

Tigercat H822 Harvester

Controls and operation

FEMALE QUICK DISCONNECT

• • SUCTION TUBE

822-D46

HAND FILL PUMP

female quick disconnect attached to the outlet hose on the hand pump. This ensures that any hydraulic oil added is filtered prior to entering the hydraulic tank.

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

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

RETURN MANIFOLD

••

•• ••

RETURN MANIFOLD PORT

CONNECT THE QUICK DISCONNECT TO THE RETURN MANIFOLD PORT

822-D40

FILLING HYDRAULIC TANK

2.41

Tigercat H822 Harvester

Controls and operation

11. ENGINE AIR PRECLEANER

EXHAUST SYSTEM

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

PRECLEANER TO TURBO CHARGER

•• ••

••

AIR CLEANER

• AIR CLEANER UNLOADER VALVE

354-15

••

AIR CLEANER

AIR CLEANER UNLOADER VALVE

DISCHARGE PORT AREA

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

13. FILTER RESTRICTION INDICATOR

218-21B

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

PRECLEANER

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

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

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

FILTER RESTRICTION INDICATOR

•

822-D42

FILTER RESTRICTION INDICATOR

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

2.42

Tigercat H822 Harvester

Controls and operation

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

•

421-15A

AIR INTAKE CLEAN-OUT COVER

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

•

CHECK CONDITION OF SEAL

•• 822-D58

PRECLEANER

AIR INTAKE SEAL

2.43

Tigercat H822 Harvester

Controls and operation A/C CONDENSER OIL COOLER

RADIATOR COOLING FAN

•

SHROUD

••

••

FINGER GUARD SURGE TANK FAN DRIVE MOTOR

••

••

••

•

••

DEBRIS SCREEN

•

822-04

COOLING ASSEMBLY - OVERALL VIEW EARLIER MACHINE 822H0123

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

CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR EARLIER MACHINE ONLY 822H0123

PROCEDURE:

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

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

2. Open rear right side engine door.

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

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

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

OIL COOLER A/C CONDENSER UNIT

LATCH

• • 822-D45

LATCH, OIL COOLER - A/C CONDENSER UNIT

2.44

Tigercat H822 Harvester

Controls and operation 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 cores.

••

422-04

SLIDE DEBRIS SCREEN OUT AND REMOVE

OIL COOLER

RADIATOR

CAUTION

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

A/C CONDENSER

Avoid the risk of fire caused by debris accumulating on surfaces that may become hot during machine operation. Always use care when cleaning to ensure that debris removed from one area of the machine does not accumulate on other areas of the machine. For more information on fire prevention refer to FIRE PREVENTION in SECTION 1 of THIS MANUAL.

• •• ••

If an oil leak occurs in this area it should be thoroughly power-washed with a mild soap to ensure that all of the oil is removed. The presence of oil causes dust and dirt to cling to surfaces which will impair the reversible fan's ability to remove dust and dirt particles.

410-24

HINGED A/C CONDENSER & OIL COOLER 5.

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

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

WARNING

This cooling assembly must be checked daily and may have to be thoroughly cleaned on a weekly or monthly basis, depending on operating conditions. Use personal protective equipment to guard against flying debris.

Stay clear of fan at all times to avoid risk of personal injury.

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

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

Always use personal protective equipment to guard against flying debris 2.45

Tigercat H822 Harvester

Controls and operation A/C CONDENSER

DEBRIS SCREEN

OIL COOLER RADIATOR COOLING FAN SHROUD FINGER GUARD

••

••

SURGE TANK FAN DRIVE MOTOR

• ••

• •• •

••

•

•

CHARGE AIR COOLER

LH830-01

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

COOLING ASSEMBLY - OVERALL VIEW LATER MACHINES 82230191 TO 82230999

CLEANING A/C CONDENSER, OIL COOLER, RADIATOR AND CHARGE AIR COOLER

PROCEDURE:

LATER MACHINES 82230191 TO 82230999

2. Open rear right side engine door.

The hydraulic oil cooler/radiator/charge air cooler (CAC) is mounted to the rear of the fan. The A/C condenser core is mounted to the rear of the oil cooler. A debris screen is used to protect the oil cooler/radiator/CAC cooling assembly. The hydraulically driven fan draws air through the screen, through the A/C condenser, the oil cooler/ radiator/CAC cooling assembly and finally blows the air across the engine.

3.

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

Slide the debris screen out.

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

5.

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

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

This cooling assembly must be checked daily and may have to be thoroughly cleaned on a weekly or monthly basis, depending on operating conditions. Use personal protective equipment to guard against flying debris. Use compressed air for cleaning only when the machine is cold to

2.46

Tigercat H822 Harvester

Controls and operation

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

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

Always use personal protective equipment to guard against flying debris 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 cores.

COOLING ASSEMBLY

LH830-08

A/C CONDENSER OIL COOLER/ RADIATOR/CAC ASSEMBLY

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

••

•• ••

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

SLIDE DEBRIS SCREEN OUT AND REMOVE

COOLING ASSEMBLY

LH830-09

• NUTS A/C CONDENSER

•

WARNING

HINGES

•• •

Stay clear of fan at all times to avoid risk of personal injury.

LH830-10

2.47

SWING OUT A/C CONDENSER

Tigercat H822 Harvester OPERATING MACHINE

Controls and operation ENGINE OIL DIPSTICK

Ensure that the appropriate lubrication and maintenance schedule has been performed prior to operating the machine. (Section 3 in this manual). Also refer to the Diesel engine manufacturers operator’s manual supplied with the machine.

