TIGERCAT ХH822C LH822C H830C LH830C HARVESTER Service Manual – PDF DOWNLOAD

SERVICE MANUAL TIGERCAT H822C/LH830C HARVESTER TABLE OF CONTENTS

ISSUE 1.0, AUGUST 2006

SECTION INTRODUCTION ................................................................................................................. ii NON-APPROVED FIELD PRODUCT CHANGES .............................................................. iii SAFETY ............................................................................................................................ 1 CONTROLS AND OPERATION ................................ See separate OPERATOR'S MANUAL LUBRICATION AND MAINTENANCE ................................................................................. 3 HYDRAULIC SYSTEM/ LOAD SENSE CONTROL ............................................................. 4 PILOT/CHARGE SYSTEM ................................................................................................. 5 ELECTRICAL, GAUGES AND ALARMS ............................................................................ 6 ENGINE START AND STOP .............................................................................................. 7 ENGINE ANTI-STALL ......................................................................................................... 9 OIL COOLER AND COOLING FAN .................................................................................. 10 TRACK DRIVE ................................................................................................................. 11 BOOM FUNCTIONS ......................................................................................................... 12 LEVELLING ..................................................................................................................... 13 SWING ............................................................................................................................ 15 ATTACHMENT DRIVE ...................................................................................................... 17 ROTATE .......................................................................................................................... 20

H822C-SM00

H822C/LH830C Harvester Available Literature Operator's Manual, English ................................. Part No. 29531A Operator's Manual, Russian ................................ Part No. 30219A Service Manual, English (this manual) ................ Part No. 29532A Service Manual, Russian .................................... Part No. 30220A Parts Catalog ....................................................... Part No. 29533A

Tigercat

®

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

Fax: (519) 442-1855

Tigercat H822C/LH830C Harvester

Introduction

ii

Tigercat H822C/LH830C Harvester Harvester Tigercat H822C/LH830C

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 H822C/LH830C Harvesters Serial numbers:H822C 82231001 to 82231999 (Open Loop) LH830C 83081001 to 83081999 (Levelling, Open Loop) The operator's manual will assist the operator with the techniques of proper and safe operation of the H822C/LH830C 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 H822C/LH830C 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.

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Tigercat H822C/LH830C Harvester

SECTION 1 - SAFETY JULY 2006

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 ........................................................................................ 1.7 CAB EXITS .................................................................................................... 1.8 COOLING SYSTEM ..................................................................................... 1.17 EMERGENCY CAB EXITS ............................................................................ 1.8 ENGINE DOORS ......................................................................................... 1.19 ER BOOM SYSTEM PRECAUTIONS .......................................................... 1.18 EXHAUST FUMES ....................................................................................... 1.19 FIRE PREVENTION ..................................................................................... 1.21 FIRE PREVENTION GUIDELINES ........................................................... 1.21 WHAT ELSE TO DO BEFORE YOU EXPERIENCE A FIRE .................... 1.21 WHAT TO DO AFTER A FIRE ................................................................. 1.22 WHAT TO DO IN CASE OF A MACHINE FIRE ........................................ 1.21 FLUID LEAKS .............................................................................................. 1.17 HARVESTING ATTACHMENT – GENERAL SAFETY ................................ 1.13 HAZARD ZONE ............................................................................................. 1.3 HYDRAULIC PRESSURE HAZARD ............................................................ 1.17 LOOSE CLOTHING HAZARD ..................................................................... 1.17 MACHINE STABILITY AND TRACTION ............................................ 1.10, 1.11 PARKING BOOM ......................................................................................... 1.18 PARKING THE MACHINE ........................................................................... 1.14 PROTECTIVE CLOTHING ............................................................................. 1.3 SAFETY INTERLOCK SWITCHES ON CAB DOORS ................................... 1.9 SAFETY PRECAUTIONS, GENERAL ........................................................... 1.3 SAFETY PRECAUTIONS, OPERATING ....................................................... 1.8 SAFETY PRECAUTIONS, SERVICING ....................................................... 1.15 SAFETY SYMBOLS ....................................................................................... 1.2 SIGNAL WORDS ........................................................................................... 1.2 WELDING, PRIOR TO ................................................................................. 1.16 WORKING WITH OIL .................................................................................... 1.5

Tigercat H822C/LH830C 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.

1.2

Tigercat H822C/LH830C Harvester

Safety

GENERAL SAFETY PRECAUTIONS IMPORTANT

24 VOLT

KEEP BACK 500 FEET 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.

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

500 FEET

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.

500 FEET

500 FEET

Always read the operator's manual before operating the machine. Pay close attention to WARNINGS and HAZARD identifications

500 FEET

LH830-02

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.

Do not let untrained persons operate the machine.

HAZARD ZONE

DANGER 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.

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

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

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

1.3

Tigercat H822C/LH830C Harvester

Safety

GENERAL SAFETY PRECAUTIONS continued

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.

To reduce risk of fire, machines should be completely cleaned of debris at least daily, particularly around the engine exhaust components. Hydraulic oil leaks, excess grease, fuel and oil accumulation (including spillage) should be eliminated immediately, always shut off engine before cleaning machine.

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

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

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

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

Do not jump off the machine at any time.

Machine should be washed completely at every major service.

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

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

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

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

Do not use the machine foot controls as steps.

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.

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

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

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, oil shields, or other devices removed.

1.4

Tigercat H822C/LH830C Harvester

Safety 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).

GENERAL SAFETY PRECAUTIONS continued

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

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

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

•

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.

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: •

Oils used in this machine may be hot enough to cause serious burns.

• •

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).

•

• • • • • •

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

1.5

Tigercat H822C/LH830C Harvester

Safety

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

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

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

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

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.

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

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.

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

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

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

If the machine must be transported, make sure that it is adequately secured to the transporting vehicle. Refer to vehicle moving instructions page in SECTION 2.

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

Reduce engine speed to LOW IDLE and let run for approximately 5 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.

1.6

Tigercat H822C/LH830C 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 as follows: •

turn off master switch in cab

•

disconnect negative starter motor cable from both battery posts

•

disconnect positive master solenoid cable from both battery posts

•

•

•

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.

1.7

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

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

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.

Tigercat H822C/LH830C 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 either of these restraint systems at all times when operating the machine.

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

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

ALWAYS shut OFF engine before using the escape hatch exit.

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

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

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

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

WARNING

THIS MACHINE IS EQUIPPED WITH A COMPUTER CONTROLLED HEATING ELEMENT IN THE ENGINE INTAKE SYSTEM. STARTING FLUIDS WILL EXPLODE ON CONTACT WITH THE HEATING ELEMENT.

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

1.8

Tigercat H822C/LH830C Harvester

Safety 4. Do not allow people or other pieces of equipment near the harvesting operation.

OPERATING SAFETY PRECAUTIONS continued

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

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

••

6. Use only prearranged and approved signalling practices.

WARNING

••

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

INTERLOCK SWITCH (FRONT DOOR)

822-D02

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

Push the red PILOT OFF switch and confirm the yellow PILOT OFF light is ON before removing seat belt. DO NOT use the front door interlock switch to turn pilot OFF.

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

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

Secure loose items in the cab.

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

CAUTION

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

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

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

To operate: Close the front door and press the PILOT RESET switch.

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

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.

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.

WARNING

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.

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

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

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

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

1.9

Tigercat H822C/LH830C Harvester

Safety

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

NEVER travel across a STEEP slope or side hill: •

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

•

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

•

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

•

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

1.10

Tigercat H822C/LH830C Harvester

Safety

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

26°

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

LH830-08 LH830-09

UPHILL

NORMAL WORKING RANGE OF BOOM SYSTEM

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

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

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

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

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

REDUCED STABILITY WORKING RANGE

• TRACK GEAR BOX AT REAR OF UNDERCARRIAGE LH830-07

22°

FIG. 1 WORKING RANGES

1.11

Tigercat H822C/LH830C Harvester

Safety

OPERATING SAFETY PRECAUTIONS continued •

NORMAL WORKING RANGE OF BOOM SYSTEM

Never travel across a STEEP slope or side hill.

••

UPHILL

•

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

•

Do not lift or move objects that exceed machine stability.

•

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

•

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

•

TRACK GEAR BOX AT REAR OF UNDERCARRIAGE

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

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

•

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

FIG. 1 WORKING RANGES

LH830-07

BOOM TO FRONT

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

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

•

•

••

REDUCED STABILITY WORKING RANGE

KEEP ATTACHMENT CLOSE TO GRADE

••

•

TRACK GEAR BOX AT REAR OF UNDERCARRIAGE LH830-04

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

FIG. 3 CLIMBING SLOPE

BOOM TO REAR

KEEP ATTACHMENT CLOSE TO GRADE

TRACK GEAR BOX AT REAR OF UNDERCARRIAGE

LH830-05

1.12

••

•

FIG.4 DESCENDING SLOPE

Tigercat H822C/LH830C 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.

1.13

Tigercat H822C/LH830C 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.

24863A

•

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

NOTE: Wait 30 seconds after engine shut down before turning off battery disconnect switch. If battery disconnect is turned off before this the engine ECM (Engine Control Module) will register a fault.

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.

1.14

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 H822C/LH830C Harvester

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

SERVICING SAFETY PRECAUTIONS

WARNING

WARNING, HOT FLUIDS AND HOT MACHINE SURFACES CAN CAUSE SERIOUS BURNS!

Conduct maintenance inspections at least as frequently as recommended in section 3 of the THIS MANUAL.

24863A

When servicing or repairing equipment, shut the engine down. Turn Battery Disconnect switch OFF and lock out the switch in accordance with local regulations. This machine is equipped with a remotely operated battery disconnect relay. Some wiring on the machine is live even when the battery disconnect switch is off. When servicing the electrical system, remove the battery cables from the batteries disconnecting the negative cables first.

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

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

1.15

•

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

•

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

•

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

Tigercat H822C/LH830C Harvester

Safety

SERVICING SAFETY PRECAUTIONS continued

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

•

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

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

822C-05

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

IQAN DISPLAY DISCONNECT

Disconnect the IQAN display 6 pin connector and the control module 42 pin connector.

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

•• DISCONNECT THE 42 PIN PLUG FROM THE XS MODULE

•• ENGINE ANT-STALL DISCONNECT Disconnect the multi-pin plug from the engine anti-stall controller located inside the cab, mounted on the rear electrical cover door.

822C-03

• • 822C-04

•

••

DISCONNECT 4 PIN ENGINE POWER CONNECTOR

•

IQAN XS MODULE DISCONNECT

IMPORTANT

24 VOLT

DISCONNECT THE TWO MULTI-PIN PLUGS FROM THE ENGINE ECM

ELECTRICAL SYSTEM

ENGINE ECM DISCONNECT -LEFT SIDE OF ENGINE Disconnect the engine ECM (Engine Control Module) by unplugging the four pin engine power connector and the two multipin connectors from the left side of the engine.

822C-34

1.16

Tigercat H822C/LH830C 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.

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.

Never use your bare hand to check for fluid leaks.

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

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.

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

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

Pressure can be maintained in a hydraulic system long after the power source and pump have been shut down. Lower the attachment to the ground, stop engine and relieve trapped pressure before performing work on components, or disconnecting any hoses. Refer to PARKING BOOM diagrams (FIG.5 ). Accumulators will self drain within 2 minutes of stopping the engine on this MODEL. Also, relieve pressure in the hydraulic reservoir by opening hydraulic tank vent valve and waiting until the sound of escaping air stops.

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.

1.17

Tigercat H822C/LH830C Harvester

Safety MACHINE MODELS EQUIPPED WITH A LEVELLING SYSTEM

SERVICING SAFETY PRECAUTIONS continued

Always install support braces in the levelling mechanism while performing service and maintenance tasks. This area is a crush zone.

Keep clear to avoid personal injury or death.

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.

DANGER

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

23526A R0

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

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

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

•

Do not use the boom to service other equipment.

(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 use the boom to lift items such as tires, engines, cylinders, boom components, 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 felling function.

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.

HOIST CYLINDER FULLY COLLAPSED HEAD

•

ROTATOR

•

•• TIP OF STICK BOOM FULLY SUPPORTED

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.

1.18

Tigercat H822C/LH830C 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.

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

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

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

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.

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

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

Dispose of fluids properly.

WARNING 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.

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

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

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

1.19

Tigercat H822C/LH830C Harvester

Safety radiator, hydraulic oil cooler, A/C condenser core and charge air cooler to prevent overheating of the engine and hydraulics.

Refer to CLEANING A/C CONDENSER AND COOLING ASSEMBLY in SECTION 2 of the OPERATOR’S MANUAL.

FIRE PREVENTION

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

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

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

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

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

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.

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

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

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

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

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

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

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

5. Remove debris and blow out dust regularly from the air intake doors, engine 1.20

Tigercat H822C/LH830C Harvester

Safety •

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

•

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

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

•

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

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

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

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

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

*NOTE: Dry chemical fire suppression

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

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

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

WHAT TO DO IN CASE OF A MACHINE FIRE •

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

•

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

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

RED FIRE BUTTON

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

••

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

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

•

WHAT 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.

FIRE SUPPRESSION CONTROLS Activate the fire suppression system* using the FIRE BUTTON. This will shut off the engine and all power to the machine.

860-029

1.21

•

If you can safely do so, after engine has stopped, hold the fire suppression system override button to supply power to the radio and call for help.

•

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.

•

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

Continued on page 22

Tigercat H822C/LH830C Harvester

Safety heat of any machine components or debris in the area.

FIRE PREVENTION continued

•

Remain with the machine at a safe distance, 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.

Continued from page 21

•

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.

WHAT TO DO AFTER A FIRE •

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

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

•

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.

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

•

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

•

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

•

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

•

•

*NOTE: Dry chemical fire suppression

20229A

•

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

TYPICAL FIRE EXTINGUISHER ACCESS HOLE

**NOTE: Water mixing with dry chemical

Attempt to locate the source of the fire then place the nozzle of the fire extinguisher into the appropriate fire extinguisher access hole and discharge the extinguisher.

•

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

•

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

powder forms an acidic paste that will damage surfaces and wiring. See fire suppression systems manual for proper cleanup procedures.

1.22

Tigercat H822C/LH830C 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

1.23

Tigercat H822C/LH830C Harvester

Safety

1.24

Tigercat H822C/LH830C Harvester SECTION 3 - LUBRICATION & MAINTENANCE JULY 2006

CONTENTS - SECTION 3 ACCESS DOOR, UNDERCARRIAGE, SWIVEL ......................................... 3.24 AIR CONDITIONING, CHECKING THE SYSTEM ...................................... 3.14 AIR INTAKE MAINTENANCE ..................................................................... 3.22 APPROVED HYDRAULIC OILS ................................................................... 3.9 CHECKING THE AIR CONDITIONING SYSTEM ....................................... 3.14 EMERGENCY EXITS, CHECK MONTHLY ................................................... 3.3 ENGINE AIR CLEANER MAINTENANCE .................................................. 3.22 ER BOOM SYSTEM .................................................................................... 3.13 FILTER AND LUBRICATION SCHEDULE .................................................. 3.11 FILTERS CHANGING HYDRAULIC RETURN FILTERS ........................................ 3.18 ENGINE FILTERS ................................................................................... 3.16 FUEL FILTER/WATER SEPARATOR ..................................................... 3.16 FUEL TANK STRAINER .......................................................................... 3.17 HYDRAULIC OIL RETURN FILTERS ..................................................... 3.18 HYDRAULIC OIL RETURN STRAINERS/DIFFUSERS .......................... 3.21 PILOT, HIGH PRESSURE ....................................................................... 3.20 SERVICING GUIDELINES FOR OIL FILTERS ....................................... 3.18 FILTERS, HYDRAULIC OIL ........................................................................ 3.18 FIRE PREVENTION ...................................................................................... 3.3 GENERAL MAINTENANCE .................................................................. 3.3, 3.4 HYDRAULIC OIL FILTERS ......................................................................... 3.18 HYDRAULIC OILS ........................................................................................ 3.9 LUBRICATION POINTS DIAGRAM, LEVELLER COMPONENTS ............... 3.7 LUBRICATION SCHEDULE ........................................................................ 3.11 NEW MACHINE MAINTENANCE .................................................................

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

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

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

3.2 3.2 3.2 3.2

OIL LOST FROM LEAKAGE ......................................................................... 3.2 PARKING BOOM .............................................................................. 3.12, 3.13 PREVENTIVE MAINTENANCE SCHEDULE ................................................ 3.2 SCHEDULED MAINTENANCE FREQUENTLY .......................................................................................... 3.5 8 HOURS ................................................................................................... 3.5 24 HOURS ................................................................................................. 3.6 125 HOURS ............................................................................................... 3.6 250 HOURS ............................................................................................... 3.7 500 HOURS ............................................................................................... 3.8 1000 HOURS ............................................................................................. 3.8 2000 HOURS ............................................................................................. 3.8 LUBRICATION POINTS DIAGRAM, LEVELLER COMPONENTS ............ 3.7 SERVICE PLATFORM (IF EQUIPPED) ...................................................... 3.25 SWING DRIVE GEARBOX LOWER BEARING LUBRICATION ......................................................... 3.12 LUBRICATION OF SWING PINION AND SWING BEARING ................. 3.12 UPPER GEARING LUBRICATION .......................................................... 3.12 TORQUE CHART ....................................................................................... 3.26 TORQUE CHART, GENERAL .................................................................... 3.27 TORQUE, FLUID CONNECTIONS ......................................... 3.28, 3.29, 3.30

Tigercat H822C/LH830C Harvester

Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE FOR H822C/LH830C 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.

Tightening points:~

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

All hydraulic connections Hose clamps All cylinder and boom pin retainers

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

Check swing bearing bolt torque Check all leveller pivot bearing retaining bolts (If equipped with leveller) Engine mounting bolts

IMPORTANT

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

Track shoe bolts Track roller retaining bolts

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

Track sprocket retaining bolts

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

Track drive gearbox mounting bolts Track drive motor mounting bolts

OIL LOST FROM LEAKAGE

Swing gearbox mounting bolts Cab securing bolts

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

Any other loose nut, bolt or fitting

3.2

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

Tigercat H822C/LH830C Harvester

Lubrication and Maintenance

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

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

Always have a fire extinguisher at hand.

Clean around filler caps before checking or adding fluids.

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

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

Always install door safety struts when working on machine.

Clean up spills as soon as possible.

Always release pressure in hydraulic tank before breaking a connection. For machines with pressurized tanks.

Always use clean oil and containers.

Clean fire suppression system sensors.

CHECK EMERGENCY EXITS MONTHLY~

Drain dirty oil while still warm.

Two alternate exit routes are provided: side door emergency exit and escape hatch/ emergency exit. These are only to be used if the front door cannot be opened.

Do not exceed recommended fluid levels.

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

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

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

Refer to EMERGENCY EXIT MAINTENANCE GUIDE in SECTION 2 of the OPERATOR'S MANUAL for checking procedure.

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

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

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

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

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

Clean away all branches, bark and chips.

Clean up all traces of oil to avoid fires.

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

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

During daily operation of the machine, the occurrence of exhaust leaks are usually

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 Continued on page 4

3.3

Tigercat H822C/LH830C Harvester

Lubrication and Maintenance

GENERAL Continued from page 3

regular cleaning program will improve the chances of successfully extinguishing a fire.

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

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

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

Also refer to FIRE PREVENTION in SECTION 1 of THIS MANUAL for additional information.

3.4

Tigercat H822C/LH830C Harvester

Lubrication and Maintenance

SCHEDULED MAINTENANCE • ‡ Cylinders; boom, stick & tilt;

FREQUENTLY:~

Standard Boom; 8-fittings - purge

• Check engine cooling air intake screens for possible restriction.

ER Boom System; 10-fittings - purge

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

‡ Lubricating cylinder pins and boom joints:1. Ensure machine is on level ground 2. Fully retract telscopic stick (if equipped)

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

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

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

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

EVERY 8 HOURS:~ • Perform "frequently" maintenance

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

And in addition:~ • Check engine coolant level

• Remove potentially damaging limbs or sticks.

• Check engine oil level

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

• Drain water from fuel/water separator • Check intake and discharge areas of engine air precleaner • Check air cleaner unloader valve

• For loose nuts, bolts and fittings.

• Check air filter restriction indicator

• Condition and tension of fan belts.

• Check hydraulic oil level

• Visually check condition of tracks.

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

• Conduct an overall visual inspection.

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

• Cylinders, Levelling; 4-fittings total - purge (If equipped with leveller) • Thrust bearing, Levelling; 2-fittings - purge (If equipped with leveller) • ‡ Boom joints: Standard Boom; 6-fittings - purge Standard w/Tilt Link; 12-fittings - purge ER Boom System; 12-fittings - purge

3.5

Tigercat H822C/LH830C Harvester

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 24 HOURS :~

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

• Perform "frequently" maintenance

• Tracks, track frames and carbody

• Perform 8 hour maintenance

• Swing bearing area

And in addition:~

• Attachment

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

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

EVERY 125 HOURS:~

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

• Perform "frequently" maintenance • Perform 8 hour maintenance

• Wear in any other components

• Perform 24 hour maintenance

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

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

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

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

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

• Check battery fluid level unless maintenance free

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

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

3.6

Tigercat H822C/LH830C Harvester

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 250 HOURS:~

• Check condition and tension of fan belts.

• Perform "frequently" maintenance

• Replace engine oil and filter.

• Perform 8 hour maintenance

• Replace engine fuel filter(s).

• Perform 24 hour maintenance

• Replace filter in fuel filter/water separator.

• Perform 125 hour maintenance

• Replace air intake primary element.

And in addition:~

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

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

Remove/replace protection plugs to access.

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

Remove/replace protection plugs to access.

(If equipped with leveller)

DANGER

• Lubricate swing drive gearbox lower bearing; 2-fittings - 5 shots each ‡ Do not use a power grease gun. ‡ With swing gearbox at operating temperature slowly add 5 shots of lithium based EP2 to each side of the gearbox. Note: During cold weather applications the swing function must be operated for several hours to achieve operating temperature. Caution: Do not force grease, gearbox failure may result. Do not use winter grease. Grease should purge from gearbox pinion seal.

23526A R0

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

LEVELLING CYLINDER 2 FTG/8

THRUST BEARING 1 FTG/8

• THRUST BEARING

• •

1 FTG/8

•

• •

• •

UPPER PIVOT BEARING 2 FTG/250

LEVELLING CYLINDER

INTERMEDIATE PIVOT BEARING

2 FTG/8

1 FTG/250 2 SIDES

2 SIDES 830-51

LEVELLER COMPONENT LUBRICATION POINTS

3.7

Tigercat H822C/LH830C Harvester

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 500 HOURS:~

EVERY 1000 HOURS:~

• Perform "frequently" maintenance

• Perform "frequently" maintenance

• Perform 8 hour maintenance

• Perform 8 hour maintenance

• Perform 24 hour maintenance

• Perform 24 hour maintenance

• Perform 125 hour maintenance

• Perform 125 hour maintenance

• Perform 250 hour maintenance

• Perform 250 hour maintenance

And in addition replace:~

• Perform 500 hour maintenance

• Air intake safety element.