••

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

ENGINE THROTTLE CONTROL

••

BEFORE YOU BEGIN: PRE-START CHECKS LEFT SIDE OF ENGINE

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

822-D49

CHECK ENGINE OIL LEVEL (SISU ENGINE)

2. Check fire extinguisher is sufficiently charged.

ENGINE OIL DIPSTICK PRESSURE GAUGE

•• PORTABLE FIRE EXTINGUISHER CHECK CHARGE GAUGE 3. Check fuel level. (Turn ignition key switch to RUN position to check this, then to OFF)

822-D21

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

FUEL LEVEL GAUGE

•• LH830-05

EXHAUST SYSTEM

INSTRUMENT PANEL

••

PRECLEANER TO TURBO CHARGER

• ••

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

AIR CLEANER

•

UPPER SIGHT GAUGE

AIR CLEANER UNLOADER VALVE

6.

CHECK HYDRAULIC OIL LEVEL 2.48

••

AIR CLEANER Check air cleaner unloader valve.

354-15

422-05A

CHECK ENGINE OIL LEVEL (CUMMINS ENGINE)

LH830-11

••

Tigercat H822 Harvester

Controls and operation

FILTER RESTRICTION INDICATOR WATER SEPARATOR BOWL

••

DRAIN TAP

•• ••

822-D52

•• ••

ENGINE FUEL LINE WATER SEPARATORS (SISU ENGINE)

FILTER RESTRICTION INDICATOR 7. Check air filter restriction indicator.

822-D42

AIR INTAKE AREA WATER SEPARATOR

DISCHARGE PORT AREA

•• DRAIN TAP

TOP SEAL 218-21B

•

UNDER SIDE OF PRECLEANER

LH830-12

CHECK AIR INTAKE PRE-CLEANER

822-D50

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

••

ENGINE FUEL LINE WATER SEPARATORS (CUMMINS ENGINE) 10. Check fuel line water separator(s) on side of engine and drain any accumulated water.

WATER SEPARATOR BOWL

DRAIN TAP

• • 830-D47

FUEL LINE WATER SEPARATOR

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

822-D51

CHECK CONDITION OF ENGINE BELTS

11. Check condition of engine belts. Cover should be removed to check tension of belts every 250 hours.

Continued on page 50

2.49

Tigercat H822 Harvester

Controls and operation

Continued from page 49

14. Check all exits.

CRACKING

BENT

WARNING WARN HOLES EDGE WEAR

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

EDGE WEAR BROKEN EDGE

CHECK CONDITION OF TRACK SHOES 15. Check condition of track shoes.

830-02

SAG DIMENSION; 4" TO 6" FOR NORMAL OPERATIONS

MEASURING SAG DIMENSION 853ILL8 16. Check track chain tension.

CHECK ENGINE COOLANT LEVEL

822-D54

17. Check attachment. Refer to attachment manufacturer's manual for more information.

12. Check the engine coolant level.

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

A/C CONDENSER OIL COOLER/ RADIATOR/CAC ASSEMBLY

••

•• •• SLIDE DEBRIS SCREEN OUT AND REMOVE

LATER MACHINE SHOWN

LH830-09

CLEAN A/C CONDENSER AND COOLING ASSEMBLY

13. Clean A/C condenser and cooling assembly.

Refer to CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR in THIS SECTION.

2.50

Tigercat H822 Harvester

Controls and operation

2.51

Tigercat H822 Harvester STARTING ENGINE, CUMMINS

Controls and operation

1. Before starting the engine, ensure that all prestart checks have been performed and that the surrounding area is clear of personnel.

4

2 LH830-23

4. Then turn ignition key switch to the START position to crank engine and then back to the RUN position.

LH830-25

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

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

2. Sound Horn to warn of machine start-up.

3

CAUTION To prevent damage to the starting motor, DO NOT engage the starting motor for more than 30 seconds. Wait 2 minutes between each attempt to start.

LH830-23

3. Turn ignition key switch to the RUN position; wait for the WAIT TO START lamp to extinguish.

5. Keep throttle in LOW IDLE position and wait 3 to 5 minutes before operating with a load.

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

3

CAUTION Do not keep the engine running at LOW IDLE for longer than 10 minutes. Fuel will not completely burn at low combustion temperatures and engine damage may result.

LH830-24

2.52

Tigercat H822 Harvester

Controls and operation

6. Increase engine speed (rpm) slowly to provide adequate lubrication to the bearings and allow oil pressure to stabilize.

If for some reason engine stalls while operating machine, Turn key switch to OFF position AND REPEAT STEPS (1) to (4).

CAUTION To avoid damage to the QSL9 or QSC engine parts, DO NOT connect jumper starting or battery charging cables to any QSL9 or QSC parts. When using an external electrical source to start the engine, turn the disconnect switch to the OFF position.

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

IMPORTANT The instructions written in this manual pertaining to starting, operating and stopping of the engine include excerpts from the original engine manufacturers operating manuals.

For additional important operating and maintenance instructions, please refer to the ORIGINAL ENGINE MANUFACTURERS OPERATING AND SERVICE MANUAL applicable to the engine in use.

2.53

Tigercat H822 Harvester STARTING ENGINE, SISU

Controls and operation COLD WEATHER STARTING

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

CUMMINS ENGINE

WARNING

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

The Cummins QSL9 or QSC engines utilizes an air intake heater grid. To avoid personal injury and property damage, NEVER use a starting fluid. Starting aid fluids, which contain Ether, can cause an explosion.

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

5. Hold down engine shut down override switch.

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

WARNING

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

Never use a liquid staring aid to start an engine.

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

IMPORTANT

9. Adjust throttle to LOW IDLE.

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

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

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

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

CAUTION

NOTE: Cold temperatures require the use of an engine block heater and the hydraulic oil heater.

Preheating of hydraulic oil is recommended as standard procedure in cold weather.

1. Follow the STARTING ENGINE - CUMMINS ENGINE instructions for this COLD WEATHER STARTING procedure, paying attention to the WAIT TO START warning light located on the instrument panel in the cab.

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

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

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

WAIT TO START WARNING LIGHT

••

LH830-24

INSTRUMENT PANEL, LATER MACHINES This YELLOW warning light will be ON during the "key ON" engine pre-heat time. Heating elements (grid heater elements) located in the engine air intake manifold are turned ON during cold weather conditions to heat the intake air when starting the engine. The engine must not be started until this light goes OFF automatically.

2.54

Tigercat H822 Harvester

Controls and operation

2. During the engine warm-up period constantly monitor engine coolant temperature and engine oil pressure. Stop engine if any pressure or temperature does not meet the specification.

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

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

CAUTION Continuous operation with a low coolant temperature below 60°C (140°F) or a high coolant temperature of 100°C (212°F), can damage the engine.

3. Continue with MACHINE PREPARATION procedure when the engine coolant temperature registers NORMAL.

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

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

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

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

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

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

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

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

3. Turn the ignition key switch to RUN. 4. Set throttle switch to just above IDLE. 5. Press and hold the cold start switch in the ON position for 20 to 25 seconds.

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

2.55

Tigercat H822 Harvester RESTARTING AN ENGINE THAT HAS RUN OUT OF FUEL

Controls and operation STOPPING ENGINE

If the engine runs out of fuel, the fuel line must be primed:

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.

1. Refill fuel tank completely.

2. Remove engine fuel filter and fill with clean fuel.

3

Bleed the system according to engine manual procedures.

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

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

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

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

1. Turn the saw switch to the OFF position and STOP the attachment. This should be done before leaving the harvesting area.

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

3. Stop the machine and lower the attachment onto firm ground.

2. Reduce engine speed to LOW IDLE and let run for approximately 3 minutes to allow gradual dissipation of heat and also to reduce turbo speed. This will also prevent loss of coolant by after boil and possible hot spot damage to the engine.

5. Do not race engine before shut-off.

6. Activate PILOT SHUT OFF switch.

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

8. Attachment must have stopped before you exit.

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

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

Remain with the machine for at least 45 minutes at the end of operations to watch for possible fires. Refer also to FIRE PREVENTION in SECTION 1 of THIS MANUAL.

2.56

Tigercat H822 Harvester MACHINE PREPARATION

Controls and operation (m) 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 (a) through (q) to accomplish the following; •

Warm up the hydraulic system.

•

Test all systems for proper operation.

•

Inspect for hydraulic oil leaks.

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

WARNING

CAUTION

Ensure that the attachment has stopped before leaving the cab.

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.

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

Assuming machine was parked on level ground at last shutdown:

WARNING

(a) Start engine. (b) Ensure gauges and warning lights are indicating normal operating conditions. (c) Check that all personnel are clear of the machine.

Never use your bare hand to check for fluid leaks.

(d) Press Pilot reset button

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.

(e) Place the anti-stall switch in the OFF position. (f) Increase engine speed to approximately 1300 rpm (Cummins QSL9 engine), 1500 rpm (Cummins QSC engine) or 1600 rpm (Sisu engine). (g) Slowly raise and lower boom. Slowly move the boom in and out. Check for proper operation.

With the attachment raised slightly off the ground: (h) Operate telescopic boom IN and OUT and check that it is operating correctly, if applicable. (i) Rotate the attachment and check that it is operating correctly. (j) Swing the upper to the left and right. (k) When cold weather conditions exist, continue the process of warming up the hydraulic system by repeating steps (g) through (j) several times. If the FILTER BYPASS warning lights come on decrease engine speed immediately and continue warming the system.

(p) Leave the cab and visually check hose connections and cylinders for leaks. Check under the machine for oil leaks. (q) After inspection return to cab and follow proper machine start-up procedure. Operate the machine with the engine at 1300 rpm (Cummins QSL9 engine), 1500 rpm (Cummins QSC engine) or 1600 rpm (Sisu engine) with the anti-stall system OFF until hydraulic oil has reached operating temperature. When ambient air temperature is below freezing, operate at this reduced engine speed for at least 45 minutes.

(l) Turn the attachment on. Refer to ATTACHMENT MANUFACTURER'S MANUAL and check attachment for proper operation according to manufacturer's instructions.

2.57

Tigercat H822 Harvester TRAVELLING (BOOM RAISED)

Controls and operation OPERATING TIPS WITH LOAD SENSING

1. Select the appropriate drive range.

Place the track switch in the LOW or DRIVE position.

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

For a more detailed description of drive range refer to TRACK, LOW/DRIVE SWITCH in THIS SECTION.

3. Move throttle control to the HIGH idle position.

Refer also to MACHINE STABILITY AND TRACTION in SECTION 1 of THIS MANUAL.

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 of the SERVICE MANUAL

2. Place swing brake switch in OFF position.

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

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

ATTACHMENT OPERATING INSTRUCTIONS AND SAFETY PRECAUTIONS 1. All tree harvesting should be carried out in LOW driving range. Refer to TRACK, LOW/ DRIVE SWITCH in THIS SECTION. 2. Refer to HARVESTING ATTACHMENT GENERAL SAFETY in SECTION 1 of THIS MANUAL. 3. Read and understand the operating and safety instructions found in the ATTACHMENT MANUFACTURER’S MANUAL for the harvesting head installed on this machine.

2.58

Tigercat H822 Harvester CARE OF THE MACHINE

Controls and operation REMOVING HAIRLINE SCRATCHES

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

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

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

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

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

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

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

5. Do not apply load to a cold engine.

6. Close and secure all doors and access covers.

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

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

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

8. Always harvest trees in LOW driving range.

Compatible Cleaning Agents

9.

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

Never park machine with attachment raised off the ground. Be sure that the attachment is resting on the ground and properly supported before servicing or parking the machine. Refer to PARKING BOOM in SECTION 1 of THIS MANUAL for complete instructions.

CLEANING INSTRUCTIONS FOR LEXAN WINDOWS

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

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

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

1. Rinse with lukewarm water.

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

3. Rinse with clean lukewarm water.

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

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

MARGARD coated lexan will start to become opaque around the edges and creep in.