And in addition check:~

• Hydraulic oil return filters. †

• Fuel in-tank strainer

• Hydraulic oil high pressure pilot filter. †

• Replace air cleaner unloader valve

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

EVERY 2000 HOURS:~

• Door cylinder pins apply oil liberally

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

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

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

• Torque on track drive gearboxes and motor mounting bolts.

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

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

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

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

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

3.8

Tigercat H822C/LH830C 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 brake.

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

3.9

Tigercat H822C/LH830C Harvester

Lubrication and Maintenance

INFORMATION TO FOLLOW THE INFORMATION FOR THIS PAGE WAS NOT AVAILABLE AT PRESS TIME AND HAS BEEN INTENTIONALLY OMITTED.

LUBRICATION DIAGRAM 3.10

Tigercat H822C/LH830C Harvester

Lubrication and Maintenance

Tigercat® Model H822C/LH830C HARVESTER FILTER AND LUBRICATION SCHEDULE

9.5

22.7

6

QTY

USG

36

REMARKS/LUBRICANT

1

COOLING SYSTEM

CHK

2

ENGINE OIL/FILTER; CUMMINS QSL9

CHK

REP

3 4 5

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

DRN

REP REP

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

14

SWING BEARING ***

15

SWING PINION

16

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

17

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

LUB

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

LUB

19

LEVELLER CYLINDERS (IF EQUIPPED WITH LEVELLER)

20

LEVELLER THRUST BEARING (IF EQUIPPED WITH LEVELLER)

21

LEVELLER PIVOTS (IF EQUIPPED WITH LEVELLER)

18

CHANGE COOLANT EVERY 2 YEARS

LITRE

2000

CAPACITY

1000

500

250

DESCRIPTION

125

SERVICE EVERY

8

SERVICE POINT NO.

REFER TO Tigercat OPERATOR'S MANUAL FOR FURTHER INFORMATION

LUB 24HR *** LUB LUB³

134 ..250

35 ..66

6

1.5

7.6

2

1

1

10 SHOTS

1

10 SHOTS

1

5 SHOTS EACH FITTING

2

PURGE

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

BY SEASONAL OIL CHANGE SEE APPROVED HYDRAULIC OILS* *Tigercat RECOMMENDS REGULAR USE OF AN OIL TESTING PROGRAM 5 STANDARD FILTERS 1 WATER ABSORBING FILTER (COLOUR BLUE) *CHECK RESTRICTION INDICATOR (IF EQUIPPED) FILL WITH S 75W-90 (SPEC) RECOMMENDED SYNTHETIC GEAR OIL FOR SEVERE DUTY APPLICATIONS IF LEAKING REMOVE AND REPAIR FILL WITH SAE 30 OR 40 GREASE WHILE SWINGING *** EVERY 24 HOURS LITHIUM BASE EP2 GREASE GREASE WHILE SWINGING LITHIUM BASE EP2 GREASE LITHIUM BASE EP2 GREASE

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

PURGE PURGE

8 10

LUB

PURGE

4

LITHIUM BASE EP2 GREASE

LUB

PURGE

2

LITHIUM BASE EP2 GREASE

PURGE

6

LITHIUM BASE EP2 GREASE

LUB

22

DOOR HINGES

LUB

1 SHOT

20

LITHIUM BASE EP2 GREASE

23

DOOR CYLINDER PINS

LUB

LUB

2

APPLY OIL LIBERALLY

24

ATTACHMENT

SEE MANUFACTURER'S MAINTENANCE SCHEDULE

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

H822C LH830C LUBCHART.XLS 06/2006

3.11

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

Tigercat H822C/LH830C Harvester LUBRICATION OF SWING DRIVE GEARBOX

Lubrication and Maintenance HOIST CYLINDER FULLY COLLAPSED HEAD

UPPER GEARING LUBRICATION

•

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'.

••

•• TIP OF STICK BOOM FULLY SUPPORTED

LH830-04

NOTE: FULLY RETRACT TELESCOPIC STICK BOOM IF EQUIPPED

PARKING BOOM FIG.5

HOIST CYLINDER FULLY RETRACTED

• LUBE FITTINGS

•• •

TIP OF STICK BOOM FULLY SUPPORTED 830-08

PARKING BOOM. FIG.6

LUBRICATION OF SWING PINION AND SWING BEARING

LH830-31

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

••

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

250 24

20065A R0

The lube fittings are remotely mounted for easy access.

•• 250 8

20065A R0

860C-032

Using a hand grease gun, pump 5 shots of grease into each grease fitting. DO NOT OVERGREASE, make sure machine is warmed up in winter or lower seal can be damaged. 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

SWING PINION & BEARING FITTINGS To lubricate the swing bearing, apply 10 shots grease while swinging every 24 hours to one of the two grease fittings located on the seat pedestal in the operator's cab. To lubricate the swing pinion (or teeth) apply 10 shots grease every 8 hours while swinging to the other grease fitting located on the seat pedestal. The grease fittings are clearly labelled.

For lubrication schedule, refer to SCHEDULED MAINTENANCE in THIS SECTION.

3.12

Tigercat H822C/LH830C 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

LH830-04

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 machines 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.

3.13

Tigercat H822C/LH830C 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 The compressor and charge valves are accessed hot during machine operation. Always use on the top left side of the engine. The receiver dryer care when cleaning to ensure that debris is mounted to the back of the engine compartment. removed from one area of the machine does Perform following inspection along with 125 HOURS not accumulate on other areas of the inspection outlined in SCHEDULED MAINTENANCE machine. in THIS SECTION. c. Check for dirt and debris; on the evaporator coil located inside the A/C-heater unit and also a. Check re-circulating and fresh air filters in the inside of the A/C-heater unit. Clean as operator's cab. Refer to SECTION 2 of the required.

OPERATOR'S MANUAL. d. With engine stopped, check and adjust compressor drive belt tension.

A/C CONDENSER OIL COOLER/ RADIATOR/CAC ASSEMBLY

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

Run air conditioning system for 3 - 5 minutes.

IMPORTANT

•

••

• SLIDE DEBRIS SCREEN OUT AND REMOVE

822C-38

CHECK A/C CONDENSER CORE

b. Check the condenser core for dirt and debris.

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

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

3.14

Check to see that compressor clutch will engage.*

Tigercat H822C/LH830C 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-

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

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

3.15

Tigercat H822C/LH830C Harvester FILTERS - REMOVE AND REPLACE

Lubrication and Maintenance ENGINE FILTERS

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.

Refer to the appropriate engine manufacturers operation and maintenance manual for correct procedures and time intervals when servicing the engine coolant, oil and fuel filters. Read and understand the SAFETY section in each of these manuals.

IMPORTANT Refer to the appropriate engine manufacturers operation and maintenance manual for correct procedures and time intervals when servicing the engine coolant, oil and fuel filters.

PRIMARY FUEL FILTER

SECONDARY FUEL FILTER/ WATER SEPARATOR

•• •• WATER-IN-FUEL SENSOR CONNECTION

822C-29

DRAIN TAP

• ••

ENGINE FUEL FILTER/WATER SEPARATOR

3.16

WARNING Do not pre-fill engine fuel filters used on Cummins QSL9 engines

Tigercat H822C/LH830C Harvester

Lubrication and Maintenance

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

CLEANOUT COVER

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).

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

9. Reinstall the strainer using the hex on end.

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

••

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

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

FUEL TANK CLEANOUT COVER Changing or cleaning the strainer: 822C-31

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

1. Park machine on level ground with 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.

3. Open the access door to the rear of the left cab door 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.

STRAINER INSIDE FUEL TANK

••

• DRAIN PLUG 822-D56

FUEL TANK STRAINER 3.17

Tigercat H822C/LH830C Harvester

Lubrication and Maintenance 5 - HYDRAULIC RETURN FILTERS

HYDRAULIC FILTER SERVICING GUIDELINES

RETURN MANIFOLD

••

IMPORTANT

•

NEVER PRE-FILL HYDRAULIC FILTERS 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.

• ••

•

• • 822C-22

1 - WATER ABSORBING RETURN FILTER (COLOUR BLUE)

HYDRAULIC OIL FILTERS

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 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.

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 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.

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

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

Note: Levelling machines are equipped with a service platform which should be installed for service procedures in the hydraulic tank compartment. Refer to SERVICE PLATFORM in THIS SECTION.

3.18

Tigercat H822C/LH830C Harvester

Lubrication and Maintenance

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

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

4. Wearing face protection, release air from the hydraulic reservoir by opening the AIR VENT VALVE. NOTE: Air pressure expelling from vent valve will blow accumulated loose debris in tray.

9. Start the engine and check for leaks.

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

AIR VENT VALVE

11. Recheck oil level.

12. Close air vent ball valve.

DRIP TRAY DRAIN HOLE/HOSE

*Refer to HYDRAULIC FILTER SERVICING GUIDELINES on PREVIOUS PAGE.

•• 822-D35

WARNING

HYDRAULIC OIL TANK

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

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

WARNING, HOT HYDRAULIC OIL AND HOT MACHINE SURFACES CAN CAUSE SERIOUS BURNS!

7. The Tigercat spin-on filter element is supplied with two gaskets. The round ('O' ring style) section gasket is used for all return filters.

Discard the square section gasket.

•

Before servicing the machine, allow the hydraulic system and machine surfaces to cool down.

•

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

•

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

FILTER HEAD

• • GASKET

• FILTR_SEALS

FILTER ELEMENT

'O' RING GASKET INSTALLATION

Remove used gasket and clean gasket seat in head.

Apply clean oil to new gasket surfaces.

Install new gasket on inside lip of filter.

DO NOT pre-fill filter *. Screw on new filter until gasket makes contact with filter head.

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.

3.19

Tigercat H822C/LH830C Harvester

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

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

3. Wearing face protection, release air from the hydraulic reservoir by opening the AIR VENT VALVE. 4.

HIGH PRESSURE PILOT FILTER 822C-40 HYDRAULIC HIGH PRESSURE PILOT FILTER There is a hydraulic high pressure pilot filter placed ahead of the pilot supply valve (pressure reducing/ pressure relieving valve) to filter the oil before it enters to pilot system.

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

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

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

WARNING

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

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

6. Place rags below to catch any spilt oil.

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

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

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

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

11. Close air vent ball valve.

WARNING, HOT HYDRAULIC OIL AND HOT MACHINE SURFACES CAN CAUSE SERIOUS BURNS!

•

Before servicing the machine, allow the hydraulic system and machine surfaces to cool down.

•

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

•

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

*Refer to HYDRAULIC FILTER SERVICING GUIDELINES in THIS SECTION.

3.20

Tigercat H822C/LH830C Harvester

Lubrication and Maintenance

HYDRAULIC OIL RETURN STRAINERS/DIFFUSERS

'O' RING

STRAINERS

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

ROUND ACCESS COVER

••

• •

••

ACCESS COVER

• •

822C-42

HYDRAULIC OIL TANK DRAIN PLUG

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.

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.

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

AIR VENT VALVE

DRIP TRAY DRAIN HOLE/HOSE

•

822-06

•

DRAIN PLUG (ONLY ACCESSIBLE WITH MAIN CONTROL VALVE REMOVED)

HYDRAULIC OIL TANK

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

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.

12. Reinstall the strainers using the hex on end.

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

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

822-D35

HYDRAULIC OIL TANK

14. Connect sensor wires to sensors on access cover.

5. Turn BATTERY DISCONNECT SWITCH to the 15. Refill and check for leaks.

OFF position. Always install a “DO NOT 16. Close air vent ball valve.

START ENGINE” sign on the operator’s cab door and in the engine compartment when making repairs to the machine.

3.21

Tigercat H822C/LH830C Harvester AIR INTAKE MAINTENANCE

Lubrication and Maintenance EXHAUST SYSTEM

PRECLEANER

ENGINE AIR PRE-CLEANER The engine air precleaner cleans engine air before it reaches the air cleaner filter elements. It removes contaminants such as dust, powder, insects, rain and snow. This precleaner is self powered and self cleaning requiring virtually no maintenance.

However, it should be checked periodically to make sure that foreign materials have not plugged the intake area or the discharge port area and that the rotor spins freely.

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

TO TURBO CHARGER

• ••

••

AIR CLEANER

AIR CLEANER UNLOADER VALVE

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

••

•• AIR CLEANER

822C-26

•

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

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

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.

PRECLEANER

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

NOTE: This does not apply to oil filters.

To ensure maximum engine protection, it is 3.22

Tigercat H822C/LH830C 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

AIR INTAKE CLEANOUT COVER

AIR INTAKE CLEANOUT COVER PLATE

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

Remove the unloader valve from the tube of the air cleaner housing. A good valve is soft and flexible.

Check and clean the valve. If it was plugged, then check the filter elements as they may need to be replaced as well. Reattach the valve to the tube.

The valve should suck closed at about 1/3 of full throttle. When operating in extreme high dust conditions this valve should be checked and squeezed frequently to release dust accumulation.

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

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

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

3.23

Tigercat H822C/LH830C Harvester

•

Lubrication and Maintenance UNDERCARRIAGE SWIVEL ACCESS DOOR

CHECK CONDITION OF SEAL

••

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.

NOTCH IN DOOR INDICATES POSITION OF PIVOT POINT

PRECLEANER

••

AIR INTAKE SEAL

822C-37

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

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

NOTCH IN DOOR INDICATES POSITION OF PIVOT POINT

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

••

RUBBER ELBOWS AND TUBING

••

• • ••

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 822C-36

INTAKE TUBING AND JOINTS

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

INTAKE TUBING AND JOINTS 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.

3.24

Tigercat H822C/LH830C Harvester SERVICE PLATFORM (IF EQUIPPED)

Lubrication and Maintenance DOOR PROP

The service platform is used on levelling machines (LH830C) which are not equipped with counterweights.

• SERVICE PLATFORM

SERVICE PLATFORM

••

•• THREADED FASTENER

• ••

822C-99

•

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

••

SNAP PINS

PUMP ACCESS DOOR 822C-102

When not in use always secure the service platform in its storage location.

SERVICE PLATFORM STORAGE LOCATION The service platform is stored on a bracket on the pump door (RH rear). The platform is secured in its storage location with two snap pins and a threaded fastener.

The service platform is used for service and maintenance access to the hydraulic tank compartment (LH rear door).

822C-100

• 822C-98

SERVICE PLATFORM INSTALLED

LINE UP PIN WITH HOLE IN FLOOR

INSTALLING SERVICE PLATFORM

Install the platform as shown. Tilt platform and line up the pin on the bottom of the platform with the hole in the floor of the hydraulic tank compartment.

Lower the platform into place and secure the door prop.

822C-101

3.25

Tigercat H822C/LH830C Harvester

Lubrication and Maintenance

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

THREAD DIAMETER

TORQUE (LUBRICATED) lbf-ft Nm

M18

6980 270

9460 367

M8 M16

hand tight 18 225

hand tight 24 305

M16

4159 126

5640 171

M22

3200 480

4340 650

Cylinder pin retaining bolts

M20

380

515

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

M20

400

530

1" UNC

475

625

7/8" UNC

450-500

620-680

M16

200

275

M24 M22 M12 5/8" UNC

675 540 80 160-175

925 725 110 215-235

1/2" 7/16" UNC GR5

80-88 40

109-119 54

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

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

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

M24

675

925

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

*T/T represents Torque-turn, this is a method of torquing the track shoe bolts which is fully described in section 11 of the Tigercat service manual.

3.26

Tigercat H822C/LH830C 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" - 14 1 1/8" - 12 1 1/4" - 12

DRY lbf-ft Nm 11 - 12 15 - 16 26 - 30 35 - 40 44 -48 60 - 65 70 - 77 95 - 104 106 - 117 144 - 158 153 - 168 208 - 228 212 - 233 288 - 316 376 - 414 510 - 561 606 - 667 822 - 904 909 - 1000 1233 - 1355 1288 - 1417 1746 - 1921 1817 - 1999 2464 - 2710 DRY lbf-ft Nm 13 - 14 18 - 19 23 - 28 31 - 38 49 - 54 67 - 73 78 - 86 106 - 116 120 - 132 163 - 179 171 - 188 232 - 255 240 - 264 326 - 358 420 - 462 570 - 626 668 - 735 906 - 996 995 - 1096 1359 - 1486 1445 - 1590 1960 - 2155 2012 - 2213 2728 - 2997

LUBRICATED DRY LUBRICATED COARSE THREAD lbf-ft Nm lbf-ft Nm lbf-ft Nm 8 - 10 11 - 13 1/4" - 20 7- 8 10 - 11 8 - 10 11 - 13 20 - 28 27 - 38 5/16" - 18 14 - 18 19 - 24 10 - 15 13 - 20 33 - 36 45 - 49 3/8" - 16 31 - 34 42 - 46 23 - 25 31 - 34 52 - 57 71 - 77 7/16" - 14 49 - 54 66 - 73 37 - 41 50 - 55 80 - 88 109 - 119 1/2" - 13 75 - 83 102 - 112 57 - 63 77 - 85 115 - 127 156 - 172 9/16" - 12 109 - 120 148 - 162 82 - 90 111 - 122 159 - 175 216 - 237 5/8" - 11 150 - 165 204 - 223 113 - 124 152 - 168 282 - 310 393 - 420 3/4" - 10 266 - 293 360 - 397 200 - 220 271 - 298 455 - 501 617 - 679 7/8" - 9 394 - 433 535 - 586 296 - 326 402 - 441 682 - 750 925 - 1016 1" - 8 591 - 649 802 - 879 443 - 489 601 - 663 966 - 1062 1310 - 1441 1 1/8" - 7 794 - 873 1077 - 1183 596 - 656 808 - 889 1360 - 1496 1844 - 2027 1 1/4" - 7 1120 - 1232 1519 - 1670 840 - 924 1139 - 1252 LUBRICATED FINE DRY LUBRICATED THREAD lbf-ft Nm lbf-ft Nm lbf-ft Nm 10 - 13 14 - 17 1/4" - 28 9 - 10 12 - 13 9 - 10 12 - 13 18 - 25 25 - 33 5/16" - 24 17 - 22 23 - 29 16 - 20 21 - 27 37 - 41 50 - 55 3/8" - 24 35 - 39 48 - 53 26 - 29 35 - 39 58 - 64 79 - 86 7/16" - 20 55 - 61 75 - 83 41 - 45 56 - 61 90 - 99 122 - 134 1/2" - 20 85 - 94 116 - 127 64 - 70 87 - 95 128 - 141 174 - 191 9/16" - 18 121 - 133 164 - 180 91 - 100 124 - 135 180 - 198 244 - 268 5/8" - 18 170 - 187 231 - 253 128 - 141 174 - 191 315 - 347 427 - 470 3/4" - 16 297 - 327 403 - 443 223 - 245 303 - 332 501 - 550 679 - 745 7/8" - 14 434 - 477 589 - 646 326 - 359 442 - 486 746 - 821 1012 - 1113 1" - 12 646 - 711 876 - 965 484 - 534 657 - 724 1083 - 1191 1469 - 1613 1 1/8" - 12 891 - 980 1208 - 1328 668 - 735 906 - 996 1509 - 1660 2046 - 2250 1 1/4" - 12 1240 - 1364 1682 - 1849 931 - 1024 1262 - 1387

METRIC

METRIC BOLT TORQUE SPECIFICATIONS SIZE

CLASS 4.8 LUBRICATED Nm lbf-ft Nm

DRY lbf-ft

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

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

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

M6 M8 M10

4.8 12.0 23.0

3.5 8.5 17.0

6.0 15.0 29.0

4.5 11.0 21.0

9.0 22.0 43.0

6.5 16.0 32.0

11.0 28.0 55.0

8.5 20.0 40.0

13.0 32.0 63.0

9.5 24.0 47.0

17.0 40.0 80.0

12.0 30.0 60.0

15.0 37.0 75.0

11.5 28.0 55.0

19.0 47.0 95.0

14.5 35.0 70.0

M12 M14 M16

40.0 63.0 100.0

29.0 47.0 73.0

50.0 80.0 125.0

37.0 60.0 92.0

75.0 120.0 190.0

55.0 88.0 140.0

95.0 150.0 240.0

70.0 110.0 175.0

110.0 175.0 275.0

80.0 130.0 200.0

140.0 225.0 350.0

105.0 165.0 225.0

130.0 205.0 320.0

95.0 150.0 240.0

165.0 260.0 400.0

120.0 190.0 300.0

M18 M20 M22

135.0 190.0 260.0

100.0 140.0 190.0

175.0 240.0 330.0

125.0 180.0 250.0

260.0 375.0 510.0

195.0 275.0 375.0

330.0 475.0 650.0

250.0 350.0 475.0

375.0 530.0 725.0

275.0 400.0 540.0

475.0 675.0 925.0

350.0 500.0 675.0

440.0 625.0 850.0

325.0 560.0 460.0 800.0 625.0 1,075.0

410.0 580.0 800.0

M24 M27 M30

330.0 490.0 675.0

250.0 360.0 490.0

425.0 625.0 850.0

310.0 650.0 450.0 950.0 625.0 1,300.0

M33 900.0 M36 1,150.0

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

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

3.27

Tigercat H822C/LH830C Harvester

Lubrication and Maintenance

Par ker ark

Assemb que Assemblly Tor orque

3.28

Tigercat H822C/LH830C Harvester

Lubrication and Maintenance

Par ker ark

Assemb que Assemblly Tor orque

JIC 37 Degree Flare SAE Dash Size -2 -3 -4 -5 -6 -8 -10 -12 -14 -16 -20 -24 -32 -40

Thread Size 5/16-24 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 3/16-12 1 5/16-12 1 5/8-12 1 7/8-12 2 1/2-12 3-12

Tube Connection FFWR

NPTF Swivel or Hose Connection FFWR

NA NA 2 2 1 1/2 1 1/2 1 1/2 1 1/4 1 1 1 1 1 1

SAE Dash Size

NA NA 2 2 1 1/4 1 1 1 1 1 1 1 1 1

F.F.W.R : Flats From Wrench Resistance All values are for Steel, Stainless Steel and Brass

-2 -3 -4 -5 -6 -8 -10 -12 -14 -16 -20 -24 -32 -40

1/8-27 NA 1/4-18 NA 3/8-18 1/2-14 7/8-14 3/4-14 NA 1-11 1/2 1 1/4-11 1/2 1 1/2-11 1/2 2-11 1/2 NA

SAE Dash Size -2 -3 -4 -5 -6 -8 -10 -12 -14 -16 -20 -24 -32 -40

Thread Size NA NA 9/16-18 NA 11/16-16 13/16-16 1-14 1 3/16-12 NA 1 7/16-12 1 11/16-12 2-12 NA NA

NA NA 1/4 TO 1/2 NA 1/4 TO 1/2 1/4 TO 1/2 1/4 TO 1/2 1/4 TO 1/2 NA 1/4 TO 1/2 1/4 TO 1/2 1/4 TO 1/2 NA NA

F.F.W.R : Flats From Wrench Resistance All values are for Steel, Stainless Steel and Brass

2-3 NA 2-3 NA 2-3 2-3 NA 2-3 NA 1.5-2.5 1.5-2.5 1.5-2.5 1.5-2.5 NA

Swivel or Hose Connection TFFT

2-3 NA 2-3 NA 2-3 2-3 NA 2-3 NA 1.5-2.5 1.5-2.5 1.5-2.5 1.5-2.5 NA

T.F.F.T. : Turns from finger tight All pipe values are for Steel, Stainless Steel and Brass

O'ring Face Seal / Seal-Lok Tube Connection FFWR

Tube Connection TFFT

Thread Size

BSPT

Swivel or Hose Connection FFWR

SAE Dash Size

NA NA 1/2 TO 3/4 NA 1/2 TO 3/4 1/2 TO 3/4 1/2 TO 3/4 1/3 TO 1/2 NA 1/3 TO 1/2 1/3 TO 1/2 1/3 TO 1/2 NA NA

-2 -3 -4 -5 -6 -8 -10 -12 -14 -16 -20 -24 -32 -40

Thread Size 1/8-28 NA 1/4-19 NA 3/8-19 1/2-14 NA 3/4-14 NA 1-11 1 1/4-11 1 1/2-11 2-11 NA

Tube Connection TFFT 2-3 NA 2-3 NA 2-3 2-3 NA 2-3 NA 1.5-2.5 1.5-2.5 1.5-2.5 1.5-2.5 NA

T.F.F.T. : Turns from finger tight All pipe values are for Steel, Stainless Steel and Brass

3.29

Swivel or Hose Connection TFFT

2-3 NA 2-3 NA 2-3 2-3 NA 2-3 NA 1.5-2.5 1.5-2.5 1.5-2.5 1.5-2.5 NA

Tigercat H822C/LH830C Harvester

Lubrication and Maintenance

Assemb que Assemblly Tor orque

EATON Aeroquip Recommended Parallel Connection Assembly torque

Eaton recommends that a

The values listed are for

Torque wrench be used to

steel connections. Contact

assure proper fitting

Eaton Aeroquip for torques values for

assembly of these

other materials

connections.