2.59

Tigercat H822 Harvester

Controls and operation

*

17714B.AI 08/04

* NOTE: For machines equipped with a speed control lever, lever should be pushed fully forward.

2.60

Tigercat H822 Harvester SECTION 3 - LUBRICATION & MAINTENANCE SEPTEMBER 2004

CONTENTS - SECTION 3 ACCESS DOOR, UNDERCARRIAGE, SWIVEL (LATER MACHINES ........... 22 AIR CONDITIONING CHECKING THE SYSTEM .......................................................................... 12 AIR INTAKE MAINTENANCE ......................................................................... 22 CHECKING THE AIR CONDITIONING SYSTEM ........................................... 12 EMERGENCY EXITS, CHECK MONTHLY ....................................................... 3 ER BOOM SYSTEM ........................................................................................ 11 FILTERS CHANGING HYDRAULIC RETURN FILTERS ............................................ 16 ENGINE AIR FILTER .................................................................................. 20 FUEL FILTER/WATER SEPARATOR ......................................................... 14 FUEL TANK STRAINER .............................................................................. 15 HYDRAULIC OIL RETURN FILTERS ......................................................... 16 HYDRAULIC OIL RETURN STRAINERS/DIFFUSERS .............................. 19 PILOT FILTER ............................................................................................. 18 REMOVE AND REPLACE ........................................................................... 14 SERVICING GUIDELINES FOR OIL FILTERS ........................................... 16 FIRE PREVENTION .......................................................................................... 3 FUEL SHUT-OFF VALVE ............................................................................... 14 GENERAL MAINTENANCE .............................................................................. 3 HYDRAULIC OIL FILTERS ............................................................................. 16 HYDRAULIC OILS ............................................................................................ 8 NEW MACHINE MAINTENANCE ..................................................................... 2 FIRST 50-100 HOUR INSPECTION AND SERVICE REPORT .................... 2 INITIAL PRE-DELIVERY INSPECTION ........................................................ 2 TIGHTENING POINTS .................................................................................. 2 OIL LOST FROM LEAKAGE ............................................................................. 2 PRESSURE SETTING PROCEDURES ...................... SEE SERVICE MANUAL PRESSURE SETTING VALUES ................................. SEE SERVICE MANUAL PREVENTIVE MAINTENANCE SCHEDULE .................................................... 2 RETURN FILTERS ~ HYDRAULIC OIL .......................................................... 16 SCHEDULED MAINTENANCE FREQUENTLY .............................................................................................. 3 8 HOURS ....................................................................................................... 4 24 HOURS ..................................................................................................... 5 125 HOURS ................................................................................................... 5 250 HOURS ................................................................................................... 6 500 HOURS ................................................................................................... 7 1000 HOURS ................................................................................................. 7 2000 HOURS ................................................................................................. 7 SWING DRIVE GEARBOX LUBRICATION OF LOWER BEARING ....................................................... 10 TORQUE CHART, GENERAL ........................................................................ 24

Tigercat H822 Harvester

Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE FOR H822 HARVESTER NEW MACHINE MAINTENANCE

*INITIAL PRE-DELIVERY INSPECTION:PERFORM THE INITIAL PRE-DELIVERY INSPECTION USING Tigercat FORM NUMBERS 5281 AND 5282; "PDI AND 50-100 HOUR INSPECTION REPORT"

*FIRST 50-100 HOUR INSPECTION AND SERVICE REPORT:WITH THE OWNER'S MECHANIC PRESENT, PERFORM AN INSPECTION AND SERVICE ACCORDING TO THE Tigercat FORM NUMBERS 5281 AND 5282; "PDI AND 50-100 HOUR INSPECTION REPORT" THIS MUST BE COMPLETED WITHIN THE FIRST 50-100 HOUR TIME FRAME.

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

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

Tightening points:~ All hydraulic connections Hose clamps All cylinder and boom pin retainers

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

Check swing bearing bolt torque Engine mounting bolts Pump mounting bolts Track shoe bolts

IMPORTANT

Track roller retaining bolts

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

Track sprocket retaining bolts Track drive gearbox mounting bolts Track drive motor mounting bolts Swing gearbox mounting bolts

OIL LOST FROM LEAKAGE

Cab securing bolts Any other loose nut, bolt or fitting

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

3.2

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

Tigercat H822 Harvester

Lubrication and Maintenance

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

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

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

Clean around filler caps before checking or adding fluids.

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

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

Clean up spills as soon as possible.

Always release pressure in hydraulic tank before breaking a connection.

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

Always use clean oil and containers.

Drain dirty oil while still warm.

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

Do not exceed recommended fluid levels.

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

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

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

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

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

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

Clean away all branches, bark and chips.

Clean up all traces of oil to avoid fires.

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

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

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

Always have a fire extinguisher at hand.

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

Always install door safety struts when working on machine.

Clean fire suppression system sensors.

3.3

Tigercat H822 Harvester

Lubrication and Maintenance

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

FREQUENTLY:~ • Check engine cooling air intake screens for possible restriction.

• ‡ Boom joints: Standard Boom; 6-fittings - purge

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

Standard w/Tilt Link; 12-fittings - purge ER Boom System; 12-fittings - purge

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

• ‡ Cylinders; boom, stick & tilt; Standard Boom; 6-fittings - purge ER Boom System; 8-fittings - purge

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

‡ Lubricating cylinder pins and boom joints:1. Ensure machine is on level ground 2. Fully retract telscopic 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.

EVERY 8 HOURS:~ • Perform "frequently" maintenance And in addition:~ • Check engine coolant level • Check engine oil level • Drain water from fuel/water separator • Check intake and discharge areas of engine air precleaner

Clean:~ • Oil cooler, engine radiator, charge air cooler (if equipped) and enclosure screens.

• Check air cleaner unloader valve • Check air filter restriction indicator

• Remove potentially damaging limbs or sticks.

• Check hydraulic oil level

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

• For loose nuts, bolts and fittings.

• Condition of fan belts.

• Visually check condition of tracks.

• Conduct an overall visual inspection.

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

3.4

Tigercat H822 Harvester

Lubrication and Maintenance

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

EVERY 24 HOURS :~ • Perform "frequently" maintenance

• Tracks, track frames and carbody

• Perform 8 hour maintenance

• Swing bearing area

And in addition:~ • Lubricate swing bearing; 1-fitting - 10 shots while swinging

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

EVERY 125 HOURS:~

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

• Perform "frequently" maintenance • Perform 8 hour maintenance

• Wear in any other components

• Perform 24 hour maintenance

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

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

Clean/replace:~ • Inspect for debris buildup between radiator and oil cooler (earlier machine 8220144) or between A/C condenser and cooling assembly on later machines (83080191 to 83080499)

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

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

• Check battery fluid level unless maintenance free

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

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

3.5

Tigercat H822 Harvester

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 250 HOURS:~

EVERY 500 HOURS:~

• Perform "frequently" maintenance

• Perform "frequently" maintenance

• Perform 8 hour maintenance

• Perform 8 hour maintenance

• Perform 24 hour maintenance

• Perform 24 hour maintenance

• Perform 125 hour maintenance

• Perform 125 hour maintenance

And in addition Lubricate:~

• Perform 250 hour maintenance

• Check all hydraulic pressures

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

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

• Hydraulic oil return filters.†

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

• Hydraulic oil high pressure pilot filter.† Lubricate:~ • Power door hinges; 2 fittings - 1 shot.

• Door cylinder pins apply oil liberally.

• Other door hinges; apply oil liberally.

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

• Check condition and tension of fan belts.

• Torque on track drive gearboxes and motor mounting bolts.

• Replace engine oil and filter.

• Replace engine fuel filter(s).

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

• Replace filter in fuel filter/water separator.

• Replace air intake primary element.

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

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

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

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

3.6

Tigercat H822 Harvester

Lubrication and Maintenance

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

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

3.7

Tigercat H822 Harvester

Lubrication and Maintenance

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

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

3.8

Tigercat H822 Harvester

Lubrication and Maintenance

Tigercat® Model H822 HARVESTER FILTER AND LUBRICATION SCHEDULE

15

25.5 23.7 19.9

6.75 6.26 5.25

QTY

USG

57

1

COOLING SYSTEM

CHK

2

CHK CHK CHK

3 4 5

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

6

AIR INTAKE PRECLEANER

CHK

7

AIR INTAKE PRIMARY ELEMENT

8

AIR INTAKE SAFETY ELEMENT

9

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

10

RETURN FILTERS

CHK

REP

5 1

11

PRESSURE FILTER, PILOT*

CHK

REP †

1

12

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

CHK ‡

13

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

CHK 1 REP

1 REP

1

CHK

D/R

D/R

CHK

SWING BEARING ***

15

SWING PINION

16

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

17

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

LUB

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

LUB

19

TELESCOPIC BOOM CYLINDER

LUB

20

DOOR HINGES

21

DOOR CYLINDER PINS

22

REP REP REP REP REP

DRN

14

18

CHANGE COOLANT EVERY 2 YEARS

REMARKS/LUBRICANT

LITRE

2000

CAPACITY

1000

500

250

DESCRIPTION

125

SERVICE EVERY

8

SERVICE POINT NO.

REFER TO Tigercat OPERATOR'S MANUAL FOR FURTHER INFORMATION

LUB 24HR *** LUB LUB³

134 ..250

35 ..66

6

1.5

7.6

2

1

1

10 SHOTS

1

10 SHOTS

1

5 SHOTS EACH FITTING

2

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

BY SEASONAL OIL CHANGE SEE APPROVED HYDRAULIC OILS* *Tigercat RECOMMENDS REGULAR USE OF AN OIL TESTING PROGRAM 5 STANDARD FILTERS 1 WATER ABSORBING FILTER (COLOUR BLUE) *CHECK RESTRICTION INDICATOR ON (IF EQUIPPED) FILL WITH S 75W-90 (SPEC) RECOMMENDED SYNTHETIC GEAR OIL FOR SEVERE DUTY APPLICATIONS IF LEAKING REMOVE AND REPAIR FILL WITH SAE 30 OR 40 GREASE WHILE SWINGING *** EVERY 24 HOURS LITHIUM BASE EP2 GREASE GREASE WHILE SWINGING LITHIUM BASE EP2 GREASE LITHIUM BASE EP2 GREASE

LITHIUM BASE EP2 GREASE u

PURGE 6 12 12

ATTACHMENT

LITHIUM BASE EP2 GREASE PURGE PURGE

8 10

PURGE

2

LUB

1 SHOT

20

LITHIUM BASE EP2 GREASE

LUB

LUB

2

APPLY OIL LIBERALLY

LITHIUM BASE EP2 GREASE

SEE MANUFACTURER'S MAINTENANCE SCHEDULE

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

H822LUBCHART.XLS R0 06/04

3.9

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

Tigercat H822 Harvester

Lubrication and Maintenance

LUBRICATION OF SWING DRIVE GEARBOX UPPER GEARING LUBRICATION

HOIST CYLINDER FULLY COLLAPSED HEAD

••

•• TIP OF STICK BOOM FULLY SUPPORTED

H822-01

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

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

LUBE FITTINGS

••

•

ROTATOR

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

••

845B-D33

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

LUBE FITTINGS

• ••

LH830-31

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

Using a hand grease gun, pump 5 shots of grease into each grease fitting. Follow the lubricating procedure on the label located beside the grease fittings and also refer to SCHEDULED MAINTENANCE - 250 HOURS in THIS SECTION. For additional information refer to SECTION 15 in the SERVICE MANUAL 3.10