Straight Thread O-Ring Boss Low Pressure with 37º (SAEJ514) Thread Size (inches) 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 3/16-12 1 5/16-12 1 5/8-12 1 7/8-12 2 1/2-12

Dash Size -03 -04 -05 -06 -08 -10 -12 -14 -16 -20 -24 -32

Straight Thread O-Ring Boss High Pressure with ORS (J1453)

Jam Nut or Jam Nut or Straight Straight Fitting Torque Fitting Torque lb.-ft.

Newton Meters 8-9 12-13 13-15 18-20 14-15 19-21 23-24 32-33 40-43 55-57 43-48 59-64 68-75 93-101 83-90 113-122 112-123 152-166 146-161 198-218 154-170 209-230 218-240 296-325

ORS

Dash Size -04 -06 -08 -10 -12 -16 -20 -24

Dash Size -03 -04 -05 -06 -08 -10 -12 -14 -16 -20 -24

Thread Size (inches) 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 3/16-12 1 5/16-12 1 5/8-12 1 7/8-12

Jam Nut or Jam Nut or Straight Straight Fitting Torque Fitting Torque lb.-ft.

Newton Meters 8-10 11-16 14-16 20-22 18-20 24-27 24-26 33-35 50-60 68-78 72-80 98-110 125-135 170-183 160-180 215-245 200-220 270-300 210-280 285-380 270-360 370-490

SAE 37º (JIC)

Thread Size (inches) 9/16-18 11/16-20 13/16-16 1-14 1 3/16-12 1 7/16-12 1 11/16-12 2-12

Swivel Nut Torque lb.-ft.

10-12 18-20 32-35 46-50 65-70 92-100 125-140 150-165

Swivel Nut Torque Newton Meters 14-16 24-27 43-47 62-68 88-95 125-136 170-190 204-224

Metric Thread Size mm M10x1 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M20x1.5 M22x1.5 M26x1.5 M27x2 M33x2 M42x2 M48x2

Dash Size -04 -05 -06 -08 -10 -12 -16 -20 -24 -32

Thread Size (inches) 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 5/16-12 1 5/8-12 1 7/8-12 2 1/2-12

Swivel Nut Torque lb.-ft.

11-12 15-16 18-20 38-42 57-62 79-87 108-113 127-133 158-167 245-258

Swivel Nut Torque Newton Meters 15-16 20-22 24-28 52-58 77-85 108-119 148-154 173-182 216-227 334-352

BSPP Straight Adapter or Locknut Torque lb.-ft.

Newton Meters 13-15 18-20 15-19 20-25 19-23 25-30 33-40 45-55 37-44 50-60 52-66 70-90 55-70 75-95 81-96 110-130 96-111 130-150 162-184 220-250 170-192 230-260 258-347 350-470

Nominal Thread Size Straight Adapter or Locknut Torque inches** lb.-ft.

Newton Meters G1/8-28 13-15 18-20 G1/4-19 19-23 25-30 G3/8-19 33-40 45-55 G1/2-14 55-70 75-95 G3/4-14 103-118 140-160 G1-11 162-184 220-250 G1 1/4-11 170-192 230-260 G1 1/2-11 258-347 350-470 ** "G" denotes parallel threads, other than ISO 6149 (Port connection only)

Eaton Aeroquip Fluid Conveyance Products A-HOOV-MC001-E January 2005

3.30

Tigercat H822C/LH830C Harvester

Lubrication and Maintenance Tigercat®

PRESSURE AND SPEED SETTINGS Model: 822C/L830C/H822C/LH830C Machine Function

Setting

ENGINE RPM (With Cummins QSL9 Engine) FULL THROTTLE, NO LOAD MAXIMUM LOW IDLE, NO LOAD RATED WORKING R.H. AND L.H. FINAL DRIVE CROSSLINE RELIEFS START OF REGULATION BRAKE RELEASE SPEED:

1900 RPM 950 RPM 1800 RPM

LOW DRIVE

4700 PSI + 1/8 turn 3600 PSI 500 PSI (WITH TRACK STALLED) 10 RPM MAX. 28 RPM MAX.

MAIN PUMP (Linde 160cc) ANTI-STALL SET POINT RPM (QSC) ANTI-STALL SET POINT RPM (SISU) STAND-BY PRESSURE MARGIN PRESSURE

2000 RPM 1850 RPM 500 PSI MEASURED @ 'P' (LOW IDLE) 300 PSI

MAIN PUMP (Linde 210cc) ANTI-STALL SET POINT RPM (QSL9) STAND-BY PRESSURE MARGIN PRESSURE

1700 RPM 500 PSI MEASURED @ 'P' (LOW IDLE) 300 PSI

MAIN VALVE (Linde) FELLER BUNCHER MAIN RELIEF LOAD SENSE RELIEF P1 LOAD SENSE RELIEF P2 BOOM PORT RELIEFS STICK PORT RELIEFS TILT PORT RELIEFS WRIST PORT RELIEFS LEVEL FORE/AFT PORT RELIEFS (LINDE) LEVEL RIGHT/LEFT PORT RELIEFS (LINDE)

NON-ADJUSTABLE SCREW IN FULLY (LOCKED OUT) 4300 PSI AT 'P' PORT (4000 PSI AT 'LS' PORT) 4700 PSI (CRACKING PRESSURE) 4700 PSI (CRACKING PRESSURE) 4700 PSI (CRACKING PRESSURE) 3000 PSI @ 'LS' PORT (FULL THROTTLE) 4700 PSI (CRACKING PRESSURE) 4700 PSI (CRACKING PRESSURE)

LEVEL FORE/AFT PORT RELIEFS (VOAC/PARKER)

330 BAR (4786PSI) PRESET

LEVEL RIGHT/LEFT PORT RELIEFS (VOAC/PARKER)

330 BAR (4786PSI) PRESET

MAIN VALVE (Linde) HARVESTER MAIN RELIEF LOAD SENSE RELIEF P1 LOAD SENSE RELIEF P2 BOOM PORT RELIEFS STICK PORT RELIEFS LEVEL FORE/AFT PORT RELIEFS (LINDE) LEVEL RIGHT/LEFT PORT RELIEFS (LINDE) LEVEL FORE/AFT PORT RELIEFS (VOAC/PARKER) LEVEL RIGHT/LEFT PORT RELIEFS (VOAC/PARKER) TELESCOPIC BOOM OUT TELESCOPIC BOOM IN PUMP 2

NON-ADJUSTABLE SCREW IN FULLY (LOCKED OUT) 4300 PSI AT 'P' PORT (4000 PSI AT 'LS' PORT) 4700 PSI (CRACKING PRESSURE) 4700 PSI (CRACKING PRESSURE) 4700 PSI (CRACKING PRESSURE) 4700 PSI (CRACKING PRESSURE) 330 BAR (4786PSI) PRESET 330 BAR (4786PSI) PRESET 3000 PSI AT 'LS' PORT (FULL THROTTLE) 4700 PSI (CRACKING PRESSURE) 3600 PSI AT 'LS' PORT (FULL THROTTLE)

PILOT SUPPLY MAIN RELIEF LEVELER PILOT RELIEF (FOR LINDE ONLY)

425 PSI 260 PSI

SWING CROSSLINE RELIEFS SPEED

3000 PSI AT 'LS' PORT (3300 PSI AT 'P' PORT) 6 RPM

SAW PUMP PRESSURE OVERRIDE - Saw, Tigercat & KW PRESSURE OVERRIDE - Shear, Tigercat PRESSURE OVERRIDE - Harvester

3600 PSI 3600 PSI 3200 PSI

SAW CONTROL VALVE MAIN RELIEF - Saw set-up SAW PORT RELIEF

4000 PSI Full in

MAIN RELIEF - Shear set-up SHEAR PORT RELIEF - Open & Close

Full In 4000 PSI

SAW MOTOR (Tigercat DT5001) START OF REGULATION SPEED

3200 PSI 1250-1300 RPM

3.31

Tigercat H822C/LH830C Harvester

Lubrication and Maintenance

3.32

Tigercat H822C/LH830C Harvester

SECTION 4 - HYDRAULIC SYSTEM AUGUST 2006

CONTENTS - SECTION 4 FILTERS, HYDRAULIC OIL FILTER SERVICE NOTE .......................................................................................................................................

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

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

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

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

4.5 4.6 4.5 4.5 4.4

HAND FILL PUMP, HYDRAULIC OIL ........................................................................................................................ 4.7 HIGH PRESSURE LIMITING CONTROL VALVE SET LOAD SENSE RELIEF VALVE .......................................................................................................... 4.26, 4.27 HYDRAULIC OIL FILTERS ........................................................................................................................................ 4.5 HYDRAULIC OIL LEVEL SIGHT GAUGES ............................................................................................................... 4.5 HYDRAULIC OIL TANK DESCRIPTION ....................................................................................................................................................... 4.4 OIL LEVEL SIGHT GAUGES ................................................................................................................................. 4.5 HYDRAULIC PUMPS PUMP 1 (ATTACHMENT PUMP) ........................................................................................................................... 4.9 PUMP 2 (MAIN PUMP) ........................................................................................................................................... 4.8 WEAR TEST ....................................................................................................................................................... 4.8 ROTATE AND FAN PUMP .................................................................................................................................... 4.9 HYDRAULIC SYSTEM OPERATION ATTACHMENT CIRCUIT ........................................................................................................................................ 4.3 CIRCUIT DESCRIPTION ..................................................................................................................................... 4.15 COOLING FAN CIRCUIT ....................................................................................................................................... 4.3 FLOW ON DEMAND AND LOAD COMPENSATION .......................................................................................... 4.15 MAIN HYDRAULIC SYSTEM; BOOM, SWING, PUMP 2, DRIVE ......................................................................... 4.2 MARGIN PRESSURE ............................................................................................................................................. 4.9 MARGIN PRESSURE, SET ................................................................................................................................. 4.25 PILOT CIRCUIT ...................................................................................................................................................... 4.3 PRESSURE GAUGE CONNECTIONS ................................................................................................................ 4.26 SWING SYSTEM .................................................................................................................................................... 4.2 TRACK DRIVE SYSTEM ........................................................................................................................................ 4.2 HYDRAULIC TANK .................................................................................................................................................... 4.4 LOAD SENSING BASIC DESCRIPTION ......................................................................................................................................... 4.11 BASIC PRINCIPLES ............................................................................................................................................ 4.10 OPERATING TIPS ................................................................................................................................................ 4.13 SET LOAD SENSE RELIEF VALVE .......................................................................................................... 4.26, 4.27 SET MARGIN PRESSURE ................................................................................................................................... 4.25 MAIN CONTROL VALVE/MANIFOLD CONTROL SPOOL SECTIONS ........................................................................................................................... 4.16 CONTROL VALVE SECTIONS ............................................................................................................................ 4.17 CONTROL VALVE SPOOL OPERATION ............................................................................................................ 4.19 HIGH PRESSURE LIMITING CONTROL VALVE ................................................................................................ 4.24 MAIN CONTROL VALVE DESCRIPTION ............................................................................................................ 4.16 PORT RELIEF AND ANTICAVITATION VALVE .................................................................................................. 4.18 ADJUSTING PROCEDURE ............................................................................................................................. 4.18 SWING AND DRIVE MOTOR SPOOL SECTIONS ............................................................................................. 4.16 PILOT FILTER, HIGH PRESSURE ............................................................................................................................ 4.6 SCHEMATIC DIAGRAMS HIGH PRESS. LIMITING CONTROL ................................................................................................................... 4.24 LOAD SENSING (FLOW ON DEMAND) ............................................................................................................. 4.10 LOAD SENSING SYSTEM CIRCUIT DIAGRAM ................................................................................................. 4.14 MAIN VALVE WITH HIGH PRESS. LIMITING CONTROL .................................................................................. 4.16 PUMP 2 (MAIN PUMP) ........................................................................................................................................... 4.8

Tigercat H822C/LH830C Harvester HYDRAULIC SYSTEM OPERATION

Hydraulic system Boom cylinders

The hydraulic system has five basic circuits;

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

1. Variable displacement main hydraulic circuit with load sensing for the boom, swing, telescopic, pump2 and travel functions.

Also included in this circuit when applicable are the levelling functions of the LH830.

Swing system

2. Variable displacement circuit for the attachment.

The swing hydraulic circuit is incorporated in the main hydraulic load sensing system. It utilizes a bent-axis piston motor incorporating two crossover relief valves. The motor is connected to a double reduction planetary gearbox which provides variable swing speeds up to 6 rpm. A rotary manifold facilitates the hydraulic connection to the undercarriage of the vehicle and permits continuous 360 degree swing. The swing drive gearbox incorporates a wet, multi-disc brake installed between the motor and gearbox. The swing brake is controlled by a switch on the instrument panel. The brake is spring-apply, hydraulic-release and will automatically apply whenever the pilot oil supply is shut off. For detailed description of the SWING system, refer to SECTION 15 of THIS MANUAL.

3. Fixed displacement open centre circuit for the rotate function.

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

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

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

Track drive system

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

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

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

Levelling system (LH830 only) Two levelling cylinders are used to operate the levelling function. Each cylinder is equipped with a counterbalance valve or pilot operated check valve for crossline relief and load holding.

An electro-hydraulically operated levelling control valve is operated by the IQAN control system. For a detailed description of the levelling system refer to SECTION 13 of THIS MANUAL. 4.2

Tigercat H822C/LH830C Harvester

Hydraulic system

2. ATTACHMENT CIRCUIT

valve installed in the manifold controls the flow of pilot oil into the manifold.

This open centre circuit uses a variabledisplacement pressure-compensated piston pump (pump 1) which delivers oil to the attachment motor. The pump 1 valve section of attachment control valve is pilot operated and controls the flow of hydraulic oil from the Pump 1 (Attachment pump) to the attachment motor. This control valve section is bolted to the rotate and no function control valve sections of the attachment control valve but operates independently except for sharing the tank return ports on a common outlet section.

To protect the attachment circuit a pump 1 relief valve is installed in the inlet section of the attachment control valve.

When this pilot shut-off valve is energized, pilot oil is made available to outlet pressure ports and three solenoid valves. When the pilot shut-off valve is de-energized, pilot oil from the pilot supply valve is blocked, preventing pilot oil from entering the manifold, thereby rendering these pilot functions inactive. Refer to PILOT SYSTEM RESET in SECTION 2 of the OPERATOR’S MANUAL. For a full description of the pilot supply manifold and the pilot circuit, refer to in SECTION 5 in THIS MANUAL. 6. COOLING FAN CIRCUIT

A solenoid operated pump 1 pilot valve in the supply pilot manifold controls the flow of pilot oil to the end of the spool in the pump 1 control valve section.

The cooling fan system consists of the following components:

•

Fan Pump

The saw switch on the control panel in the cab is used to turn the saw ON or OFF.

•

Fan Motor

•

Fan Control Valve

•

Electronic Control

Refer to ATTACHMENT DRIVE description in SECTION 17 of this manual.

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

3. ROTATE ATTACHMENT CIRCUIT This is an open-centre circuit with a fixed displacement gear pump and a two-section spool valve. The spool valve also includes an inlet (mid) section and an outlet section. The gear pump provides a continuous supply of oil to the rotate and no function control valve sections of the attachment valve which will divert the oil back to tank if neither of the functions are in use. The return oil from this open centre circuit is returned to tank via the spin-on return filters.

The fan direction is controlled by the fan control valve.

The fan operation is controlled by the cooling fan switch, service mode switch and the computer control unit.

For a full description of the COOLING FAN circuit operation refer to SECTION 2 of THE OPERATOR'S MANUAL, and for adjustment procedures, refer to SECTION 10 of THIS MANUAL.

For a full description of the ROTATE circuit, refer to SECTION 20 of THIS MANUAL. 4. PILOT CIRCUIT The closed centre pilot circuit receives oil from the main hydraulic system (main pump).

Oil from the main hydraulic system passes through a "high pressure" filter to the pilot supply valve (pressure reducing/relieving valve) which maintains the pilot pressure at 425 psi. From there, pilot oil (425 psi) is supplied to the P port of the pilot supply manifold.

The pilot supply manifold is a distribution center, directing pilot oil to pilot operated functions on the machine. A pilot shut-off 4.3

Tigercat H822C/LH830C Harvester HYDRAULIC OIL TANK

Hydraulic system

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

•• AIR VENT FILTER

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

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

O-RING

REUSABLE STRAINERS/ DIFFUSERS (3 PLACES)

ROUND ACCESS COVER

•

•

•

••

HYDRAULIC OIL TANK 822-D35 VENT/BREATHER, HYDRAULIC TANK The air space in the top of the hydraulic tank is vented to atmosphere via a check valve and spinon filter. The check valve will open or "crack" when the pressure in the hydraulic tank reaches 10 psi. The pressure build-up in the tank can be due to thermal expansion as the hydraulic oil heats up.

•

AIR VENT FILTER CONNECTION TO PRESSURE GAUGE

FIRST SIGHT GAUGE

• •

AIR VENT VALVE

•

SOME COMPONENTS REMOVED FOR CLARITY

AIR VENT VALVE

•

•

SECOND SIGHT GAUGE

•

LOW LEVEL SENDING UNIT, FOR WARNING BUZZER DRAIN PLUG

822-06

•

•

DRAIN PLUG (ONLY ACCESSIBLE WITH MAIN CONTROL VALVE REMOVED)

HYDRAULIC TANK

••

CHECK VALVE 10 PSI.

LOW LEVEL SENDING UNIT, FOR WARNING LIGHT

822-D41

TOP OF HYDRAULIC TANK

•

VENT, HYDRAULIC TANK

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

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.

4.4

Tigercat H822C/LH830C Harvester

Hydraulic system return manifold. The output side of the filter heads direct the oil to tank via three return lines.

FIRST SIGHT GAUGE

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.

• SECOND SIGHT GAUGE

•• ••

HYDRAULIC OIL LEVEL SIGHT GAUGES

••

LOW LEVEL SENDING UNIT, FOR WARNING LIGHT

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

FILTER SERVICE NOTE

LOW LEVEL SENDING UNIT, FOR WARNING BUZZER

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

822C-42

OIL LEVEL SIGHT GAUGES

RETURN STRAINERS/DIFFUSERS

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

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

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

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

5 - HYDRAULIC RETURN FILTERS

RETURN MANIFOLD

•• •

• •• •

• 822C-22

• 1 - WATER ABSORBING RETURN FILTER (COLOUR BLUE)

HYDRAULIC OIL FILTERS

RETURN FILTERS ~ HYDRAULIC OIL The majority of return oil entering the tank first passes through six spin-on hydraulic oil filters mounted onto three double filter heads, one of the filters is a water absorbing filter (colour blue) the purpose of which is to assist with removing moisture from the hydraulic oil. The input side of the filter heads are connected in parallel to a 4.5

Continued on page 6

Tigercat H822C/LH830C Harvester

Hydraulic system

HIGH PRESSURE PILOT FILTER HIGH PRESSURE PILOT FILTER 822C-40

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

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

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

4.6

Tigercat H822C/LH830C Harvester

Hydraulic system

•• TO TANK VIA FILTERS

SHUT-OFF VALVE IN OFF POSITION

•• HAND FILL PUMP

•• • SUCTION HOSE

HAND FILL PUMP HYDRAULIC HAND FILL PUMP 822C-25

The hydraulic hand fill pump, located on the rear left door, is used for adding oil to the hydraulic oil tank. Hydraulic oil is pumped directly into the hydraulic tank via the return filter manifold This ensures that any hydraulic oil added is filtered prior to entering the hydraulic tank. Refer to APPROVED HYDRAULIC OILS ~MAIN HYDRAULIC SYSTEM in SECTION 3 of THIS MANUAL. IMPORTANT: Ensure that all connection points and the suction tube are thoroughly cleaned and dried before use. Small amounts of water can cause serious damage to the hydraulic components. The water absorbing element will remove small amounts of water but will not protect the system from careless use. Dust left on the suction tube will significantly reduce the life of the filters. Failure to keep the suction tube clean will significantly reduce the life of the filter elements.