PARKING BOOM FIG.5

NOTE: FULLY RETRACT TELESCOPIC STICK BOOM IF EQUIPPED

Tigercat H822 Harvester ER BOOM SYSTEM

Lubrication and Maintenance HOIST CYLINDER FULLY COLLAPSED HEAD

WARNING

••

ROTATOR

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

••

• TIP OF STICK BOOM FULLY SUPPORTED

H822-01

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

PARKING BOOM FIG.5

NOTE: FULLY RETRACT TELESCOPIC STICK BOOM IF EQUIPPED

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

The main and stick boom cylinder circuits are connected hydraulically. Thus, disconnecting a hydraulic line to a boom cylinder may cause either boom to move unexpectedly. The boom may also move unexpectedly if a port relief adjusting screw is unscrewed (counterclockwise) too far and the pressure drops below that which is required to hold the weight of the boom and head. Ensure that the boom is properly parked for service (as described on this page, see also fig. 5) and engine is shut off before disconnecting any hydraulic lines. Also, for earlier machines (822H0123, 82230191 TO 82230349) equipped with pressurized hydraulic tanks, relieve pressure in the hydraulic reservoir by opening hydraulic tank vent valve and waiting until the sound of escaping air stops.

(a) The machine is parked on level ground with the head laying flat on the ground. (b) The hoist cylinder fully collapsed. (fig. 5) (c) The telescopic boom fully retracted (if equipped) and the tip of the stick boom supported at the rotator pin. (d) Do NOT rely on the 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 OF THIS MANUAL. Also note that because of the hydraulic connection between the main boom and ER cylinders, the ER cylinder can overpower the stick cylinders under certain conditions, causing the stick boom to move unexpectedly. This most often occurs when setting the MAIN BOOM UP relief valve, causing the stick to extend, but it may also happen at other times if the relief settings are not correct. Ensure that all personnel and equipment are clear of the boom path and that there is sufficient overhead clearance for the head to rise before making any adjustments.

3.11

Tigercat H822 Harvester CHECKING THE AIR CONDITIONING SYSTEM

Lubrication and Maintenance CAUTION

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

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

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

Always use personal protective equipment to guard against flying debris

A/C SYSTEM TOTAL CAPACITIES R134a REFRIGERANT

PAG OIL (polyalkylene glycol)

3 LBS. 0 OZ.

7 OZ.

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

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

Perform following inspection along with 125 HOURS inspection outlined in SCHEDULED MAINTENANCE in THIS SECTION.

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

a. Check re-circulating and fresh air filters in operator's cab. Refer to SECTION 2 of the OPERATOR'S MANUAL.

OIL COOLER/ RADIATOR/CAC ASSEMBLY

d. Check and adjust compressor drive belt tension.

CHECK A/C CONDENSER CORE

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

Run air conditioning system for 3 - 5 minutes.

IMPORTANT

••

•

•

It is recommended that during cold weather, when the A/C system is not in use, the system be run for a period of 5 minutes every two weeks. This will circulate oil to all components of the A/C system.

SLIDE DEBRIS SCREEN OUT AND REMOVE

LH830-09

g. Check air temperature exiting vents in cab.

CHECK A/C CONDENSER CORE

b. Check the condenser core for dirt and debris.

Clean as required. Refer to CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR in SECTION 2 of the OPERATOR'S MANUAL.

h. Listen to compressor and blower motor for abnormal noises.* i.

3.12

Check to see that compressor clutch will engage.*

Tigercat H822 Harvester j.

Lubrication and Maintenance

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

•• ••

BINARY SWITCH, SYSTEM PROTECTION

•

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

• A/C RECEIVER/DRYER

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

870-D43

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

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

3.13

Tigercat H822 Harvester FILTERS - REMOVE AND REPLACE

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

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

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

FUEL SHUT-OFF VALVE

IMPORTANT Filters that are an integral part of the engine (fuel and lubricating oil) should be serviced and replaced according to the engine manufacturer's operation and maintenance manual.

•

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

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

822-D34

FUEL SHUT-OFF VALVE

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

8. Remove the water sediment bowl from the bottom of the old filter. Discard this gasket also. Dispose of old filter and any fuel properly.

9. Clean the water sediment bowl.

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

WATER SEPARATOR BOWL

11. Lubricate gasket for bottom of filter and water sediment bowl with clean engine oil and carefully hand tighten the water sediment bowl onto the new filter. It is plastic and will break if over tightened. Close the water drain valve.

DRAIN TAP

•• •• 830-D47

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

FUEL LINE WATER SEPARATOR

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

2. Open engine enclosure doors fully.

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

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

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

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

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

3.14

Tigercat H822 Harvester

Lubrication and Maintenance

FUEL TANK STRAINER

STRAINER INSIDE FUEL TANK

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

•

CLEANOUT COVER

•• DRAIN PLUG

••

FUEL TANK STRAINER 822-D56 6. Before removing the strainer, clean any debris from the bottom of the tank and wipe it clean.

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

822-D55

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

FUEL TANK CLEANOUT COVER

Changing or cleaning the strainer:

9. Reinstall the strainer using the hex on end.

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

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

1. Park machine on level ground with attachment resting on the ground.

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

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

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

REMOVE FASTENERS AND SWING OUT THE LIGHT HOUSING

••

830-D41

•

ACCESS TO FUEL TANK

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

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

5. Remove the round fuel tank access cover plate and “O” ring.

3.15

Tigercat H822 Harvester

HYDRAULIC FILTER SERVICING GUIDELINES FOR H822 HARVESTERS

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

The oil from the 3 return lines passes through return strainers located inside the hydraulic tank.

IMPORTANT

NEVER PRE-FILL ANY HYDRAULIC FILTERS ON H822 HARVESTERS

HYDRAULIC TANK PRESSURE GAUGE

Tigercat generally does not recommend the prefilling of spin-on filters due to the risk of damage to the hydraulic system caused by unfiltered oil.

Unfiltered oil used to pre-fill filters enters directly into the hydraulic circuit. Contaminants in unfiltered oil can cause significant and costly damage to hydraulic valves, pumps and motors.

The cleanliness of hydraulic oil cannot be guaranteed unless it is always prefiltered before use.

•

••

•• •• ••

••

1 - WATER ABSORBING RETURN FILTER (COLOUR BLUE)

HYDRAULIC OIL FILTERS

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

The pressures stated are for normal operating conditions and temperatures.

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

FILTER SERVICE NOTE The filters should be checked/changed when the FILTER BYPASS warning light in the cab comes ON. For service and replacement intervals see SERVICE AND LUBRICATION CHART in THIS SECTION.

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

•

••

422-07

RETURN MANIFOLD

5 - HYDRAULIC RETURN FILTERS

Changing the filter: 1. Park machine on level ground with attachment resting on the ground. Stop engine.

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

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

4. For earlier machines only (822H0123, 82230191 TO 82230349). Wearing face protection, release air from the hydraulic reservoir by opening the AIR VENT VALVE. NOTE: Air pressure expelling from vent valve will blow any accumulated loose debris in tray.

3.16

Tigercat H822 Harvester

Lubrication and Maintenance Tighten filter an additional 3/4 turn.

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

AIR VENT VALVE

FILTER HEAD

DRIP TRAY DRAIN HOLE/HOSE

• •

•

GASKET

• HYDRAULIC OIL TANK (EARLIER MACHINES ONLY)

822-D35

FILTR_SEALS 2

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

Remove used gasket and clean gasket seat in head.

Apply clean oil to new gasket surfaces.

Install new gasket on inside lip of filter.

HYDRAULIC OIL FILTERS

••

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

DRIP TRAY

DRAIN HOSE

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

•

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

DRIP TRAY DRAIN HOSE

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

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

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

11. Recheck oil level.

• GASKET

•

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

9. Start the engine and check for leaks.

FILTER HEAD

•

FILTER ELEMENT

12. For earlier machines only (822H0123, 82230191 TO 82230349). Close air vent ball valve. *Refer to HYDRAULIC FILTER SERVICING GUIDELINES on PREVIOUS PAGE.

SQUARE SECTION GASKET INSTALLATION FILTR_SEALS 2

'O' RING GASKET INSTALLATION

z 'O' Ring Gasket

•

822-D69

FILTER ELEMENT

Square Section Gasket Remove used gasket and clean groove in head.

Apply clean oil to new gasket surfaces.

Install new gasket into groove in filter head.

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

3.17

Tigercat H822 Harvester

Lubrication and Maintenance

HYDRAULIC HIGH PRESSURE PILOT FILTER

Changing the filter:

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

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

CLOG INDICATOR SIGHT GLASS (IF EQUIPPED)

•

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

3. For earlier machines only (822H0123, 82230191 TO 82230349). Wearing face protection, release air from the hydraulic reservoir by opening the AIR VENT VALVE. 4.

822-D47

HIGH PRESSURE PILOT FILTER

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

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

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

6. Place rags below to catch any spilt oil.

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

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

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

EARLIER MACHINES ONLY

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

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

On earlier machines this filter incorporates a clog indicator.

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

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

11. For earlier machines only (822H0123, 82230191 TO 82230349). Close air vent ball valve. *Refer to HYDRAULIC FILTER SERVICING GUIDELINES on PREVIOUS PAGE.

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

3.18

Tigercat H822 Harvester

Lubrication and Maintenance

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

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

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

STRAINERS

ACCESS COVER

'O' RING ROUND ACCESS COVER

•

•

•

•• • 409-04

HYDRAULIC OIL TANK

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

•

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

DRAIN PLUG

1. Park machine on level ground with attachment resting on the ground.

2. Stop engine.

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

4. For earlier machines only (822H0123, 82230191 TO 82230349). Wearing face protection, release air from the hydraulic reservoir by opening the AIR VENT VALVE.

AIR VENT VALVE

822-06

•

DRAIN PLUG (ONLY ACCESSIBLE WITH MAIN CONTROL VALVE REMOVED)

HYDRAULIC OIL TANK

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

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

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

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

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

DRIP TRAY DRAIN HOLE/HOSE

•

12. Reinstall the strainers using the hex on end. Note: Repair any burrs created when removing the strainer before reinstalling.

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

14. Connect sensor wires to sensors on access cover.

15. Refill and check for leaks.

822-D35

HYDRAULIC OIL TANK (EARLIER MACHINES ONLY)

16. For earlier machines only (822H0123, 82230191 TO 82230349). Close air vent ball valve.

3.19

Tigercat H822 Harvester AIR INTAKE MAINTENANCE

Lubrication and Maintenance EXHAUST SYSTEM

ENGINE AIR PRE-CLEANER

PRECLEANER TO TURBO CHARGER

••

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

•

•

AIR CLEANER

•• AIR CLEANER UNLOADER VALVE

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

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

•

•

354-15

AIR CLEANER OUTLET TUBE

••

PRIMARY ELEMENT

••

•

•

•

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

SAFETY ELEMENT

ONLY THE PURIFIED AIR GOES TO THE AIR FILTER

PRECLEANER OPERATION

AIRCLEANER

AIR FILTER ELEMENTS

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

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

DISCHARGE PORT AREA

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

218-21B

PRECLEANER

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

OVER SERVICING Filter elements increase in dust cleaning efficiency as dust builds up on the media. Looks can be deceiving. A filter that looks dirty is actually more efficient than one that is clean. A filter with dust build up on the media reaches nearly 100% dust cleaning efficiency. Only when a filter is so clogged with dirt that air restriction goes beyond engine manufacturer’s guidelines, should a filter be replaced.

NOTE: This does not apply to oil filters.