4.7

Tigercat H822C/LH830C Harvester ROTATE/FAN PUMP (DOUBLE GEAR PUMP)

Hydraulic system

PUMP 1 PUMP 1 (ATTACHMENT ) PRESSURE (PISTON PUMP) COMPENSATOR

PILOT SUPPLY MANIFOLD

•• •• ••

•• •• •• ••

PUMP 2 PUMP 2 (MAIN PUMP) CONTROLLER (PISTON PUMP) (LS. CONTROL)

PILOT FILTER

••

• •

COOLING FAN CONTROL VALVE PILOT SUPPLY VALVE

822C-136

HYDRAULIC PUMPS

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

The first pump, Pump 2 (main pump) is a piston pump with load sensing and horsepower limiting controls used for main hydraulic circuit (travel, swing, boom, pump 2 and levelling - if equipped).

Driven off the PTO of Pump 2 is Pump 1 (attachment pump). It is a pressure compensated piston pump.

Driven off the PTO of Pump 1 is the fixed displacement gear pump used for the rotate and cooling fan circuits.

PUMP 2 (MAIN PUMP) Pump 2 is a Linde HPR, axial-piston, variabledisplacement pump with load sensing, and horsepower limiting controls.

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

860C-045

PUMP 2 (MAIN PUMP) SCHEMATIC DIAGRAM

PUMP 2 (MAIN PUMP) WEAR TEST 1

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

2

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

4.8

Tigercat H822C/LH830C Harvester 3

Position the machine so that the upper is perpendicular to the tracks. Fully extend the stick cylinder, place the attachment on the ground and turn the swing brake ON.

4

With the engine at high idle, simultaneously hold the boom OUT control and hold the SWING CONTROL fully over relief.

5

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

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

Record the flow coming out of the Pump 2 case drain.

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

'P' GAUGE TEST CONN.

••

••

••

ENGINE ANTI-STALL SOLENOID VALVE

PUMP 2

••

• •

•• 'LS' CONNECTION FROM MAIN VALVE

• •• •

••

•• 103-17A

GAUGE TEST PORT ANTI-STALL SIGNAL PRESSURE

HIGH PRESSURE LIMITING CONTROL

MAIN VALVE MANIFOLD

Also refer to ENGINE ANTI-STALL in SECTION 9 of THIS MANUAL. The pump is protected by a high pressure limiting control which is attached to the main control valve manifold. Refer to HIGH PRESSURE LIMITING CONTROL in THIS SECTION.

GAUGE TEST PORT 'L.S.'

MARGIN PRESSURE ADJUSTING SCREW

822C-

HIGH PRESSURE LIMITING CONTROL

L.S. GAUGE TEST CONN.

PUMP 1 (ATTACHMENT PUMP)

PUMP 2 (MAIN PUMP) CONTROLLER (LS CONTROL)

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

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

ROTATE AND FAN PUMP The rotate and fan pump is a dual gear pump driven off the back of the main pump. For detailed information on this pump, refer to SECTION 10 and SECTION 20 of THIS MANUAL.

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

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

Tigercat H822C/LH830C Harvester

Hydraulic system

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

FLOW

853SM18

W USED PRESSURE

FIG. 1

FIXED DISPLACEMENT PUMP

853SM16

FIG. 2

HP

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

WASTED

=CO NS

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

TAN T

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

SEE FIGS. 5 & 6.

FLOW

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

WASTED

W USED PRESSURE

853SM19 FIG. 3

HP REGULATED PUMP

FIG. 4

853SM16

HP =C ON STA

FLOW

NT

∆p LS W USED PRESSURE

853SM17 FIG.5

LOAD SENSING (FLOW ON DEMAND) 4.10

FIG.6

853SM16

Tigercat H822C/LH830C Harvester LOAD SENSING BASIC DESCRIPTION

Hydraulic system

OPEN CENTRE VS. CLOSE CENTRE OPEN CENTRE SYSTEM:

853SM21

853SM20

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

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

853SM21 853SM20

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

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

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

853SM20

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

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

4.11

Tigercat H822C/LH830C Harvester CLOSED CENTRE SYSTEM: Load sensing systems use variable flow pumps and only flow oil when required. Unlike the open centre system, the control valve does not have an open centre passage. When in neutral, no oil flows through the control valve to tank and the pump output flow is zero. The pump’s output flow is controlled by a “stroking piston” which is connected to the pump output, and to the valve’s workport or “load”. This sense line to the actual working load defines the system as load sensing.

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

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

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

853SM22

853SM22

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

853SM22

The following are key differences from open centre systems;

853SM22

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

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

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

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

Moving the lever further will not increase the lifting force.

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

4.12

Tigercat H822C/LH830C Harvester

Hydraulic system

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

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

Refer to SET MARGIN PRESSURE in this section.

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

Refer to SET FLOW (FUNCTION SPEED) RATE in appropriate BOOM or SWING sections of THIS MANUAL. When operating the swing function move the lever slowly. Operating the swing harshly or quickly reversing direction wastes power and generates excessive heat, as oil is dumped over the crossline reliefs.

4.13

Tigercat H822C/LH830C Harvester

822C-24

Hydraulic system

LOAD SENSING SYSTEM CIRCUIT DIAGRAM 4.14

Tigercat H822C/LH830C Harvester MAIN HYDRAULIC (LOAD SENSING) CIRCUIT CIRCUIT DESCRIPTION The main hydraulic circuit includes the components for boom, stick, telescopic, swing, pump 2 and travel operations. Also included in this circuit when applicable are the levelling functions of the LH830.

Pump 2 (main pump), an axial piston, swashplate controlled pump supplies oil for the main hydraulic system. A load sensing signal is sent back from the Linde control valve manifold (LS port) to the main pump regulator (LS port) to control the pump output pressure.

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

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

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

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

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

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

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

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

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

The levelling control valve (if equipped) is also supplied by Pump 2 (main pump). A load sensing signal is sent back from levelling control valve (LS port) to the main pump regulator (LS port) to control the pump output pressure. Refer to SECTION 13 for more complete information about the levelling circuit.

4.15

Tigercat H822C/LH830C Harvester CONTROL VALVE MANIFOLD

DRIVE, LEFT

DRIVE, RIGHT

TELESCOPIC CYLINDER (IF EQUIPPED)

Hydraulic system STICK CYLINDERS

HIGH PRESSURE LIMITING CONTROL

PUMP 2

MAIN BOOM CYLINDER

SWING

•• •• •

•

••

•

•

•

B

••

••

SIDE

A SIDE

RETURN MANIFOLD

822-D63A

MAIN CONTROL VALVE

MAIN CONTROL VALVE DESCRIPTION

CONTROL VALVE SECTIONS

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

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

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

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

2. Two return passages (connected internally).

3. Two for Load Sense (connected internally).

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

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

2

3

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

1

853SM24

MANIFOLD/VALVE SECTION SCHEMATIC WITH RELIEF 4.16

Tigercat H822C/LH830C Harvester MAKE UP OR ANTICAVITATION VALVE

Hydraulic system MAKE UP OR ANTICAVITATION VALVE

WORK PORTS

•

•

PILOT CHECK

•

PILOT END CAP

•

SPOOL TRAVEL STOP (ADJUSTABLE)

AIR BLEED PLUG

• • • • BALL AND SPRING

LOAD SENSING 'LS'

•

• • COMPENSATOR VALVE PUMP 'P' RETURN 'T'

RETURN 'T'

LOAD SENSING 'LS'

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

90919

WORK PORTS

ANTICAVITATION RELIEF VALVE MAX. FLOW ADJUSTING SCREW

•

ANTICAVITATION RELIEF VALVE

• •

•

•

•

• MAIN CONTROL SPOOL COMPENSATOR

RETURN 'T'

PUMP 'P'

RETURN 'T'

90744

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

90744-2

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

Tigercat H822C/LH830C Harvester PORT RELIEF AND ANTICAVITATION VALVE OPERATION

Hydraulic system MEDIUM SYSTEM PRESSURE

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

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

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

PILOT POPPET 'D'

• WORK PORT

• •

ORIFICE 'A'

•

•

RETURN

NORMAL OPERATION

90744-4A

(Step 2) The piston seats against the poppet.

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

MEDIUM SYSTEM PRESSURE

HIGHEST SYSTEM PRESSURE

•

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

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

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

•

WORK PORT

•

RETURN

RELIEF OPERATION

90744-6A

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

LOW WORK PORT PRESSURE

ADJUSTING PROCEDURE 1. Loosen locknut.

•

WORK PORT

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

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

• 90744-5A

RETURN

ANTICAVITATION OPERATION

4. Re-check pressure gauge reading.

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

PORT RELIEF VALVE

LOCKNUT • 17MM WRENCH

•

• •

• MAIN VALVE BODY

90744-4

4.18

ADJUSTING SCREW • 5MM ALLEN KEY

MAIN VALVE PORT RELIEF VALVE

Tigercat H822C/LH830C Harvester

Hydraulic system

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

PILOT END CAP

SHUTTLE COMPENSATOR CONTROL VALVE VALVE SPOOL

COMPENSATOR VALVE

SHUTTLE VALVE

PILOT END CAP

•

•

•

• CENTERING SPRING

•

•

• •

•

•

• •

• •

•

•

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

LOAD SENSING PASSAGE 'LS'

CENTERING SPRING

(A) CONTROL VALVE SECTION ~ IN NEUTRAL

853SM25

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

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

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

PILOT OIL

LS PORT JUST OPENED

SHUTTLE VALVE

•

CONTROL SPOOL

•

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

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

4.19

Tigercat H822C/LH830C Harvester PILOT OIL

Hydraulic system

SHUTTLE VALVE

•

BALANCE VALVE

•

CONTROL SPOOL

•

WORK PORT 'A' JUST OPENED

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

853SM27

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

PILOT OIL

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

CONTROL SPOOL

TANK PORT 'T' (RETURN)

(1) ANGLED VENT PORT OPENS

• •

•

•

• •

(4) OIL FLOWS TO 'LS' PASSAGE

(3) PRESSURE PORT OPENED SLIGHTLY

(2) WORK PORT 'B' OPENS

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

• PRESSURE PORT OPENED SLIGHTLY • HIGHEST WORKING PRESSURE

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

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

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

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

4.20

Tigercat H822C/LH830C Harvester PILOT OIL

(1) COMPENSATOR VALVE

Hydraulic system CONTROL SPOOL FULLY SHIFTED TO RIGHT

SHUTTLE VALVE

•

•• •

•

•

•

•

•

•

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

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

853SM29

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

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

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

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

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

PILOT OIL

LS PORT JUST OPENED

COMPENSATOR (2) SHUTTLE VALVE MOVES TO RIGHT VALVE

••

(1) CONTROL SPOOL STARTS TO MOVE

•

CENTERING SPRING

•

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

• LS PORT JUST OPENED • LOWER WORKING PRESSURE

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

4.21

Tigercat H822C/LH830C Harvester SHUTTLE VALVE

PILOT OIL

Hydraulic system CONTROL SPOOL

COMPENSATOR VALVE

•

•

•

WORK PORT 'A' JUST OPENED

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

853SM31

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

PILOT OIL

SHUTTLE VALVE

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

•

CONTROL SPOOL

•

TANK PORT 'T' (RETURN)

(1) ANGLED VENT PORT OPENS

• •

• •

OIL FLOWS TO 'LS' PASSAGE

(3) PRESSURE PORT OPENED SLIGHTLY

(2) WORK PORT 'B' OPENS

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

• PRESSURE PORT OPENED SLIGHTLY • LOWER WORKING PRESSURE

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

4.22

Tigercat H822C/LH830C Harvester PILOT OIL

Hydraulic system (1) CONTROL SPOOL FULLY SHIFTED TO RIGHT

(2) COMPENSATOR VALVE SETTLES IN A BALANCE POSITION

•

• •

•

•

•

•

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

•

• LOAD SENSING PASSAGE 'LS'

RETURN PASSAGE 'T'

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

• LOWER WORKING PRESSURE

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

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

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

4.23

Tigercat H822C/LH830C Harvester HIGH PRESSURE LIMITING CONTROL VALVE The main pump is protected by a High Pressure Limiting control which consists of three relief valve cartridges. The H.P.L. control is attached to the main control valve manifold and contains three relief valves: The first relief valve (P2) limits L.S. pressure to approx. 4000 psi. (Gauge at 'L.S.' test port) which in turn limits the pump output pressure to 4300 psi. (Gauge at 'P' test port) The 300 psi. differential is known as margin pressure. See SET MARGIN PRESSURE in THIS SECTION.

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

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

•

SYSTEM RELIEF VALVE NON-ADJUSTABLE

• HIGH PRESSURE LIMITING CONTROL

845B-D20

HIGH PRESSURE LIMITING CONTROL VALVE

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

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

853SM24

• •

•

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

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

P1. SCREWED FULLY IN NOT USED

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

Tigercat H822C/LH830C Harvester

Hydraulic system

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

••

MARGIN PRESSURE ADJUSTING SCREW

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

ENGINE ANTI-STALL SOLENOID VALVE

PUMP 2

••

•• •• 'LS' CONNECTION FROM MAIN VALVE

• •• •

••

860C-003.AI

PUMP 2 (MAIN PUMP) CONTROLLER VALVE

GAUGE TEST PORT ANTI-STALL SIGNAL PRESSURE

GAUGE TEST PORT 'L.S.'

MARGIN PRESSURE ADJUSTING SCREW

822C-

PUMP 2 (MAIN PUMP) CONTROLLER (LS CONTROL)

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

Continued on page 26

4.25

Tigercat H822C/LH830C Harvester

Hydraulic system

Continued from page 25 'P' GAUGE TEST CONN.

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

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

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

••

••

••

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

103-17A

••

GAUGE TEST PORTS ON MAIN VALVE

••

available, one single 0-5000 psi gauge may be used; First placing it on the L.S. test port and noting the reading, Then on 'P' test port and noting the reading. 'P' should be 300 psi. greater than 'L.S.'.

PUMP 2 (MAIN PUMP)

•

ENGINE ANTI-STALL SOLENOID VALVE

••

•• ••

GAUGE TEST PORT ANTI-STALL SIGNAL PRESSURE

•• ••

PUMP OUTLET MANIFOLD

••

MARGIN PRESSURE ADJUSTING SCREW

GAUGE TEST PORT 'L.S.'

•• GAUGE TEST PORT 'P' H822C-18

MAIN VALVE MANIFOLD

*If a differential pressure gauge is not

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

PUMP 1 (ATTACHMENT PUMP)

HIGH PRESSURE LIMITING CONTROL

L.S. GAUGE TEST CONN.

PRESSURE TEST PORTS ON PUMP 2 (MAIN PUMP) AND CONTROLLER 4.26

Tigercat H822C/LH830C Harvester 2. With hydraulic oil at operating temperature, Connect one side of the differential pressure gauge to the L.S. gauge port and the other side of the gauge to the pressure 'P' gauge test port.

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

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

3. Close and latch the cab front door.

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

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

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

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

2. Close and latch the cab front door.

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

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

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

• •

••

••

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

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

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

HIGH PRESSURE LIMITING CONTROL

L.S. GAUGE TEST CONN.

••

SET LOAD SENSE RELIEF VALVE 103-17A

• •

MAIN VALVE MANIFOLD

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

6. Stop engine and remove pressure gauge.

4.27

Tigercat H822C/LH830C Harvester

Hydraulic system

4.28

Tigercat H822C/LH830C Harvester

SECTION 5 - PILOT SYSTEM AUGUST 2006

CONTENTS - SECTION 5 ACCUMULATOR CHARGING .............................................................................................. 5.12 CHECK PRE-CHARGE PRESSURE ........................................................ 5.12 GENERAL DESCRIPTION ......................................................................... 5.5 TESTING DEVICE .................................................................................... 5.12 CIRCUIT DESCRIPTION ............................................................................... 5.9 CIRCUIT DIAGRAM ............................................................................. 5.8, 5.10 ELECTRICAL CIRCUIT ............................................................................... 5.10 PILOT SYSTEM COMPONENTS ACCUMULATOR .............................................................................. 5.5, 5.12 ATTACHMENT PILOT MANIFOLD ............................................................ 5.6 GENERAL DESCRIPTION ......................................................................... 5.2 HIGH PRESSURE FILTER ......................................................................... 5.3 JOYSTICKS AND FOOT PEDALS ............................................................. 5.6 PILOT SHUT OFF VALVE .......................................................................... 5.5 PILOT SUPPLY MANIFOLD ....................................................................... 5.5 PILOT SUPPLY VALVE .............................................................................. 5.3 PRESSURE SETTINGS .............................................................................. 5.11

Tigercat H822C/LH830C Harvester

Pilot system

PILOT SYSTEM COMPONENTS GENERAL DESCRIPTION The pilot circuit is supplied with oil from Pump 2 (main pump). Oil is first filtered by an inline high pressure filter before entering the pilot supply valve. The pilot supply valve reduces and maintains the pressure of the oil from the main pump to 425 psi for the pilot system. The pilot oil (425 psi) is then supplied to the P port of the pilot supply manifold.

The pilot supply manifold is a distribution center, directing pilot oil to pilot operated functions on the machine. A pilot shut-off valve installed in the manifold controls the flow of pilot oil into the manifold.

Pilot oil is distributed by the pilot supply manifold to the various pilot actuated functions of the machine. Solenoid operated pilot valves, within the pilot manifold, control the flow of pilot oil to various functions. Solenoid operated valves in the attachment pilot manifold control the flow of pilot oil to additional functions. Joysticks and foot pedals also distribute oil to shift spools in their corresponding control valves.

ROTATE/FAN PUMP (DOUBLE GEAR PUMP)

822C-137

PUMP 1 PUMP 1 (ATTACHMENT ) PRESSURE (PISTON PUMP) COMPENSATOR

ATTACHMENT PILOT MANIFOLD

PILOT SUPPLY MANIFOLD

•• •• ••

•• •• •• ••

PUMP 2 PUMP 2 (MAIN PUMP) CONTROLLER (PISTON PUMP) (LS. CONTROL)

••

PILOT FILTER

••

COOLING FAN CONTROL VALVE PILOT SUPPLY VALVE

822C-136

HYDRAULIC PUMPS 5.2

Tigercat H822C/LH830C Harvester

Pilot system PILOT SUPPLY VALVE (PRESSURE REDUCING/RELIEVING VALVE) The pilot supply valve is a pressure reducing relief valve located below the pilot supply manifold.

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

822C-40

HIGH PRESSURE PILOT FILTER

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.

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

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

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

5.3

Tigercat H822C/LH830C Harvester

Pilot system

ACCUMULATOR

•

•

822C-38

822C-37

PILOT SUPPLY MANIFOLD SCHEMATIC 5.4

PILOT SHUT OFF VALVE

Tigercat H822C/LH830C Harvester

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

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

The swing brakewill be applied if the swing brake switch in the cab has been left in the ON position.

The swing brake will be released when the switch is in the OFF position. The accumulator will also be charged when the pilot shut-off valve is energized.

822C-136

When the pilot shut-off valve is de-energized by either opening the front door or momentarily pressing the pilot OFF switch, disables all pilot actuated functions electrically and hydraulically. The swing brake is also applied at this time due to the lack of pilot pressure. The accumulator is drained at this time..

PILOT SUPPLY MANIFOLD

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

ACCUMULATOR

The manifold distributes oil to the following circuits through the ports listed below: • Levelling Valve (if equipped) • Attachment Pilot Manifold

There is one accumulator used on this machine for the pilot system. It is a bladder type and is installed pre-charged with a nitrogen. The pilot system accumulator is pre-charged to 325 psi. The gas pressure in the pilot accumulator should be checked if the pilot system exhibits repeated and frequent charging cycles. Refer to CHECKING PRECHARGE PRESSURE in THIS SECTION.

P1 P3

Pilot oil enters the pilot supply manifold through the inlet port 'P'.

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

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

The outlet pressure ports ('P1, P2, P3 & P4') on the bottom of the manifold, feeds levelling valve (if equipped) and the attachment pilot manifold.

VALVE GUARD

••• • •

Tank ports ('T') drain oil to the reservoir.

VALVE CAP

•

The following functions are also pilot operated.

They are activated electrically by individual solenoid valves on the attachment valve that direct pilot oil to move the spool valve and activate the selected function: • • • •

Track Drive Low Port X1 Swing Brake Release Port Y Attachment Valve - Pump 1 Section Spare

GAS VALVE

BODY

BLADDER

C4 C3 C2 C1

• HYDRAULIC CONNECTION ACCU-1

5.5

••

• POPPET (Seats against oil port after oil evacuation)

ACCUMULATOR (BLADDER TYPE)

Tigercat H822C/LH830C Harvester

Pilot system

P1

T1

T2

822C-137

P2

P3

ATTACHMENT PILOT MANIFOLD

ATTACHMENT PILOT MANIFOLD The attachment pilot manifold is located in the hydraulic tank compartment at the rear left corner of the upper frame. Pilot oil from port P3 of the pilot supply manifold enters the attachment pilot manifold through port P.

T3 P4

The attachment pilot manifold supplies pilot pressure to joysticks, drive foot pedals and the brake release manifold.

• • • •

Brake release manifold RH Joystick LH Joystick Foot pedals

T4

P3 P4 P5 P6 T5

Six solenoid valves in the attachment pilot manifold when energized by switches in the cab, will distribute pilot oil to; • • • • • •

Telescopic 'OUT' No factory standard function No factory standard function Pump 2 No factory standard function Telescopic 'IN'

P5

C1 C2 C3 C4 C5 C6

P6

T6

822C-39

Oil from the tank lines in the brake manifold, joysticks, foot pedals, pilot supply valve and pilot supply manifold passes through attachment pilot manifold and is directed back to tank via the filter return manifold.

ATTACHMENT PILOT MANIFOLD

5.6

Tigercat H822C/LH830C Harvester

Pilot system

JOYSTICKS AND FOOT PEDALS

OPERATING DESCRIPTION

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

In the neutral position the joystick lever is held centered by return springs (4). When the lever (1) is operated, the plunger (5) is pushed against its return spring (4). At the same time the regulating spool (2) is moved through the regulating spring (3). When the regulating stroke begins, there is a connection from port 'P' via hole (8) in the spool and work ports 1, 2, 3 or 4 in the base of the valve, to the boom valve pilot end caps.

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

RR-12

JOYSTICK PILOT VALVE

valves (pedals) use similar spool arrangements.

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

'P' PORT

AU013-2

•

•

5

• •

4 3

• •

•

2

•

1

•

WORK PORTS 1, 2, 3 OR 4

SPOOL ARRANGEMENT

5.7

Tigercat H822C/LH830C Harvester

822C-34

Pilot system

PILOT SYSTEM CIRCUIT DIAGRAM 5.8

Tigercat H822C/LH830C Harvester

Pilot system

PILOT SYSTEM CIRCUIT DESCRIPTION

Six solenoid valves in the attachment pilot manifold when energized by switches in the cab, will distribute pilot oil to;

Oil from the main pump 'P' port manifold flows through the high pressure filter to the pilot supply valve. This pressure reducing/relieving valve controls and provides pilot oil at 425psi. to the 'P' port of the pilot supply manifold

• • • • • •

The pilot manifold is a distribution center, directing pilot oil to pilot operated functions on the machine. A pilot shut-off valve installed in the manifold controls the flow of pilot oil into the manifold.

NOTE: The manifold has test ports before and after valve. A secondary relief is also added as a safety precaution.

The outlet pressure ports ('P1, P2, P3 & P4') on pilot supply manifold feed the: P1 P3

Four solenoid valves in the pilot supply manifold, when energized by switches in the cab, will distribute pilot oil to; • • • •

Track Drive Low Port X1 Swing Brake Release Port Y Attachment Valve - Pump 1 Section Spare

C4 C3 C2 C1

The ACC outlet pressure port is connected to the pilot accumulator which is in place to maintain a constant pressure source (500 psi), ensuring that the controls remain responsive during heavy duty cycles.

The attachment pilot manifold supplies pilot pressure to joysticks, drive foot pedals and the brake release manifold.

• • • •

Brake release manifold RH Joystick LH Joystick Foot pedals

C1 C2 C3 C4 C2 C2

A gauge test port located on the pilot supply manifold is provided for use when testing the pilot system pressure.

When this pilot shut-off valve is energized, pilot oil is made available to outlet pressure ports and four solenoid valves. When the pilot shut-off valve is de-energized, pilot oil from the pilot supply valve is blocked, preventing pilot oil from entering the manifold, thereby rendering these pilot functions inactive. Refer to PILOT SYSTEM RESET in SECTION 2 of the OPERATOR’S MANUAL.

• Levelling Valve (if equipped) • Attachment Pilot Manifold

Telescopic 'OUT' No factory standard function No factory standard function Pump 2 No factory standard function Telescopic 'IN'

P3 P4 P5 P6

Movement of the joystick levers or the foot pedals will direct pilot oil to the pilot end caps of the main control valve to operate the various machine functions such as lifting the boom or driving the machine.

5.9

Tigercat H822C/LH830C Harvester

Pilot system Whenever the front door is opened the door limit switch opens interrupting the voltage to the function lockout relay coil, this opens the contacts of the function lockout relay and de-energizes the pilot shut off valve and shuts down the pilot system. This prevents pilot oil from reaching the controls. The amber pilot off light will be turned ON.

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

When this switch is pressed, the coil on the function lock-out relay is energized closing the circuit between wires RED 489A and TAN 105B. Wire TAN 105B connects to the front door switch.

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

A second pilot shut off switch is in the same circuit as the front door switch. If an emergency situation should arise, pressing the pilot shut-off switch (Red button) located in the cab will have the same effect as opening the front door.

CIRCUIT "OFF"

CIRCUIT "ON"

822C-40

PILOT SYSTEM ELECTRICAL CIRCUIT DIAGRAM 5.10

Tigercat H822C/LH830C Harvester

Pilot system

SET PILOT PRESSURE 1. With hydraulic oil at operating temperature, connect a 0-1000 psi. gauge to the gauge test port 'G' fitting located on the pilot supply manifold.

• • ••

NOTE: The stand-by pressure of the Pump 1 (main pump) can vary from 400 psi. to 600 psi. The anti-stall can cause the stand-by pressure to drop to 200 psi. when the engine is running below 1800 rpm. Because Pump 1 is the original source of the pilot supply (via the main valve manifold), this will in turn affect the pilot supply.

822C-137

ADJUSTING SCREW LOCKNUT PRESSURE REDUCING/RELIEVING VALVE CARTRIDGE

PILOT SUPPLY VALVE

2. Turn anti-stall switch OFF. GAUGE TEST PORT 'G'

3. Loosen locknut and turn adjusting screw all the way OUT on pilot supply valve, tighten locknut on adjusting screw.

•

4. Start engine and set throttle in IDLE position.

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

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

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

822C-136

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

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

8. Stop engine, and remove pressure gauge.

5.11

PILOT SUPPLY MANIFOLD

Tigercat H822C/LH830C Harvester

Pilot system

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

•

Close the drain valve on the charging and testing device and connect the hose to the nitrogen bottle.

•

Remove the valve guard and cap.

•

Screw the charging and testing device onto the gas valve.

HOSE*

PRESSURE GAUGE*

ADAPTER* ADAPTER* NITROGEN BOTTLE

ACCUMULATOR

ASSEMBLY PART NO. 90254 INCLUDES PARTS SHOWN * ACCU-

CHARGING AND TESTING DEVICE

•

Open the gas shut-off valve on the nitrogen bottle and allow gas to flow slowly into the accumulator.

•

Close the shut-off valve frequently and check the value of the pre-charge by depressing the button on the charging device and observing the gauge.

•

If pre-charge pressure is high, lower it by opening the drain valve and carefully depressing the button on the charging device.

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

NOTE: The pre-charge pressure will vary depending on the temperature. Once the desired pre-charge is reached, wait two minutes for the gas temperature to equalize. Re-check pre-charge and adjust if necessary.

•

Disconnect hose from nitrogen bottle.

•

Remove charging and testing device from accumulator and install valve cap and guard, torque to 175-350 lbf-ins.

•

Check to ensure there are no leaks, if the gas valve is leaking, it should be replaced. Use only valves approved for accumulator service.

NEVER USE AN AUTOMOTIVE TYPE VALVE.

5.12

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

Install the charging and testing device on the gas valve While depressing the button on the charging device, observe gas pressure reading on gauge. Refer to CHARGING THE ACCUMULATOR above for correct pressure.

If the gas pre-charge pressure is low, investigate the cause and correct it. Possible causes of lost pre-charge pressure include a leaking or damaged gas valve, or a damaged bladder.

Tigercat H822C/LH830C Harvester

SECTION 6 - ELECTRICAL, GAUGES, ALARMS AND COMPUTERS JULY 2006

CONTENTS - SECTION 6 CAB MODULE .........................................................................................................................

CHANNELS ..............................................................................................................................

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

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

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

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

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

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

COMPUTER CONTROL SYSTEM (IQAN MDM DISPLAY) .....................................................

ALTERNATE MENUS ...........................................................................................................

CYCLE COUNTER ...........................................................................................................

MACHINE SERVICE - HYDRAULIC OIL ..........................................................................

TREE COUNTER ..............................................................................................................

CONTROL SYSTEM OVERVIEW ........................................................................................

DIAGNOSTICS ADJUSTMENT MENUS ..............................................................................

ADJUST DATE TIME SETTINGS (SETTINGS MENU) ....................................................

ADJUST FUNCTION PARAMETERS (PROPERTIES MENU) .........................................

ADJUST LCD DISPLAY BRIGHTNESS (SETTINGS MENU) ...........................................

ADJUST OUTPUTS (PROPERTIES MENU) ....................................................................

LANGUAGE SETTINGS (SETTINGS MENU) ..................................................................

MENU DESCRIPTIONS ....................................................................................................

MENU OPERATION ..........................................................................................................

SOUND SETTINGS (SETTINGS MENU) .........................................................................

SYSTEM COMPONENTS ....................................................................................................

SYSTEM WARNING MESSAGES .......................................................................................

INFORMATION MESSAGES ............................................................................................

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

WARNING MESSAGES ....................................................................................................

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

6.27 6.40 6.40 6.40 6.40 6.40 6.40 6.40 6.24 6.31 6.31 6.32 6.31 6.24 6.33 6.38 6.43 6.36 6.45 6.37 6.34 6.35 6.37 6.24 6.53 6.55 6.48 6.53 6.40

DOWNLOADING APPLICATIONS FROM DEALER WEBSITE .............................................. 6.60 ELECTRICAL INSTALLATION - CAB ............................................................................ 6.21, ELECTRICAL KIT - SERVICE AND DIAGNOSTICS ...............................................................

ELECTRICAL SCHEMATIC ....... 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 6.10, 6.11, 6.12, 6.13, ENGINE MODULE ......................................................................................................... 6.28, ERROR MESSAGES AND ALARMS FAULT CODES : ERROR MESSAGES ...............................................................................

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

6.22 6.58 6.14 6.29

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

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

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

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

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

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

6.56 6.56 6.56 6.56 6.56 6.56

6.56 6.48

Tigercat H822C/LH830C Harvester

Electrical, gauges, alarms and computers

FUSES AND RELAYS .............................................................................................................. 6.16 GET APPLICATION ................................................................................................................. 6.66 GET ERROR/EVENT LOG ...................................................................................................... 6.70 ID-TAG .....................................................................................................................................

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

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

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

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

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

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

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

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

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

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

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

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

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

6.30 6.48 6.48 6.60 6.60 6.67 6.66 6.71 6.70 6.69 6.68 6.60 6.64 6.62

MAIN SYSTEM ERRORS XP2-A0 MODULE OFFLINE ERRORS ................................................................................ 6.52 XS-A0 MODULE OFFLINE ERROR .................................................................................... 6.50 XT2-A0 MODULE OFFLINE ERROR .................................................................................. 6.51 PDA REGISTRATION .............................................................................................................. 6.60 REAR ELECTRICAL PANEL ................................................................................................... 6.20 SWITCH AND SENSOR LOCATIONS .................................................................................... 6.23 UPDATE APPLICATION .......................................................................................................... 6.62 WIRE COLOUR CODE CHART ............................................................................................... 6.15

6.2

Tigercat H822C/LH830C Harvester

822C-08 (32206B R2)

Electrical, gauges, alarms and computers

MACHINE ELECTRICAL SCHEMATIC DIAGRAM PAGE 1 OF 12 6.3

Tigercat H822C/LH830C Harvester

822C-09 (32206B R2)

Electrical, gauges, alarms and computers

MACHINE ELECTRICAL SCHEMATIC DIAGRAM PAGE 2 OF 12 6.4

Tigercat H822C/LH830C Harvester

822C-10 (32206B R2)

Electrical, gauges, alarms and computers

MACHINE ELECTRICAL SCHEMATIC DIAGRAM PAGE 3 OF 12 6.5

Tigercat H822C/LH830C Harvester

822C-11 (32206B R2)

Electrical, gauges, alarms and computers

MACHINE ELECTRICAL SCHEMATIC DIAGRAM PAGE 4 OF 12 6.6

Tigercat H822C/LH830C Harvester

822C-12 (32206B R2)

Electrical, gauges, alarms and computers

MACHINE ELECTRICAL SCHEMATIC DIAGRAM PAGE 5 OF 12 6.7

Tigercat H822C/LH830C Harvester

822C-13 (32206B R2)

Electrical, gauges, alarms and computers

MACHINE ELECTRICAL SCHEMATIC DIAGRAM PAGE 6 OF 12 6.8

Tigercat H822C/LH830C Harvester

822C-14 (32206B R2)

Electrical, gauges, alarms and computers

MACHINE ELECTRICAL SCHEMATIC DIAGRAM PAGE 7 OF 12 6.9

Tigercat H822C/LH830C Harvester

822C-15 (32206B R2)

Electrical, gauges, alarms and computers

MACHINE ELECTRICAL SCHEMATIC DIAGRAM PAGE 8 OF 12 6.10

Tigercat H822C/LH830C Harvester

822C-16 (32206B R2)

Electrical, gauges, alarms and computers

MACHINE ELECTRICAL SCHEMATIC DIAGRAM PAGE 9 OF 12 6.11

Tigercat H822C/LH830C Harvester

Electrical, gauges, alarms and computers APPLICABLE TO L830C AND LH830C ONLY

822C-17 (32206B R2)

MACHINE ELECTRICAL SCHEMATIC DIAGRAM PAGE 10 OF 12 6.12

Tigercat H822C/LH830C Harvester

Electrical, gauges, alarms and computers APPLICABLE TO LX830C ONLY

822C-18 (32206B R2)

MACHINE ELECTRICAL SCHEMATIC DIAGRAM PAGE 11 OF 12 6.13

Tigercat H822C/LH830C Harvester

822C-19 (32206B R2)

Electrical, gauges, alarms and computers

MACHINE ELECTRICAL SCHEMATIC DIAGRAM PAGE 12 OF 12 6.14

Tigercat H822C/LH830C Harvester

Electrical, gauges, alarms and computers

Tigercat wire colour code chart applicable to all products manufactured by Tigercat Industries Inc. COLOUR Red Black White Blue Purple Tan Yellow Grey Brown Green Orange

FUNCTION EXAMPLE Power ........................................ (protected and unprotected) Ground Engine control ........................... (fuel shut-off, start aid) Propulsion Control .................... (transmission/reverser solenoids) Monitor, electrical and mechanical systems ................. (air cleaner, alternator, wheel speed, engine speed) Electrical and electromechanical control ......... (park brake, alternator excitation) (power door motor, backup alarm) Monitors .................................... (flow, pressure, temperature, level) Standard monitor system .......... (logic module to monitor) Lights Electro-hydraulic control ........... (pilot solenoids) Accessories .............................. (horn, A/C, heater)

6.15

Tigercat H822C/LH830C Harvester SYSTEM FUSES AND RELAYS

Electrical, gauges, alarms and computers The cab electrical controls, fuse and relay panel on this machine is located in the cab on the right rear side panel. IQAN fuses are located here.

IMPORTANT 24 VOLT ELECTRICAL SYSTEM

ENGINE DIAGNOSTICS PLUG

•

822C-07

ENGINE DIAGNOSTICS PLUG

The engine diagnostics plug is on the left side of the instrument panel. Refer also to ENGINE DIAGNOSTICS CONNECTION in SECTION 2 of THE OPERATOR’S MANUAL.

822C-10

The electrical box fuses/relays panel is located in the right rear compartment. The engine ECM (Engine Control Module) run signal fuse is located here.

CAB ELECTRICAL CONTROLS, FUSE AND RELAY PANEL

6.16

Tigercat H822C/LH830C Harvester

822C-09

Electrical, gauges, alarms and computers

ELECTRICAL BOX FUSES/RELAYS PANEL

6.17

Tigercat H822C/LH830C Harvester

Electrical, gauges, alarms and computers

•

60 AMP FUSE CAB WORKLIGHTS

60 AMP FUSE CAB POWER

60 AMP FUSE KEY SWITCH RUN/ACC

60 AMP FUSE ELECTRICAL BOX SWITCHED POWER

••

40 AMP START SOLENOID RELAY FUSE

••

••

••

125 AMP GRID HEATER RELAY FUSE

GRID HEATER RELAY

•• • •• DOOR PUMP RELAY 125 AMP DOOR PUMP RELAY FUSE

60 AMP FUSE ELECTRICAL BOX UNSWITCHED POWER

••

••

START SOLENOID RELAY

•• 822C-08

FUSES AND RELAYS ENGINE COMPARTMENT

6.18

Tigercat H822C/LH830C Harvester

Electrical, gauges, alarms and computers

Another electrical box is located in the engine compartment at the right rear of the engine beside the battery box.

Two 125 amp, one 40 amp and four 60 amp fuses are installed ahead of the system circuit fuses and are there to prevent major damage to the electrical systems of the machine in the event of a short circuit in any of these switched power feed lines.

Each circuit on the machine is further protected against current overload by individual circuit fuses.

A separate 60 amp fuse provides unswitched power for battery disconnect relay and service lights.

7.5 AMP FUSE

••

FIRE SUPPRESSION SYSTEM IN LINE FUSE (IF EQUIPPED) A 7.5 amp in-line fuse protects the fire suppression system when an AMEREX fire suppression system is installed. This fuse is located in the fire suppression power lead from the battery.

If a fuse “blows” it should be replaced with a fuse of the same amperage rating. If the fuse "blows" again, the circuit in question must be inspected for a possible short circuit.

6.19

Tigercat H822C/LH830C Harvester

Electrical, gauges, alarms and computers

IQAN MDM CONTROL MODULE

IQAN HARNESS

•

IQAN XS CAB MODULE

•

• FUSE AND RELAY PANEL

• TERMINAL RAIL

••

CAPACITOR DIODE

•• •• • REAR PANEL HARNESS

822C-22

REAR ELECTRICAL PANEL

6.20

Tigercat H822C/LH830C Harvester

Electrical, gauges, alarms and computers REAR PANEL

DISPLAY MODULE

CAB MODULE

TERMINAL RAIL

SYSTEM FUSE AND RELAY PANEL

FIRE SUPPRESSION CONTROL PANEL

STEREO RADIO

CONTROL PANEL

••

PILOT SHUT-OFF LIMIT SWITCH ON FRONT DOOR

ANTENNA

•• ••

INSTRUMENT PANEL

•

•

•• ••

• •

822C-20

ELECTRICAL INSTALLATION - CAB 6.21

•

••

Tigercat H822C/LH830C Harvester

822C-21

Electrical, gauges, alarms and computers

INSTRUMENT PANEL 6.22

Tigercat H822C/LH830C Harvester

Electrical, gauges, alarms and computers

POWER DOOR PUMP/ MOTOR

DOOR SENSOR ENGINE SIDE DOOR

FUSES AND RELAYS - ENGINE COMPARTMENT

DOOR SENSOR PUMP DOOR FAN CONTROL VALVE

BATTERIES ALTERNATOR

••

•

•

••

ENGINE COOLANT LEVEL SENSOR

• ••

LEVELLING CONTROL VALVE (IF EQUIPPED)

••

••

••

IQAN XP2 MODULE (IF EQUIPPED) ELECTRICAL BOX (FUSES AND RELAYS)

••

••

•

•• HYDRAULIC OIL FILTER BYPASS SWITCH

A/C COMPRESSOR

•

TO CAB HYDRAULIC OIL TANK

HYDRAULIC OIL TEMPERATURE SENSOR (IQAN)

• •• •

HYDRAULIC OIL TEMPERATURE SWITCH (LIGHT AND HORN)

FUEL TANK

HYDRAULIC OIL TEMPERATURE SENDER (GAUGE)

•• • ••

BRAKE PRESSURE SWITCH HORN (SWITCH ON CONTROL PANEL)

H822C-I02

IQAN XT2 MODULE

••

•• •

• •

DOOR SENSOR HYDRAULIC TANK DOOR MOTION ALARM HYDRAULIC OIL LEVEL SIGHT GAUGE AND TEMP. GAUGE LEVEL SWITCH ( LOW ALARM) HYDRAULIC OIL LEVEL SIGHT GAUGE AND LEVEL SWITCH (EXTREME LOW ALARM)

FUEL LEVEL SENDER (GAUGE)

SWITCH AND SENSOR LOCATIONS 6.23

Tigercat H822C/LH830C Harvester

Electrical, gauges, alarms and computers

IQAN MDM COMPUTER DISPLAY AND CONTROL SYSTEM

3

IQAN MDM COMPUTER DISPLAY MODULE)

MENUS SWITCH

•

•

4

2

ECM 1

IQAN DISPLAY MODULE 822C-05 The IQAN MDM (master display module) computer display is the operator interface with the IQAN control system. The IQAN MDM is the central unit in the IQAN control system which works as both a master control and a display unit.

SYSTEM COMPONENTS

The IQAN MDM has a backlit graphic LCD display.

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

1.

2.

3.

4.

5.

SCROLL UP/DOWN BUTTON

LCD DISPLAY

•• F1 BUTTON 860C-024

••

••

•• ••

••

F2 BUTTON

F3 BUTTON

ESCAPE BUTTON

MDM COMPUTER MODULE

The IQAN-MDM computer is mounted on the right side of the cab roof air plenum. The computer displays, controls and monitors the following machine functions: •

Hydraulic Cooling Fan

•

Pump 2

•

Telescopic Boom Functions (if equipped)

•

Levelling Functions (if equipped)

5

XSCAB MODULEAG010 DISPLAYMODULEAG009 XP2FRAMECRANEMODULE

MDM Display/Control Module (XS-A0) Cab Module (XT2-A0) Engine Module Engine Control Module (XP2-A0) OC Leveller Module (if equipped)

Inputs: The computer monitors analogue, digital, and J1939 inputs (CAN Bus inputs). CAN Bus is a data bus system that allows several input/output signals to be sent between modules through a reduced number of wires.

Outputs: The computer directs a proportional output (24 Volt electrical current) to the solenoids on the fan valve, attachment valve and levelling valve (if equipped).

The MENUS switch to the left of the IQAN-MDM display is used to select between the ALTERNATE MENUS and the SYSTEM DIAGNOSTICS MENUS. Press the top of the MENUS switch to display the ALTERNATE MENUS. Refer to COMPUTER ~ ALTERNATE MENUS in THIS SECTION. Press the bottom of the MENUS switch to display the SYSTEM DIAGNOSTICS MENUS. Refer to COMPUTER ~ DIAGNOSTICS ADJUSTMENT MENUS in THIS SECTION.

6.24

Tigercat H822C/LH830C Harvester

Electrical, gauges, alarms and computers

SYSTEM WARNING MESSAGES and INFORMATION MESSAGES are displayed on the IQAN-MDM screen regardless of the position of the MENUS switch.

The master alarm on the instrument panel will sound whenever a DOOR OPEN or ENGINE ALARM warning message is shown on the screen.

When a DOOR OPEN warning message or PILOT ON information message a warning light on the instrument panel will also notify the operator.

Refer to COMPUTER ~ SYSTEM WARNING MESSAGES in THIS SECTION. NOTE: The IQAN control system is softwarebased. This software may be updated after the machine is in service as a part of on-going product improvement programs and service newsletters.

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

6.25

Tigercat H822C/LH830C Harvester

Electrical, gauges, alarms and computers MDM MODULE WIRING PIN ASSIGNMENT

COMPONENT REPLACEMENT MDM DISPLAY MODULE

••

•

RELEASE TABS

MDM MODULE REPLACEMENT

1014-035

1. Turn battery disconnect switch OFF. 2. Remove the four screws and lift the cover panel to access the wiring and back of the MDM module.

3. Disconnect the wiring harness at the module.

4. Press the four tabs on the module (snap on attachment) and lift the module out of the panel.

5. Install module in reverse order as removed.

NOTE: Refer to Update the Application in THIS SECTION.

1. CAN LOW 2. ALARM OUT 3. BATTERY GROUND

6

5

2

5

•

••

3

•• ••

4. CAN HIGH 5. POWER SUPPLY - Real Time Clock

••

6. POWER SUPPLY NOTE: Refer to the Electrical schematics in this section for detailed pin and wiring assignment.

•• •• 1014-032

1

•• 5

4

•• 5

REAR OF MDM MODULE The back of the MDM Module consists of the following: 1. Tag with serial number and part number.

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

3. Voltage supply indicator. green LED light ON indicates supply voltage is activated. LED light OUT indicates supply voltage is OFF. 4. Main connector for voltage supply, CAN communication and alarm output.