3.20

Tigercat H822 Harvester

Lubrication and Maintenance

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

FILTER RESTRICTION INDICATOR

••

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

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

822-D42 FILTER RESTRICTION INDICATOR FILTER RESTRICTION INDICATOR

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

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

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

4. Always clean the inside of the outlet tube.

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

CLEAN OUT COVER

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

••

6. Inspect the new filter for damage.

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

8. Check connections and ducts for air tight fit.

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

421-15A

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

Remove the unloader valve from the tube of the air cleaner housing. A good valve is soft and flexible.

Check and clean the valve. If it was plugged, then check the filter elements as they may need to be replaced as well. Reattach the valve to the tube.

The valve should suck closed at about 1/3 of full throttle. When operating in extreme high dust conditions this valve should be checked and squeezed frequently to release dust accummulation.

AIR INTAKE CLEAN-OUT COVER

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

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

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

Continued on page 22

3.21

Tigercat H822 Harvester

Lubrication and Maintenance UNDERCARRIAGE SWIVEL ACCESS DOOR (LATER MACHINES)

Continued from page 21

••

• 822-D58

The undercarriage swivel access door is used on later machines. The notch in the door indicates the position of the bolt at the swivel point. The bolt at the swivel point is longer and is equipped with a clamp to prevent it from being fully removed from the undercarriage.

CHECK CONDITION OF SEAL

PRECLEANER

NOTCH IN DOOR INDICATES POSITION OF PIVOT POINT

AIR INTAKE SEAL

••

AIR INTAKE SEAL Periodically check to ensure seal on top of precleaner is making proper contact with the sealing surface of the inside top of the power door.

Hot air leakage at this seal will reduce engine power.

830-D45

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

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

NOTCH IN DOOR INDICATES POSITION OF PIVOT POINT

•• RUBBER ELBOWS AND TUBING

•

•• •• •

822-D58

INTAKE TUBING AND JOINTS

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

830-D44

SWIVEL ACCESS DOOR

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

DANGER

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

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

3.22

Tigercat H822 Harvester

Lubrication and Maintenance

TORQUE CHART LOCATION Cylinder, Hoist, (9442B) Piston nut Cylinder end cap bolts Cylinder, Stick, (15733B & 15734B) Piston nut Cylinder end cap bolts

THREAD DIAMETER

TORQUE (LUBRICATED) lbf-ft Nm

M18

6980 270

9460 367

M16

4159 126

5640 171

Cylinder pin retaining bolts

M20

380

515

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

M20

400

530

1" UNC

475

625

7/8" UNC

450-500

620-680

M16

200

275

M24 M22 M12 M12

675 540 80 80

925 725 110 110

M24 M22 M12 M16

675 540 80 200

925 725 110 275

M24 M22 M12 M12

675 540 80 80

925 725 110 110

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

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

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

Cab securing bolts Swing bearing Swing bearing bolts Swing gearbox mounting bolts Engine mounting Sisu Engine Bolts, brk’t/mount to chassis rear Bolts, brk’t/mount to chassis front Bolts, bracket to engine, front Bolts, bracket to engine, rear Cummins QSL9 Engine Bolts, bracket/mount to chassis rear Bolts, bracket/mount to chassis front Bolts, bracket to engine, front Bolts, bracket to engine, rear Cummins QSC Engine Bolts, bracket/mount to chassis rear Bolts, bracket/mount to chassis front Bolts, bracket to engine, front Bolts, bracket to engine, rear Undercarriage Track shoe bolts (D6) Track shoe bolts (FH400) Idler bolts Idler bolts Roller mounting bolts Roller mounting bolts Sprocket bolts Gearbox mounting bolts Drive motor mounting bolts

*T/T represents Torque-turn, this is a method of torquing the track shoe bolts which is fully described in section 11 of the Tigercat service manual.

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

TORQUECHART.XLS

3.23

Tigercat H822 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 5 BOLTS

GRADE 8 BOLTS

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

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

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

DRY LUBRICATED COARSE lbf-ft Nm lbf-ft Nm THREAD 1/4" - 20 7- 8 10 - 11 8 - 10 11 - 13 5/16" - 18 14 - 18 19 - 24 38275 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

METRIC

METRIC BOLT TORQUE SPECIFICATIONS SIZE

CLASS 4.8 LUBRICATED Nm lbf-ft Nm

DRY lbf-ft

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

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

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

M6 M8 M10

4.8 12.0 23.0

3.5 8.5 17.0

6.0 15.0 29.0

4.5 11.0 21.0

9.0 22.0 43.0

6.5 16.0 32.0

11.0 28.0 55.0

8.5 20.0 40.0

13.0 32.0 63.0

9.5 24.0 47.0

17.0 40.0 80.0

12.0 30.0 60.0

15.0 37.0 75.0

11.5 28.0 55.0

19.0 47.0 95.0

14.5 35.0 70.0

M12 M14 M16

40.0 63.0 100.0

29.0 47.0 73.0

50.0 80.0 125.0

37.0 60.0 92.0

75.0 120.0 190.0

55.0 88.0 140.0

95.0 150.0 240.0

70.0 110.0 175.0

110.0 175.0 275.0

80.0 130.0 200.0

140.0 225.0 350.0

105.0 165.0 225.0

130.0 205.0 320.0

95.0 150.0 240.0

165.0 260.0 400.0

120.0 190.0 300.0

M18 M20 M22

135.0 190.0 260.0

100.0 140.0 190.0

175.0 240.0 330.0

125.0 180.0 250.0

260.0 375.0 510.0

195.0 275.0 375.0

330.0 475.0 650.0

250.0 350.0 475.0

375.0 530.0 725.0

275.0 400.0 540.0

475.0 675.0 925.0

350.0 500.0 675.0

440.0 625.0 850.0

325.0 560.0 460.0 800.0 625.0 1,075.0

410.0 580.0 800.0

M24 M27 M30

330.0 490.0 675.0

250.0 360.0 490.0

425.0 625.0 850.0

310.0 650.0 450.0 950.0 625.0 1,300.0

M33 900.0 M36 1,150.0

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

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

3.24