5. Snap on attachment for mounting in panel.

6. Membrane valve for condensation prevention inside unit.

6.26

Tigercat H822C/LH830C Harvester

Electrical, gauges, alarms and computers

XS-A0 CAB MODULE COMPONENTS

XS CAB MODULE

••

1014-038

A. Supply Voltage LED. LED OFF indicates supply voltage is OFF. LED ON solid green light indicates supply voltage is ON. B. Arrow and Heart Status Indicator LEDs. LED for Heart and Arrow flash alternately (solid green) indicates Status is Correct.

822C-10

CAB ELECTRICAL CONTROLS, FUSE AND RELAY PANEL

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

XS-A0 CAB MODULE REPLACEMENT

•

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

1. Turn battery disconnect switch OFF.

•

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

2. Remove the screws and cover panel from the fuse/relay compartment.

3. Disconnect the wiring harness connectors on the module.

•

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

4. Remove the two screws and lift the module out.

•

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

5. Reverse procedure to install module.

•

Five flashes in a row indicates that the fault is related to the address.

•

Continuous flashing indicates the fault is related to software.

Error code

Blink (red light)

I/O and voltage errors Low/High temperature CAN error Hardware error Address error Software error 1014-037

C. Connectors CAN1 and CAN2 for CAN-bus.

D. C1 connector for inputs and outputs.

E. Module assembly.

NOTE: Refer to the XS-A0 CAB MODULE wiring schematic and Electrical schematics in this section for detailed pin and wiring assignment.

6.27

Tigercat H822C/LH830C Harvester

Electrical, gauges, alarms and computers

XT2-A0 ENGINE MODULE 2 1

• • XT2-AO MODULE LED INDICATORS

1014-042

XT2-A0 ENGINE MODULE LED INDICATORS

1014-041

1. Supply Voltage LED. LED with green light ON indicates supply voltage is ON. LED OFF indicates supply voltage is OFF. 2. Status indicator LED. LED yellow flashing light indicates status is correct.

LED flashing red light indicates error status as follows: •

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

•

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

•

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

•

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

•

Five flashes in a row indicates that the fault is related to the address.

•

Continuous flashing indicates the fault is related to software.

Error code

1014-043

XT2-A0 MODULE WIRING PIN ASSIGNMENT NOTE: Refer to the XT2-A0 ENGINE MODULE Wiring Schematic and Electrical Schematics in this section for detailed pin and wiring assignment.

Blink (red light)

I/O and voltage errors Low/High temperature CAN error Hardware error Address error Software error

6.28

Tigercat H822C/LH830C Harvester

Electrical, gauges, alarms and computers

XP2-A0 OPTIONAL MODULE 2 1

• • XP2-AO MODULE LED INDICATORS

1014-042

XP2-A0 MODULE LED INDICATORS

1014-041

1. Supply Voltage LED. LED with green light ON indicates supply voltage is ON. LED OFF indicates supply voltage is OFF. 2. Status indicator LED. LED yellow flashing light indicates status is correct.

LED flashing red light indicates error status as follows: •

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

•

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

•

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

•

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

•

Five flashes in a row indicates that the fault is related to the address.

•

Continuous flashing indicates the fault is related to software.

Error code

1014-043

XP2-A0 MODULE WIRING PIN ASSIGNMENT NOTE: Refer to the XT2-A0 ENGINE MODULE Wiring Schematic and Electrical Schematics in this section for detailed pin and wiring assignment.

Blink (red light)

I/O and voltage errors Low/High temperature CAN error Hardware error Address error Software error

6.29

Tigercat H822C/LH830C Harvester ID-TAG

Electrical, gauges, alarms and computers

ADDRESSING Each module has a specific address, enabling the master module to communicate with it through the CAN-bus. Practically, the system distinguishes between different modules through firstly verifying the module type and then, secondly, through the modules having a unique addresses.

EXAMPLE If a system has an XP2 module with address 0, the system will denote this one as XP2-A0, The letter “A” refers to CAN-bus A. In order to assign any XP2 module a unique CANaddress, an Id-Tag will have to be connected to the positions ADDR-H and ADDR-L.

42

29

28

15

14

1

ADDR-L, pos. 14

ADDR-H, pos. 1

Id-Tag

CONNECTING ID-TAG (XT2 OR XP2)

TERMINATING To eliminate interference in communication, through the CAN-bus, the CAN-bus must be terminated. Because the master module always is located at the beginning of the bus, the master is provided with an internal termination. If an IQANXP2 is located at the end of the CAN-bus then use an Id-tag having a combined address and terminating function. This is denoted with a “T” for terminating, after the appropriate address such as; 0T, 1T, 2T...

ASSEMBLING ID-TAG (XT2 OR XP2)

Selecting appropriate Id-Tag •

Check the address number of the module.

•

If the module is located at the end of the CANbus then select the appropriate Id-Tag denoted with a “T”.

MODULE MDM XS-A0 XT2-A0 XP2-A0

ID-TAG NO TAG NO TAG 0 0T

RESISTANCE 287 Ω 432 Ω

ASSEMBLING OF THE ID-TAG The Id-Tag is placed in the connector in order to address/ terminate the module. The Id-Tag is mounted under the connector casing. Bend the IdTag’s cables towards the opposite side, where the other cables enter the connector.

6.30

Tigercat H822C/LH830C Harvester

Electrical, gauges, alarms and computers ATTACH

ALTERNATE MENUS Press the top of the MENUS switch to display the ALTERNATE MENUS. The display will appear as shown. If the display does not appear as shown press the ESCAPE button repeatedly until it does appear as shown.

822C-54

1. Tree Counter Not used for Harvester applications.

H822C-04

Press the F1 or F3 buttons on the IQAN-MDM display unit to view the ATTACH or SERVICE menu displays as indicated on the LCD menu display.

Use the F1, F2 or F3 function button to move through the menus as indicated on the LCD menu display.

822C-55

2. Cycle Counter This electronic menu display provides access to the cycle counter function.

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

Pressing RESET (F3) will reset the cycle counter to zero.

SCROLL BUTTON

The cycle counter function provides the operator with a count of the number of times right joystick button # 1 is pressed. This function provides a custom counter for use as required by the operator.

• •• F1 BUTTON H822C-04

•• • F2 BUTTON

NOTE: This description applies only to machines equipped with factory installed six button joysticks, it does not take into account any changes or modifications made after shipment.

•• F3 BUTTON

ESCAPE BUTTON

MDM COMPUTER MODULE

BUTTON #1

••

860C-002

6.31

RIGHT HAND JOYSTICK

Tigercat H822C/LH830C Harvester

Electrical, gauges, alarms and computers

SERVICE 3. Machine Service - Hydraulic Oil This electronic menu display provides access to the machine service hydraulic oil type selection mode.

860C-076

Press ISO 68 (F1) or NEXT (F3)

860C-073

Shown here SERVICE (F3) has been selected and Machine Service Hyd Oil can be selected.

Press HYD OIL (F1) to access Select Hydraulic Oil Grade - Current Hyd Oil.

860C-073

When the type of oil has been selected the display will return to Machine Service display.

Select ESC.

860C-074

Press ISO 22 (F1), ISO 32 (F2), or NEXT (F3) H822C-04

The display will return to ATTACH - SERVICE, Select ESC to return to the following display,

860C-075

Press ISO 36 (F1), ISO 46 (F2), or NEXT (F3)

822C-46

or, press the bottom of the MENUS switch to display the IQAN-MDM diagnostic and function adjustment menus.

Note: Whenever an alarm is activated, the current display menus are replaced with the alarm warning message. When the alarm function is cleared, diagnostic and function adjustment menus appear.

Press the top of the MENUS switch to display the ALTERNATE MENUS. 6.32

Tigercat H822C/LH830C Harvester

Electrical, gauges, alarms and computers

SYSTEM DIAGNOSTICS AND FUNCTION ADJUSTMENT MENUS DISPLAY MENUS SWITCH

•

•

1014-D001B 822C-05

IQAN DISPLAY MODULE

Press the bottom of the MENUS switch to display the IQAN-MDM system diagnostics and function adjustment menus.

TIME

SOFTWARE VERSION

••

•• •• •• F1 BUTTON

822C-46

OPERATOR MODE

DATE

•• • F2 BUTTON

••

SCROLL BUTTON

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

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

•

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

••

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

F3 BUTTON

ESCAPE BUTTON

MDM COMPUTER MODULE

The display should show the current date, time, operator mode, machine model number and software version identification.

6.33

Tigercat H822C/LH830C Harvester MENU DESCRIPTIONS

Electrical, gauges, alarms and computers C. Computer SOUND volumes can be adjusted.

D. Computer DATE and TIME can be adjusted.

630C-70

1. MODE MENU DESCRIPTION Not currently used in program, no modes to select.

1014-D097

4. MEASURE MENU DESCRIPTION A. Input and output VOLTAGE and CURRENT can be measured.

B. EVENT COUNTER can be viewed.

C. J1939 CANBUS DATA can be viewed.

1014-D095

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

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

822C-56

5. PROPERTIES MENU DESCRIPTION A. FUNCTION PARAMETERS for adjustable machine functions can be adjusted.

WARNING Do not make adjustments in this menu.

Machine warning alarms can be disabled in this menu.

B. INPUTS for adjustable machine functions can be adjusted.

C. OUTPUTS for adjustable machine functions can be adjusted.

1014-D096

3. SETTINGS MENU DESCRIPTION A. LCD display CONTRAST and LIGHT (BRIGHTNESS) can be adjusted.

B. The LANGUAGE that the text is displayed in can be selected.

6.34

Tigercat H822C/LH830C Harvester MENU OPERATION

Electrical, gauges, alarms and computers LATEST CHANGE DATE & TIME

1. MODE MENU OPERATION

• • •• •

Not currently used in program, no modes to select..

KEY I.D. KEY LABEL

H822C-06

Press MORE (F1) to show LATEST CHANGE DATE and TIME, KEY I.D. and KEY LABEL. 860C-101

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

APPLICATION INFORMATION H822C-07

Press ESC, then press COMMENT (F2) to show application COMMENTS.

H822C-05

Press APPLIC (F1) to select APPLICATION INFORMATION. H822C-08

The display can show four rows of comments, use UP/DOWN scroll buttons to see more comments.

6.35

Tigercat H822C/LH830C Harvester

Electrical, gauges, alarms and computers CHANGE LIGHT (DISPLAY BRIGHTNESS)

1014-D096

3. SETTINGS MENU OPERATION

630C-27

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

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

A. LCD Press LCD (F1) to select LCD SETTINGS. CHANGE CONTRAST

630C-73

Change to desired BRIGHTNESS using UP/ DOWN scroll buttons and press OK (F1) to save setting and return to previous menu.

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

630C-27

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

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

630C-74

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

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

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

6.36

Tigercat H822C/LH830C Harvester

Electrical, gauges, alarms and computers

B. LANGUAGE SETTINGS

C. SOUND SETTINGS

Press LANGUAGE (F2) to select LANGUAGE SETTINGS.

Adjusting BUZZER VOLUME and change BUTTON SOUND.

CHANGE LANGUAGE

1014-D110 1014-D096

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

Press LANGUAGE (F2) to select the function LANGUAGE.

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

1014-D109

Change to desired LANGUAGE using UP/ DOWN scroll buttons and press OK (F1) to save setting and return to previous menu.

630C-75

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

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

630C-76

Change to desired VOLUME using UP/DOWN scroll buttons. There are Ten volume levels. 0 implies that sound is turned OFF. 100 is the loudest. Thereafter, press OK (F1) to save setting and return to previous menu.

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

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

6.37

Tigercat H822C/LH830C Harvester

Electrical, gauges, alarms and computers

CHANGE BUTTON SOUND

D. DATE TIME SETTINGS

1014-D096

1014-D110

Press SOUND (F1) to select the function SOUND SETTINGS.

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

630C-75 1014-D110

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

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

630C-77

630C-78

Change to desired VOLUME using UP/DOWN scroll buttons. There are ten button beep levels. 0 implies that the button beep is turned OFF. 100 is the loudest. Thereafter, press OK (F1) to save setting and return to previous menu.

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

YEAR - MONTH - DAY - HOUR - MINUTE

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

Reset the Button Sound Level RESET (F3) resets the button sound level to the preset factory value which corresponds to 50.

630C-78A

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

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

6.38

Tigercat H822C/LH830C Harvester

Electrical, gauges, alarms and computers

4. MEASURE MENU OPERATION Measurements can be viewed for the following channels:

H822C/LH830C HARVESTER INPUTS TYPE SCREEN MESSAGE VOLTAGE IN PUMP 1 Input VOLTAGE IN Level Left VOLTAGE IN Level Right VOLTAGE IN Left JS Trigger VOLTAGE IN PUMP 2 Input VOLTAGE IN Level Fore VOLTAGE IN Level Rear VOLTAGE IN Right Js Trigger VOLTAGE IN Proportional Telescopic VOLTAGE IN OC Leveller VOLTAGE IN Hydraulic Oil Temp VOLTAGE IN Hydraulic Tank Door VOLTAGE IN Pump Door VOLTAGE IN Engine Side Door

FUNCTION Pump 1 Signal Level Left Level Right Telescopic Boom IN Pump 2 Signal Level forward Level back Telescopic Boom OUT Proportional Control XP2-A0 module enable

ACTIVATING CONTROL/SENSOR/SWITCH N/A Left joystick button 2* Left joystick button 3* Left joystick trigger * N/A Right joystick button 2* Right joystick button 3* Right joystick trigger * Proportional Control (if equipped after shipment) XP2-A0 module Hydraulic Temperature Sensor Hydraulic Tank Door Sensor Pump Door Sensor Engine Side Door Sensor

LOCATION Left Joystick Left Joystick Left Joystick Right Joystick Right Joystick Right Joystick XP2-A0 module Hydraulic Tank LH Rear Door RH Rear Door Engine Side Door

DIGITAL IN DIGITAL IN DIGITAL IN DIGITAL IN DIGITAL IN DIGITAL IN DIGITAL IN DIGITAL IN DIGITAL IN DIGITAL IN DIGITAL IN DIGITAL IN

Left JS Button 4 Left JS Button 5 Left JS Button 6 Right JS Button 4 Right JS Button 5 Right JS Button 6 Pilot System ON Air Conditioner ON Fan Purge Switch Fan Override Switch Gauges Fan Service Mode

No factory standard function No factory standard function No factory standard function No factory standard function No factory standard function No factory standard function Pilot on switch signal A/C ON signal Fan Clean Cycle Fan full on (override) IQAN menu toggle Service Mode (fan rotation)

Left joystick button 4* Left joystick button 5* Left joystick button 6* Right joystick button 4* Right joystick button 5* Right joystick button 6* Pilot system ON (reset) switch Air conditioner ON/OFF switch Cooling Fan Switch - CLEAN position Cooling Fan Switch - FULL ON position Menus Switch Service Mode Switch

Left Joystick Left Joystick Left Joystick Right Joystick Right Joystick Right Joystick Rear Control Panel Rear Control Panel Rear Control Panel Rear Control Panel Next to IQAN MDM module Instrument Panel

OUTPUTS TYPE CURRENT OUT CURRENT OUT CURRENT OUT

SCREEN MESSAGE Right Level Cylinder Left Level Cylinder OC Fan Prop.

FUNCTION Right Level Cylinder Control Left Level Cylinder Control Fan speed

CONTROL ACTIVATED Levelling control valve right cylinder (+extend/-retract) Levelling control valve left cylinder (+extend/-retract) Fan Control (Open Loop)

LOCATION Pump compartment Pump compartment Fan Control (Open Loop)

DIGITAL OUT DIGITAL OUT DIGITAL OUT

A/C Cut Out Fan Reverse Door Sensor Light

A/C Off Fan clean cycle Warning light

A/C Off Relay Fan Control (Open Loop) Door/Roof Open warning light

Relay panel in cab Fan Control (Open Loop) Instrument panel

PWM OUT PWM OUT PWM OUT

Pump 2-Attachmt 3 Tele-Attachmt 2 PUMP 1-Attachmt

Pump 2 ON/NOT USED Telescopic Boom IN/OUT Pump 1 ON/NOT USED

Attachment pilot manifold Pump 2 solenoid Attachment pilot manifold Telescopic solenoids Pilot supply manifold Pump 1 solenoid

Hydraulic tank compartment Hydraulic tank compartment Pump compartment

* NOTE: Activating control refers to factory installed machine functions and controls. It does not take into account any changes or modifications made after shipment. Verify all functions before servicing or operating this machine.

6.39

Tigercat H822C/LH830C Harvester CHANNELS

Electrical, gauges, alarms and computers CURRENT OUT - TROUBLESHOOTING FOR OPEN CIRCUITS

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

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

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

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

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

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

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

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

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

• CURRENT OUT VALUE MEASURED AT COUT

OUTPUTS CURRENT OUT (COUT)

620C-34

CURRENT OUT CONNECTIONS

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

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

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

DIGITAL OUT (DOUT)

630C-211

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

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

6.40

DIAGNOSTIC BREAKOUT HARNESS

Tigercat H822C/LH830C Harvester EXAMPLE ~ VIEW INPUT CHANNELS

Electrical, gauges, alarms and computers

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

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

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

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

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

Press ESCAPE button to return to previous screen.

6.41

Tigercat H822C/LH830C Harvester Electrical, gauges, alarms and computers EXAMPLE ~ VIEW OUTPUT CHANNELS

Press SELECT (F1) to select CURRENT OUT.

Press OUTPUTS (F2) to select OUTPUTS.

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

Press ESCAPE button to return to previous screen.

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

6.42

Tigercat H822C/LH830C Harvester

Electrical, gauges, alarms and computers EXAMPLE:

822C-56

5. PROPERTIES MENU OPERATION

822C-56

Changes can be made to the settings for adjustable machine functions. Adjustments will only affect the settings in the current operator mode.

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

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

A. ADJUST FUNCTION PARAMETERS Adjustable functions include: •

Forward Level Speed - Adjusts forward levelling speed

•

Rear Level Speed - Adjusts rearward levelling speed.

•

Telescopic Activate - Turns controls for telescopic boom OFF or ON as required by machine options ( 0=OFF, 1=ON).

•

•

620C-73

Proportional Telescopic - Turns proportional control of telescopic boom OFF or ON as required by the type of joystick in use ( 0=OFF, 1=ON).

Press SELECT (F1) to select.

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

Timed Purge Interval - Adjusts the time interval between automatic cooling fan clean cycles.

Adjusta ble Function Pa ra m e te rs

Function Pa ra m e te r Forward Level Speed Rear Level Speed Timed Purge Interval Telescopic activate Proportional Telescopic

Minim um Ma x im um 0% 100% 0% 100% 0.25 hrs 4 hrs 0 1 0 1

Fa ctory De fa ult (Re se t) 80% 80% 2 hrs 0 0

822C-76

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

For more detailed instructions and information about electronic adjustment of the levelling system refer also to LEVELLING ELECTRONIC ADJUSTMENT PROCEDURE in THIS SECTION.

6.43

Tigercat H822C/LH830C Harvester

Electrical, gauges, alarms and computers

822C-77

Use UP/DOWN scroll buttons adjust parameter setting or press RESET (F1) to return to factory default setting.

822C-78

Select OK (F1) to confirm new setting.

6.44

Tigercat H822C/LH830C Harvester

Electrical, gauges, alarms and computers C. ADJUST OUTPUTS Adjustable outputs include: Right Level Cylinder (Current Out)

•

Left Level Cylinder (Current Out)

•

Pump 2 - Attachment (PWM Out)

•

Telescopic - Attachment (PWM Out)

For more detailed instructions and information about electronic adjustment of the levelling system refer also to LEVELLING ELECTRONIC ADJUSTMENT PROCEDURE in THIS SECTION.

822C-56

B. ADJUST INPUTS AND OUTPUTS Adjustable inputs include: •

•

Proportional Telescopic (Voltage In) (if equipped)

For more detailed instructions and information about electronic adjustment of functions refer also to TELESCOPIC BOOM AND PUMP 2 ELECTRONIC ADJUSTMENT PROCEDURE in THIS SECTION.

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

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

These settings (defined below) fine tune the operating speeds and start/stop ramps for the adjustable current out operated functions.

MINIMUM CURRENT Minimum current settings control function start speed. Coils on hydraulic valves require a certain amount of current before they begin to operate the valve. The Min current value is the current that will be sent to the hydraulic valve coil when the function switch is activated.

The min current is adjusted to a value that causes the function to just begin to move.

Adjusta ble Inputs Function

Fa ctory de fa ult va lue s

VOLTAGE IN Proportional Telescopic

(-) retract

Min (m V) 0

Ma x (m V) 5000

(-) retract cylinder retract cylinder

Min curre nt (Ma ) 300 300

Ma x curre nt (Ma ) 600 600

Min MR (%) 30 50

Ma x MR (%) 100 95

(+) extend

Adjusta ble Outputs Function

Fa ctory de fa ult va lue s

CURRENT OUT Right Level Cylinder Left Level Cylinder

(+) extend cylinder extend cylinder

Function

Pum p2 - Attachmt 3 Tele-Attachmt 2

Stop slope (Ms) 250 250

Fine control (%) 0 0

Fa ctory de fa ult va lue s

PW M OUT (+) not used extend

Sta rt slope (Ms) 250 250

(-) on retract

6.45

Sta rt slope (Ms) 500 100

Stop slope (Ms) 250 250

Fine control (%) 0 0

Tigercat H822C/LH830C Harvester

Electrical, gauges, alarms and computers

MAXIMUM CURRENT Maximum current settings control the maximum speed the function will operate.

START/STOP SLOPE Start and stop slope is the time it will take for the current to rise from minimum to maximum and maximum to minimum respectively.

FINE CONTROL Fine Control changes the current output curve from being a straight line to being close to a type of curved line. Lower numbers create more output. Higher numbers create less output.

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

By varying the ratio between on and off time (modulation ratio or duty cycle) an output proportional to the system voltage can be obtained.

PWMOUT maintains a constant output voltage, and the output current is governed by the resistance in the circuit.

These settings (defined below) fine tune the operating speeds and start/stop ramps for the adjustable pwm out operated functions.

MINIMUM MR (MODULATION RATIO) Minimum MR settings control function start speed. Coils on hydraulic valves require a certain MR before they begin to operate the valve. The Min MR value is the modulation ratio that will be sent to the hydraulic valve coil when the function switch is activated.

The min MR is adjusted to a value that causes the function to just begin to move.

MAXIMUM MR (MODULATION RATIO) Maximum MR setting controls the maximum speed the function will operate.

START/STOP SLOPE Start and stop slope is the time it will take for the MR to rise from minimum to maximum and maximum to minimum respectively.

FINE CONTROL Fine Control changes the PWM output curve from being a straight line to being close to a type of curved line. Lower numbers create more output. Higher numbers create less output.

6.46

Tigercat H822C/LH830C Harvester

Electrical, gauges, alarms and computers

EXAMPLE:

DISPLAY 8

Use UP/DOWN scroll buttons adjust setting.

822C-56

Press OUTPUTS (F2) to select ouputs for adjustment.

Select OK (F1) to confirm new setting.

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

630C-105

Press SELECT (F1) to select.

DISPLAY 3

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

Press SELECT(+) (F1) or SELECT(-) (F2) to select a function and direction for adjustment.

DISPLAY 6

Use UP/DOWN scroll buttons to select the setting to be adjusted.

Press SELECT (F1) to select.

6.47

Tigercat H822C/LH830C Harvester MAIN SYSTEM ERRORS

Electrical, gauges, alarms and computers

822C-62

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

Likely causes are: • Power - Fuse (MDM or CLOCK) • Ground

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

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

• LCD display settings too light to read • Faulty MDM module

CAUTION Do not make adjustments in this menu.

Machine service indicators can be affected.

620C-43

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

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

6.48

Tigercat H822C/LH830C Harvester

Electrical, gauges, alarms and computers

Note also an exception to the rule: H822C series Harvester programs contain information for all H822C/LH830C models including module programming for the XT2-A0 OC Leveller module (open loop leveller, used only on the L830C and LH830C) and the XT2-A1 CC Leveller module (closed loop leveller, used only on the LX830C).

Depending on the model of machine the program is installed in one or both of these modules will be disabled because the module is not used on the machine. In the case where a newer version of the program and/or a new MDM module has been installed during a service procedure it may be necessary for the service technician to disable the appropriate module(s).

822C/H822C/830C/X830C machines should have both levelling modules disabled.

822C-73

L830C and LH830C machines should have the XT2-A1 CC Leveller module (closed loop leveller, used only on the LX830C) disabled.

822C-74

LX830C machines should have XT2-A0 OC Leveller module (open loop leveller, used only on the L830C and LH830C) disabled.

6.49

Tigercat H822C/LH830C Harvester

Electrical, gauges, alarms and computers

860C-117

XS-A0 MODULE OFFLINE ERROR Expect all machine functions controlled by this module to cease and all alarms and warnings associated with this module to be triggered.

1. CHECK FOR OTHER ERROR/ALARM MESSAGES ON SCREEN

1014-038

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

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

Supply Voltage LED. LED ON solid green light indicates supply voltage is ON.

If XS-A0 MODULE IS OFFLINE is the only module is offline error message the likely causes are:

LED OFF indicates supply voltage is OFF.

• Power - Fuse (XS MODULE)

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

Arrow and Heart Status Indicator LEDs.

• Ground

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

• Address (ID-Tag) If the XS-A0 MODULE IS OFFLINE is followed by XT2-A0 and/or XP2-A0 MODULE IS OFFLINE errors the likely cause is: • CAN wire connection

•

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

•

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

•

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

•

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

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

6.50

Blink (Arrow only green light)

Tigercat H822C/LH830C Harvester

Electrical, gauges, alarms and computers 2 1

•• •• XT2-A0 MODULE LED INDICATORS

1014-042 860C-115

2. CHECK MODULE STATUS INDICATORS XT2 MODULE OFFLINE ERROR

Status lights can also give an immediate indication of the nature of the error.

Expect all machine functions controlled by this module to cease and all alarms and warnings associated with this module to be triggered.

(1) Supply Voltage LED. LED ON solid green light indicates supply voltage is ON.

1. CHECK FOR OTHER ERROR/ALARM MESSAGES ON SCREEN

LED OFF indicates supply voltage is OFF.

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

(2) Status indicator LED (yellow/red).

LED yellow flashing light indicates status is correct.

LED flashing red light indicates error status as follows:

If XT2-A0 MODULE IS OFFLINE is the only module is offline error message the likely causes are:

•

• Power - Fuse (XT2 MODULE)

•

• Ground • Address (ID-Tag)

•

• CAN wire connection

• • •

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

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

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

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

Five flashes in a row indicates that the fault is related to the address.

Continuous flashing indicates the fault is related to software.

LX-, XP2- and XT2- module Error code I/O and voltage errors Low/High temperature CAN error Hardware error Address error Software error

6.51

Blink (red light)

Tigercat H822C/LH830C Harvester

Electrical, gauges, alarms and computers 2 1

•• •• 860C-119

1014-042 XP2-A0 MODULE LED INDICATORS 2. CHECK MODULE STATUS INDICATORS

XP2 MODULE OFFLINE ERRORS (LEVELER)

Status lights can also give an immediate indication of the nature of the error.

Expect all machine functions controlled by this module to cease and all alarms and warnings associated with this module to be triggered.

(1) Supply Voltage LED. LED ON solid green light indicates supply voltage is ON.

1. CHECK FOR OTHER ERROR/ALARM MESSAGES ON SCREEN

LED OFF indicates supply voltage is OFF.

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

(2) Status indicator LED (yellow/red).

LED yellow flashing light indicates status is correct.

LED flashing red light indicates error status as follows:

If the XT2-A0 MODULE IS OFFLINE is the only module is offline error message the likely causes are:

•

• Power - Fuse (XP2 MODULE)

•

• Ground • Address (ID-Tag)

•

• CAN wire connection • • •

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

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

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

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

Five flashes in a row indicates that the fault is related to the address.

Continuous flashing indicates the fault is related to software.

LX-, XP2- and XT2- module Error code I/O and voltage errors Low/High temperature CAN error Hardware error Address error Software error

6.52

Blink (red light)

Tigercat H822C/LH830C Harvester SYSTEM WARNING MESSAGES

Electrical, gauges, alarms and computers WARNING MESSAGES

When system warning messages are displayed the master alarm may sound, see specific warning message descriptions for details. All system warning messages are logged and recorded by the IQAN system for use by Tigercat service technicians. Operator's should respond to all warning messages immediately by bringing the machine to a safe stop and investigating the cause of the alarm.

The alarm can be acknowledged by pressing OK (F1), if applicable. Note that acknowledging the warning message does not address the cause of the alarm. Ignoring system warning messages may result in component damage and/or subsequent malfunction. In addition ignoring system warning messages may also affect warranty claims. All warning messages should be addressed immediately to help ensure the efficient long term operation of the machine and avoid costly repairs.

822C-44

1. PILOT SYSTEM OFF This warning will be displayed and PILOT OFF warning light will come on when the pilot system has been de-activated. To reset the pilot system close the doors and press the PILOT ON (RESET) switch.

For more information on the pilot shut off system refer to PILOT SYSTEM OFF SWITCH, PILOT SYSTEM ON SWITCH, PILOT SYSTEM INTERLOCK SWITCH, PILOT ON LIGHT and PILOT OFF LIGHT in SECTION 2 of the OPERATOR’S MANUAL.

822C-53

2. HYDRAULIC TANK DOOR OPEN This warning will be displayed, master alarm will sound and ROOF/DOOR warning light will come on when pilot system is ON and the tank door (LH rear door) is open for more than 2 seconds. The warning can be acknowledged on the IQAN MDM to silence the alarm but the warning light will stay on until the open door(s) is(are) closed.

Refer also to ROOF/DOOR OPEN LIGHT, MASTER ALARM and SERVICE ACCESS DOORS in SECTION 2 of the OPERATOR’S MANUAL.

6.53

Tigercat H822C/LH830C Harvester

Electrical, gauges, alarms and computers

822C-59

3. PUMP DOOR OPEN

822C-69

5. ENGINE ALARM

This warning will be displayed, master alarm will sound and ROOF/DOOR warning light will come on when pilot system is ON and the engine side door is open for more than 2 seconds. The warning can be acknowledged on the IQAN MDM to silence the alarm but the warning light will stay on until the open door(s) is(are) closed.

This warning will be displayed and master alarm will sound when a J1939 red stop signal is detected. See engine display module on the instrument panel for more detailed engine information. Refer also to INSTRUMENT PANEL ~ ENGINE DISPLAY AND DIAGNOSTIC MODULE in SECTION 2 of the OPERATOR’S MANUAL for more information about the engine display module.

Refer also to ROOF/DOOR OPEN LIGHT, MASTER ALARM and SERVICE ACCESS DOORS in SECTION 2 of the OPERATOR’S MANUAL.

The following alarm/error messages may also accompany an engine alarm message.

822C-70 822C-58

4. ENGINE SIDE DOOR OPEN This warning will be displayed, master alarm will sound and ROOF/DOOR warning light will come on when pilot system is ON and the pump door (RH rear door) is open for more than 2 seconds. The warning can be acknowledged on the IQAN MDM to silence the alarm but the warning light will stay on until the open door(s) is(are) closed.

822C-71

Refer also to ROOF/DOOR OPEN LIGHT, MASTER ALARM and SERVICE ACCESS DOORS in SECTION 2 of the OPERATOR’S MANUAL. Note: If the engine side access door is not securely latched the engine power door may damage the latch as it closes.

6.54

Tigercat H822C/LH830C Harvester INFORMATION MESSAGES

Electrical, gauges, alarms and computers

822C-60 822C-48

3. FAN SERVICE MODE This message will be displayed whenever the service mode switch is placed in the ON position while servicing the machine. Note that one of the three service access doors equipped with sensors (engine side door, pump door or hydraulic tank door) must be open to reverse the fan rotation using the service mode switch.

Refer also to INSTRUMENT PANEL ~ SERVICE MODE SWITCH in SECTION 2 of the OPERATOR’S MANUAL.

1. FAN CLEAN MODE This message will be displayed while the cooling fan control is performing a CLEAN cycle. The graphical display indicates to the operator the percentage of the cycle completed.

The CLEAN cycle is either operated manually from the COOLING FAN SWITCH or automatically by the timed purge function of the computer control system. Note that the pilot system must be ON to operate the clean cycle. Refer also to COOLING FAN SWITCH and COMPUTER ~ DIAGNOSTICS ~ ADJUST FUNCTION PARAMETERS in SECTION 2 of the OPERATOR’S MANUAL.

822C-57

822C-49

2. FAN OVERRIDE MODE This message will be displayed whenever the cooling fan switch is placed in the FULL ON position. Refer also to COOLING FAN SWITCH in SECTION 2 of the OPERATOR’S MANUAL

822C-72

4. JOYSTICK BUTTON INTERLOCK This message will be displayed whenever a joystick button interlock occurs. The joystick button interlock prevents accidental operation of the joystick button functions as the pilot system is reset (door closed and pilot ON switch pressed). Joystick buttons activated (either by the operator or due to button malfunction) during a pilot system reset must first be released before they will operate normally.

For more information on the pilot system reset refer to PILOT SYSTEM ON SWITCH, PILOT SYSTEM INTERLOCK SWITCH, PILOT ON LIGHT and PILOT OFF LIGHT in SECTION 2 of the OPERATOR’S MANUAL. 6.55

Tigercat H822C/LH830C Harvester FAULT CODES : ERROR MESSAGES A typical fault code error message is described below.

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

1

5

3

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

Probable cause: Short circuit to ground.

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

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

ERROR: OUTPUT LOW

2 4

•••• •

••

••

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

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

ERROR: OUTPUT HIGH

822-D77

TYPICAL ERROR MESSAGE

1. TYPE OF ERROR

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

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

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

ERROR: INPUT LOW

•

ERROR :INPUT HIGH

•

ERROR: OUTPUT LOW

•

ERROR: OUTPUT HIGH

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

In this case XP-A0.

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

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

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

6.56

Tigercat H822C/LH830C Harvester

Electrical, gauges, alarms and computers

Example 1: 1. ERROR: OUTPUT HIGH 2. XP2-A0 IQAN module 3. Connector 1 : Pin 17 (on XP2 module) 4. Right Level cylinder 5. Defaults to 0.0 mA in the event of an error Probable cause: Return current is higher than the set value.

Example 2: 1. ERROR: OUTPUT LOW 2. XP2-A0 module 3. Connector 1 : Pin 19 4. Left Level Cylinder 5. Error value Probable cause: Return current is lower than the set value.

6.57

Tigercat H822C/LH830C Harvester ELECTRICAL KIT - SERVICE AND DIAGNOSTICS

Electrical, gauges, alarms and computers

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

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

630C-211

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

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

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

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

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

7. ID-TAG ‘0’ (AN068)

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

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

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

8. ID-TAG ‘0T’ (AN071)

5. IQAN DATA CABLE FOR PDA (DG029)

This is a replacement address/terminating tag.

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

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

9. DEUTSCH 2 POLE SERVICE HARNESS (24860B)

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

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

DIAGNOSTIC BREAKOUT HARNESS

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

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

WARNING Damage may occur to the PDA if the wrong data cable is used. Ensure the appropriate cable is selected when using a PDA; DO NOT USE AN ADAPTER TO MATCH UP SERIAL PORTS. 6.58

Tigercat H822C/LH830C Harvester

630C-56

Electrical, gauges, alarms and computers

ELECTRICAL KIT - SERVICE AND DIAGNOSTICS - SELECTED ITEMS 6.59

Tigercat H822C/LH830C Harvester IQAN SOFTWARE IQAN software can be downloaded from the Tigercat Dealer Website (click on Customer Service/ Warranty to find Machine Software).

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

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

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

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

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

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

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

2. The application file itself can be downloaded.

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

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

APPLICATION PROGRAM UPDATES FOR PRODUCT SERVICE BULLETINS

DOWNLOADING APPLICATIONS AS EXE FILES

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

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

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

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

6.60

Tigercat H822C/LH830C Harvester

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

2. Click on Open.

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

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

2. Click on Save.

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

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

4. Click on Save.

5. Click on Close.

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

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

6.61

Tigercat H822C/LH830C Harvester

Electrical, gauges, alarms and computers

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

To perform this procedure you will require: • • •

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

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

PDA MAIN IQAN WINDOW

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

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

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

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

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

PDA SERIAL PORT ADAPTER CABLE

IQAN - MDM PALM OS PDA

CONNECTING MDM TO PDA PDA DROP DOWN MENU DISPLAY

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

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

6.62

Tigercat H822C/LH830C Harvester

Electrical, gauges, alarms and computers

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

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

19. Turn the key switch to ‘OFF’.

20. Turn off power on the PDA.

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

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

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

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

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

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

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

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

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

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

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

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

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

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Electrical, gauges, alarms and computers

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

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

To perform this procedure you will require: • • •

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

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

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

OR

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

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

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

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

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

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

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

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

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

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

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

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

6.64

Tigercat H822C/LH830C Harvester

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

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

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

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

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

Select the ‘Yes’ box to continue.

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

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

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

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

18. Turn the key switch to ‘OFF’.

19. Turn off power on the computer.

6.65

Tigercat H822C/LH830C Harvester GET APPLICATION (DOWNLOAD FROM MDM)

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

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

To perform this procedure you will require: • • •

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

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

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

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

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

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

PDA SERIAL PORT ADAPTER CABLE

IQAN - MDM PALM OS PDA

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

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

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Electrical, gauges, alarms and computers

8. In the IQANdevelop main screen, select the

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

icon.

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

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

B. GET APPLICATION USING A A PC/LAPTOP

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

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

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

To perform this procedure you will require: • • •

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

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

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

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

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

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

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

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

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

6. Turn the key switch to ‘RUN’. DO NOT START THE MACHINE. 6.67

Tigercat H822C/LH830C Harvester 12. When the download is complete, the computer display will return to the IQANdevelop G3 main screen.

13. Turn the key switch to ‘OFF’.

14. Turn off power on the computer.

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

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

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

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

2. Tap the channels icon.

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

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

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

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

assignment at the bottom of screen.

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

6.68

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Electrical, gauges, alarms and computers

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

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

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

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

Contact Tigercat service department for more information

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

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

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

Notice: Due to limited power of the processor of Palm, the measurement is not performed at full speed with respect to the 6.69

Tigercat H822C/LH830C Harvester GET ERROR/EVENT LOG

Electrical, gauges, alarms and computers

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

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

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

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

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

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

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

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

The time format depends on your PDA formats settings.

6.70

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Electrical, gauges, alarms and computers

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

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

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

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

3. The receiving channels pop up box will appear.

6.71

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Electrical, gauges, alarms and computers

6.72

Tigercat H822C/LH830C Harvester

SECTION 7 - ENGINE START AND STOP JULY 2006

CONTENTS - SECTION 7 ENGINE, RESTARTING AFTER ENGINE RUN OUT OF FUEL .................. 7.4 ENGINE, STARTING CUMMINS QSL9 ......................................................................................... 7.2 ENGINE, STARTING, COLD WEATHER CUMMINS QSL9 ......................................................................................... 7.3 ENGINE, STOPPING ..................................................................................... 7.4 SCHEMATIC DIAGRAM START CIRCUIT - AT REST ...................................................................... 7.5 START CIRCUIT - BATTERY DISCONNECT SWITCH 'ON' ..................... 7.6 START CIRCUIT - RUN ............................................................................. 7.8 START CIRCUIT - RUN, PILOT RESET SWITCH 'OFF' .......................... 7.10 START CIRCUIT - RUN, PILOT RESET SWITCH 'ON' ............................. 7.9 START CIRCUIT - START ......................................................................... 7.7 STARTING ENGINE CUMMINS QSL9 ......................................................................................... 7.2

Tigercat H822C/LH830C Harvester

Engine start and stop

STARTING ENGINE, CUMMINS QSL9 1. Before starting the engine, ensure that all prestart checks have been performed and that the surrounding area is clear of personnel.

speed and 5. Set throttle to LOW IDLE wait 3 to 5 minutes before operating with a load.

IMPORTANT HORN

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.

• IGNITION SWITCH

••

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

SAW SWITCH

••

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

CONTROL PANEL 860C-023.DWG 2. Sound Horn to warn of machine start-up.

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

CAUTION

244-046

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

DISPLAY MODULE

3. Turn ignition key switch to the RUN position; wait for the WAIT TO START message on PowerView Display to turn off.

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

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

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.

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.

7.2

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.

Tigercat H822C/LH830C Harvester

Engine start and stop

COLD WEATHER STARTING

1. Start engine and keep throttle at low idle.

CUMMINS QSL9 ENGINE

•

DO NOT ACTIVATE PILOT SYSTEM.

•

Hydraulic filter bypass light must be off before proceeding to Step 2.

•

Engine coolant temperature must reach 140°F (60°C) before proceding to Step 2.

•

Hydraulic Oil temperature must reach 20°F (-7°C) before proceding to Step 2.

•

Check that cooling fan is turning before proceding to Step 2.

WARNING The Cummins QSL9 engine 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.

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

NOTE: At 0°F (-18°C) starting temperature it will take approximately 30 minutes to complete step 1.

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

2. Increase engine speed to 1300 rpm and begin slow boom movements

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

•

Hydraulic filter bypass light must be off.

•

Follow the STARTING ENGINE - CUMMINS QSL9 ENGINE instructions for this COLD WEATHER STARTING procedure, paying attention to the WAIT TO START message on PowerView Display.

Operate main boom to raise attachment off ground.

•

Operate stick boom slowly in and out.

•

Operate telescopic boom IN and OUT and check that it is operating correctly, if applicable.

•

Rotate the attachment and check that it is operating correctly. Refer to manufacturers manual for more information.

This warning message 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.

3. Swing upper 360° to the left then 360° to the right.

NOTE: If at any time during the warming procedure the hydraulic filter bypass light comes on, return . the engine speed to LOW IDLE

4. Place travel speed switch in LOW position and drive machine forward pressing the foot pedals very gradually. DO NOT exceed 1/2 pedal position.

5. Watch hydraulic oil temperature, it must reach 50°F (10°C) before any work may begin.

244-046

6. Increase engine speed to 1500 rpm, and begin driving to work area in LOW travel speed. Do not fully depress foot pedals until the hydraulic oil reaches 90°F (32°C). Harvesting may begin but work very slowly. The machine functions will seem to operate much slower until the systems are warmed up. Avoid operating the boom functions quickly until the hydraulic oil is above 90°F (32°C). Work the machine for 30 minutes at 1500 rpm.

DISPLAY MODULE

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.

7.3

7. When hydraulic oil reaches 90°F (32°C) and machine has been operated for 30 minutes it is safe to increase engine speed to full throttle.

Tigercat H822C/LH830C Harvester RESTARTING AN ENGINE THAT HAS RUN OUT OF FUEL

Engine start and stop STOPPING ENGINE IMPORTANT

If the engine runs out of fuel perform the following:

1. Refill fuel tank completely.

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.

Always follow this engine shut down procedure. The important benefits are:

2

•

Extended life of engine, cooling and exhaust systems.

•

Reduced risk of post shutdown fires.

•

Interior of machine cools significantly reducing risk of touching hot surfaces.

WARNING Do not pre-fill engine fuel filters used on Cummins QSL9 engines

Bleed the system according to engine manual procedures.

IMPORTANT To prevent damage to starter, do not engage starter motor for more than 20 seconds. Wait 2 minutes between each attempt to start the engine. If engine fails to start, refer to engine manufacturer operator's manual.

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 clear and level area a least 50 feet from any other equipment to park the machine.

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

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

NOTE: The use of ether to aid in starting the engine is not recommended.

4. Reduce engine speed to LOW IDLE , de-activate the pilot system and let engine run at low idle speed for approximately 3 minutes minimum to allow dissipation of heat and also to reduce turbo speed. This will also prevent loss of coolant by after boil and possible hot spot damage to the engine.

5. Open power engine door and place fan switch in Full ON position.

6. Do not race engine before shut-off.

7. Place fan switch in AUTO position.

8. Stop engine by turning ignition key switch to the OFF position.

9. Attachment must be stopped before exiting cab.

10. Perform daily maintenance at the end of the shift (Greasing, clean engine compartment etc.). This allows the machine time to cool down while under the watchful eye of the operator.

7.4

Tigercat H822C/LH830C Harvester

Engine start and stop

822C-07

START CIRCUIT - AT REST 7.5

Tigercat H822C/LH830C Harvester

Engine start and stop

822C-07A

START CIRCUIT - AT REST BATTERY DISCONNECT SWITCH - ON

7.6

Tigercat H822C/LH830C Harvester

Engine start and stop

822C-07B

START CIRCUIT - START IGNITION KEY - START POSITION

7.7

Tigercat H822C/LH830C Harvester

Engine start and stop

822C-07C

START CIRCUIT - RUN IGNITION KEY - RUN POSITION

7.8

Tigercat H822C/LH830C Harvester

Engine start and stop

822C-07D

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

7.9

Tigercat H822C/LH830C Harvester

Engine start and stop

822C-07E

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

7.10

Tigercat H822C/LH830C Harvester

SECTION 9 - ENGINE ANTI-STALL JULY 2006

CONTENTS - SECTION 9 CONTROL MODULE IN CAB ........................................................... 9.2 CONTROL MODULE PIN CONNECTIONS ...................................... 9.3 ENGINE ANTI-STALL CURVE.......................................................... 9.3 ENGINE ANTI-STALL SWITCH ........................................................ 9.2 FAULT FINDING PROCEDURE ~ ANTI-STALL QUICK CHECK ..... 9.6 FAULT FINDING PROCEDURES, ADDITIONAL ............................. 9.7 HORSEPOWER LIMITING CONTROL GENERAL DESCRIPTION ............................................................ 9.2 SEE ALSO SECTION 4 LOAD SENSE; SET MARGIN PRESSURE ................ SEE SECTION 4 PUMP 2 (MAIN PUMP) CONTROLLER (LS CONTROL) ................. 9.3 SCHEMATIC DIAGRAMS ENGINE ANTI-STALL CIRCUIT .................................................... 9.4 LOAD SENSING SYSTEM CIRCUIT DIAGRAM ........................... 9.5 SET PILOT PRESSURE ............................................. SEE SECTION 5 SPEED SENSOR, ADJUSTING ........................................................ 9.3 SPEED SENSOR ON ENGINE ......................................................... 9.2 VERIFY ANTI-STALL SETTING ................................. SEE SECTION 4

Tigercat H822C/LH830C Harvester HORSEPOWER LIMITING CONTROL

Engine anti-stall module from the power supply and all sensor connections.

GENERAL DESCRIPTION In the past it was common to lug an engine down when several functions with high loads were used at the same time and engine stalling was avoided only by the operator. In order to prevent engine over loading, the Tigercat machine is equipped with an electronic system which detects any drop in engine speed and de-strokes Pump 2 (main pump) to reduce the load on the engine and at the same time maintain engine speed. This is done without any input from the operator and in most cases he will be unaware of the operation of this system.

ANTI-STALL SWITCH

••

•

The engine anti-stall system monitors the swing, main boom, stick boom, telescopic, pump2 and track drive functions. The anti-stall system also monitors the levelling system when the machine is configured as a leveller.

CONTROL MODULE

••

•

A two position anti-stall switch labelled ON/ OFF, is located on the control panel and used to turn the anti-stall system ON or OFF. When this switch in is the ON position and the engine is set to FULL throttle, the engine RPM, when under load, is limited to 1700 RPM, to compensate the engine anti-stall valve will signal the pump 2 (main pump) to de-stroke and reduce the flow of oil to the main valve.

The anti-stall incorporates the following components: WIRING HARNESS WITH 25 PIN CONNECTOR

ANTI-STALL SWITCH

822-D79

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

•

ENGINE ANTI-STALL SOLENOID VALVE

PUMP 2 822C-03

•

CONTROL MODULE IN CAB

A control module on the rear electrical panel.

••

SPEED SENSOR 'LS' CONNECTION FROM MAIN VALVE

•• 860-054

•

•

A solenoid valve mounted on pump 2 (main pump).

•

A wiring harness. A disconnect plug is incorporated into the harness. Remove the plug to completely disconnect the control

• •• •

••

GAUGE TEST PORT ANTI-STALL SIGNAL PRESSURE

GAUGE TEST PORT 'L.S.'

MARGIN PRESSURE ADJUSTING SCREW

SPEED SENSOR ON ENGINE

A speed sensor mounted on the engine below the fuel injection pump. This sensor provides RPM data to the engine ECM and gauges in cab.

••

••

822C-

PUMP 2 (MAIN PUMP) CONTROLLER (LS CONTROL)

WARNING Before welding anywhere on machine, disconnected the 25 pin connector from the control module and the two multi-pin plugs from the engine CPU to prevent damage to the electrical system.

9.2

Tigercat H822C/LH830C Harvester

Engine anti-stall The system control module constantly monitors the engine speed and any drop in RPM from the rated 1700 RPM will result in a signal being sent to the pump 2 (main pump) solenoid via wires 91, 92 and 82 from pins 11 and 16. This signal will cause the solenoid valve to shift which directs pressure from the pilot system to shift the displacement control valve causing the pump to destroke, "lightening" the load on the engine without affecting engine speed. This electrical signal is a pulse width modulated signal which provides for precise modulation of the hydraulic valve and the resulting smooth control of the pump 2 (main pump) displacement.

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

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

CONTROL MODULE PIN CONNECTIONS Refer to Engine anti-stall circuit diagram; •

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

•

Pin 13 is connected to ground.

•

Pins 8 and 17 jump wire connected to each other.

•

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

•

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

•

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

ADJUSTING SPEED SENSOR 1. Stop engine.

2. Loosen locknut on speed sensor.

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

4. Turn speed sensor OUT one full turn.

5. Tighten locknut.

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

NOTE: THIS GRAPHIC OF THE ANTI-STALL CURVE IS ONLY A PICTORIAL REPRESENTATION FOR EXPLANATION PURPOSES. IT SHOULD NOT BE USED TO IDENTIFY OR DETERMINE ACTUAL VALUES AS THEY CAN VARY FROM ONE MACHINE TO ANOTHER.

870B-21A

TYPICAL ENGINE ANTI-STALL CURVE ~ ENGINE RPM VS. PSI 9.3

Tigercat H822C/LH830C Harvester

Engine anti-stall

PUMP 2 (MAIN PUMP ) CONTROL VALVE

PUMP 2 (MAIN PUMP)

822C-23

ENGINE ANTI-STALL CIRCUIT

9.4

Tigercat H822C/LH830C Harvester

822C-24

Engine anti-stall

LOAD SENSING SYSTEM CIRCUIT DIAGRAM 9.5

Tigercat H822C/LH830C Harvester FAULT FINDING ~ ANTI-STALL QUICK CHECK

Engine anti-stall B. ANTI-STALL 'OFF' 1. Connect a 0-1000 psi gauge to the ‘X1’ gauge test port on the pump 2 (main pump) regulator.

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

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

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

4. Activate each "Load Sense" controlled function one at a time (swing, main boom, stick boom, telescopic, pump2, track drive and levelling - if equipped).

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

A. WHEN DOES THE PROBLEM OCCUR ?

Does problem occur with anti-stall ON or OFF? ANSWERS: • Occurs with the system ON or OFF The problem is likely hydraulic related which could include the anti-stall solenoid valve on the pump 2 (main pump).

•

•

Expected Results: All functions should operate normally.

•

X1 pressure should be less than 20 psi.

C. ANTI-STALL 'ON', THROTTLE IDLE 1. Connect a 0-1000 psi gauge to the ‘X1’ gauge test port on the pump 2 (main pump) regulator.

Occurs only with the system ON.

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

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

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

4. Fully activate MAIN BOOM UP function.

• •

9.6

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

Tigercat H822C/LH830C Harvester

Engine anti-stall ADDITIONAL FAULT FINDING PROCEDURES

D. ANTI-STALL ON, THROTTLE FULL 1. Connect a 0-1000 psi gauge to the ‘X1’ gauge test port on the pump 2 (main pump) regulator.

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

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

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

A. VERIFY ENGINE 'FULL' THROTTLE SETTING

4. Fully activate MAIN BOOM UP function.

•

Expected Results: Boom up function should operate normally.

•

X1 pressure should be less than 20 psi.

1. Place reflector on engine crank shaft pulley for use with a phototach.

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

E. BEGIN OF MOVEMENT

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

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

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

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

3. Fully activate MAIN BOOM UP function.

(Initially, the boom should not move)

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

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

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

•

Example:

Expected Results: The boom should not move initially.

•

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

•

The point where the boom begins to move should be approximately 1700 RPM

•

SWING SPEED AND SWING PRESSURE SETTINGS.

•

MAIN SYSTEM (L.S.) PRESSURE SETTINGS.

Refer to the H822C/LH830C PRESSURE SETTINGS CHART in SECTION 4 of THIS SERVICE MANUAL for correct values.

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

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

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

4. Place swing brake switch in the ON position.

5. Activate the SWING function fully.

• Measure the engine speed.

6. Place the track drive low switch in the ON position.

9.7

Tigercat H822C/LH830C Harvester 7. Drive the machine forward.

Engine anti-stall H. SPEED SENSOR OUTPUT

While moving forward activate the SWING function fully (do this slowly to avoid stalling the engine).

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

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

• Measure the engine speed.

3. Measure the AC voltage across 12 and 14 on connector.

• The speed sensor output should be greater than 0.5 VAC.

• The engine speed should always be above "rated speed" of 1700 RPM. If engine speed falls below rated speed during the above tests, the problem is not likely to be with the engine anti-stall system.

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

Refer to ADJUST SPEED SENSOR in THIS SECTION.

C. PILOT PRESSURE. 1. Ensure pilot pressure is correct.

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

I.

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

D. MARGIN PRESSURE

2. Measure resistance between pins 12 and 14 on connector • The resistance should be: 130 to 140 ohms at 72ºF (22ºC)

1. Ensure margin pressure is correct.

To verify MARGIN PRESSURE refer to SET MARGIN PRESSURE in SECTION 4 of THIS MANUAL. E. ELECTRICAL POWER TO ANTI-STALL CONTROL MODULE.

3. Check for continuity from pin 14 to 13 and 12 to 13. (Pin 13 is connected to ground) J. SPEED SENSOR COIL

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

1. Remove connector from anti-stall speed sensor.

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

2. Measure resistance of speed sensor coil between terminals on sensor.

• The resistance should be: 130 to 140 ohms at 72ºF (22ºC)

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

• Voltage should be 13 ± 2 VDC. F.

SPEED SENSOR WIRES

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

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

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

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

2. Measure resistance of solenoid coil.

• The resistance should be 6.6 ±2 ohms.

9.8

Tigercat H822C/LH830C Harvester SECTION 10- OIL COOLER AND COOLING FAN AUGUST 2006

CONTENTS - SECTION 10 CHARGE AIR COOLER ............................................................................. 10.16 COOLING ASSEMBLY - OVERALL VIEW ...................................... 10.3, 10.17 COOLING FAN ............................................................................................ 10.8 COOLING FAN CIRCUIT DESCRIPTION ................................................. 10.12 COOLING FAN CIRCUIT DIAGRAM ......................................................... 10.14 FAN DRIVE CONTROL VALVE ................................................................. 10.10 FAN MOTOR ................................................................................................ 10.9 FAN PUMP (ROTATE/FAN PUMP) ............................................................. 10.8 FAN SPEED CHECKS ............................................................................... 10.15 CHECK FOR NO A/C DURING CLEAN MODE ...................................... 10.15 FAN 'CLEAN' SPEED ............................................................................. 10.15 FAN FULL ON SPEED ........................................................................... 10.15 MINIMUM FAN SPEED WITH A/C "ON" ................................................ 10.15 HYDRAULIC OIL FILTERS .......................................................................... 10.5 HYDRAULIC TANK ...................................................................................... 10.5 MAIN CONTROL VALVE ........................................................ SEE SECTION 4 MAIN PUMP ............................................................................ SEE SECTION 4 OIL COOLER ............................................................................................... 10.2 OIL COOLER BYPASS/ RETURN MANIFOLD............................................ 10.3 OIL COOLER CIRCUIT DESCRIPTION ...................................................... 10.6 OIL COOLER CIRCUIT DIAGRAM .............................................................. 10.7 RADIATOR ................................................................................................. 10.16 RETURN MANIFOLD/RETURN FILTERS ................................................... 10.4

Tigercat H822C/LH830C Harvester

Oil Cooler and Cooling Fan

OIL COOLER 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. The air is expelled to atmosphere through the perforated panels that make up the engine enclosure.

The complete cooling assembly is rubber isolation mounted to reduce the transmission of noise and to isolate the components from vibration.

COOLING ASSEMBLY

822C-39

The fan drive system has a CLEAN(PURGE) function which reverses the direction of the fan to clean the cooling assembly by blowing air in the opposite direction through the cooling assembly to remove dust and debris.

A/C CONDENSER OIL COOLER/ RADIATOR/CAC ASSEMBLY

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

••

••

•• SLIDE DEBRIS SCREEN OUT AND REMOVE

COOLING ASSEMBLY 822C-38

Use personal protective equipment to guard against flying debris. Compressed air or water may be used to clean this assembly, but care must be taken not to set the pressure too high otherwise damage to the components could result.

•

A/C CONDENSER NUTS

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

•• HINGES

822C-27

10.2

••

•

SWING OUT A/C CONDENSER

Tigercat H822C/LH830C Harvester

Oil Cooler and Cooling Fan

OIL COOLER A/C CONDENSER

RADIATOR

DEBRIS SCREEN

COOLING FAN SHROUD FINGER GUARD

•

•

•

SURGE TANK

•

•

FAN DRIVE MOTOR

•

••

•• •

• CHARGE AIR COOLER

822C-01

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

COOLING ASSEMBLY - OVERALL VIEW

OIL COOLER BYPASS/ RETURN MANIFOLD The oil cooler bypass return manifold collects oil from the main control valve, attachment return, swing motor and levelling control valve (if equipped). The oil cooler bypass return manifold incorporates an oil cooler bypass valve. All oil passing through the oil cooler first passes through the cooler bypass valve. The cooler bypass valve ensures that the differential pressure between the oil cooler inlet and outlet does not exceed set limits. When differential pressure becomes too high oil is returned to tank bypassing the oil cooler, preventing damage to the oil cooler.

Pressure increases within the oil cooler can occur in cold weather when the oil temperatures at start-up are very low. Oil from the oil cooler outlets is directed by the oil cooler bypass return manifold to the return manifold and filters before it is returned to tank.

OIL COOLER BYPASS/RETURN MANIFOLD 822C-135

10.3

Tigercat H822C/LH830C Harvester 5 - HYDRAULIC RETURN FILTERS

Oil Cooler and Cooling Fan

RETURN MANIFOLD

•• •

• •• •

• 822C-22

• 1 - WATER ABSORBING RETURN FILTER (COLOUR BLUE)

HYDRAULIC OIL FILTERS

RETURN MANIFOLD/ RETURN FILTERS The return manifold collects return oil from the oil cooler bypass/return manifold and various other tank lines. Before being sent back to the hydraulic tank oil first passes through six spin on hydraulic oil filters mounted onto three double filter heads, one of the filters is a water absorbing filter (colour blue) the purpose of which is to assist with removing moisture from the hydraulic oil. The input side of the filter heads are connected in parallel to the return manifold. The output side of the filter heads direct the oil to tank via three return lines.

For complete description and operation refer to HYDRAULIC OIL TANK in SECTION 4 of this MANUAL. Refer also to SECTION 2 and SECTION 3 of the OPERATOR'S MANUAL.

10.4

Tigercat H822C/LH830C Harvester

Oil Cooler and Cooling Fan MAIN PUMP

FILTER GROUP RETURN MANIFOLD

• •

•• ••

DRIP TRAY

••

HYDRAULIC TANK

For operation and adjustment of this pump refer to SECTION 4 of THIS MANUAL. MAIN CONTROL VALVE For operation and description of this valve refer to SECTION 4 of THIS MANUAL.

•• WATER ABSORBING ELEMENT (COLOUR BLUE)

••

H822C-01

HYDRAULIC OIL TANK

HYDRAULIC TANK Located at the rear left corner of the machine beside the fuel tank. All return oil entering the tank is screened prior to entering the tank by passing through three reusable suction strainers attached to the ends of the return tubes at the bottom of the tank. Case drain return oil from the pumps is also screened by a fourth reusable strainer attached to the inside of the round access cover.

The air space in the top of the hydraulic tank is vented to atmosphere via a check valve and spinon filter.

For complete description and operation refer to HYDRAULIC OIL TANK in SECTION 4 of this MANUAL. Refer also to SECTION 2 and SECTION 3 of the OPERATOR'S MANUAL.

10.5

Tigercat H822C/LH830C Harvester

Oil Cooler and Cooling Fan

OIL COOLER CIRCUIT DESCRIPTION The oil cooler circuit operates as a part of the main hydraulic circuit.

The main pump draws oil from the hydraulic tank and sends it to the main control valve. Return oil from the main control valve sections exits the base manifold at two 'T' ports and 75 psi internal check valves. From there the oil passes through the oil cooler via the oil cooler bypass return manifold, which includes a bypass valve for the oil cooler.

The cooler bypass ensures that the differential pressure between the oil cooler inlet and outlet does not exceed set limits. Pressure increases within the oil cooler can occur in cold weather when oil temperatures at start-up are very low.

Cooling of the oil occurs as air is drawn over the oil cooler cooling fins by the cooling fan. Cooled oil then passes back through the cooler bypass valve and on to the return manifold and return filters and then to the hydraulic tank. A 25 psi bypass valve is incorporated into each pair of return filter heads.

Oil entering the hydraulic tank from the return manifold and filters passes through 3 strainers situated inside the tank below the oil surface.

Refer to HYDRAULIC OIL TANK in SECTION 4 of this MANUAL. Refer also to SECTION 2 and SECTION 3 of the OPERATOR'S MANUAL. Refer to HYDRAULIC SYSTEM OPERATION MAIN HYDRAULIC SYSTEM in SECTION 4 of this MANUAL.

10.6

Tigercat H822C/LH830C Harvester

822C-26

Oil Cooler and Cooling Fan

OIL COOLER CIRCUIT 10.7

Tigercat H822C/LH830C Harvester COOLING FAN The cooling fan is mounted in front of the cooling assembly and draws air through debris screen and cooling assembly. The air is expelled to atmosphere through the perforated panels that make up the engine enclosure.

Oil Cooler and Cooling Fan The operation of a typical external gear pump (so called because the gear teeth are on the external surface of the hub) is shown in Figure gear1.

OUTLET DRIVEN (IDLER) GEAR

The CLEAN (PURGE) fan function, operated by a switch in the cab, reverses the direction of air flow, thus dust and debris is forced out of the radiator, oil cooler, A/C condenser core debris screen and perforated panels that make up the engine enclosure.

DRIVE GEAR

•

•

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

For additional information regarding operation of the cooling fan refer to COOLING FAN -SWITCH and CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR in SECTION 2 of THE OPERATOR'S MANUAL. THRUST PLATES DRIVE GEAR ON INPUT SHAFT

•

THRUST PLATES DRIVE GEAR ON INPUT SHAFT

CONNECTING SHAFT

• • •

•

INLET GEAR1

TYPICAL GEAR PUMP

A gear pump carries oil from the inlet to the outlet in the spaces between gear teeth. The pumping chamber is formed by the gears, the pump housing, and thrust plates. One of the two gears, called the drive gear, will be connected to the drive shaft. The other idler gear is driven by the drive gear.

• • •

ROTATE/FAN PUMP

PUMP 1 (ATTACHMENT PUMP)

•

AP179

•

• GEAR HOUSINGS

•• PORT PLATE, REAR

ROTATE/FAN PUMP

ROTATE/FAN PUMP This is a two cartridge dual gear pump driven off the power take-off of the Pump 1 (Attachment pump) . The input drive shaft is connected to the Pump 1 (Attachment pump) drive shaft by a drive coupling.

822-D73

One of the two cartridges in the rotate/fan pump provides hydraulic oil flow to the cooling fan circuit. The second cartridge provides hydraulic oil flow to the attachment rotate function*. * NOTE: This description of functions applies only to standard factory installed features, it does not take into account any changes or modifications made after shipment.

10.8

PUMP ASSEMBLY

•

INPUT DRIVE SHAFT (CONNECTED TO PUMP 1)

Tigercat H822C/LH830C Harvester

Oil Cooler and Cooling Fan

FAN MOTOR The fan drive motor is a fixed displacement piston type motor. The fan drive motor is driven by hydraulic pressure from the fan pump via the fan manifold and in turn directly drives the fan.

DANGER PRESSURE PORT 'B'

CAUTION

PRESSURE PORT 'A'

Ensure that ALL hydraulic connections at fan motor are tight and leak free. leaking oil will be blown into engine area TANK LINE

•• ••

FAN MOTOR

H822-02

ROTATE/FAN PUMP (DOUBLE GEAR PUMP)

PUMP 1 PUMP 1 (ATTACHMENT ) PRESSURE (PISTON PUMP) COMPENSATOR

PILOT SUPPLY MANIFOLD

•• •• ••

•• •• •• ••

PUMP 2 PUMP 2 (MAIN PUMP) CONTROLLER (PISTON PUMP) (LS. CONTROL)

••

PILOT FILTER

••

COOLING FAN CONTROL VALVE PILOT SUPPLY VALVE

822C-136

HYDRAULIC PUMPS 10.9

Tigercat H822C/LH830C Harvester

Oil Cooler and Cooling Fan

FAN DRIVE CONTROL VALVE

The direction of fan rotation is controlled by the flow of oil through the directional solenoid valve (SV1), which is operated by the fan control switch (DIGITAL IN - Fan Purge Switch) via the computer control system (DIGITAL OUT - Fan Reverse).

The directional solenoid valve is a cartridge style valve, which is factory set and nonadjustable.

The speed of fan rotation is controlled by the proportional solenoid (SV2) relief valve, which is operated by an electrical signal (CURRENT OUT OC Fan Prop.) generated by the computer control system. The flow of oil from the pump to the fan motor is controlled by the SV2 pressure relief valve. With a low pressure, fan pump oil is diverted to tank resulting in low fan speed. With a higher pressure, more pump oil is directed to the fan motor resulting in higher fan speed.

The computer control system generates a fan speed electrical signal based on the position of the fan control switch (full on, automatic or clean), the air conditioning controls (on/off), hydraulic oil temperature sensor readings, engine coolant temperature sensor readings and charge air cooler temperature sensor readings. Fan speed will default to full rpm if a wire is cut.

FROM FAN PUMP

TO TANK

The fan drive control valve controls speed and direction of fan rotation. Oil from the fan pump passes through the P port into the fan control valve and is directed to the fan motor.

•

••

• TEST PORT G

PROPORTIONAL SOLENOID VALVE (FAN SPEED-SV2)

•• ••

••

•

FORWARD PRESSURE LINE

DIRECTIONAL SOLENOID VALVE (FAN DIRECTION- SV1)

REVERSE PRESSURE LINE

FAN DRIVE CONTROL VALVE

825C-25

TO FAN MOTOR

PILOT OPERATED DIRECTIONAL VALVE (PD1)

•

DIRECTIONAL SOLENOID VALVE (SV1)

••

PROPORTIONAL RELIEF VALVE (SV2)

Return oil from the fan motor passes back through the fan control valve and back to tank via the T port.

TO TANK

860C-106

T

•• FROM FAN PUMP

FAN CONTROL VALVE SCHEMATIC

10.10

Tigercat H822C/LH830C Harvester

822C-13

Oil Cooler and Cooling Fan

FAN DRIVE ELECTRICAL SCHEMATIC 10.11

Tigercat H822C/LH830C Harvester COOLING FAN CIRCUIT DESCRIPTION The fan "cooling" circuit is an open loop hydraulic system consisting of a fixed displacement pump, fan control valve and a fixed displacement motor.

Oil from the fan pump passes through the P port into the fan control valve and is directed to the fan motor.

The direction of fan rotation is controlled by the flow of oil through the directional solenoid valve (SV1), which is operated by the fan control switch (DIGITAL IN - Fan Purge Switch) via the computer control system (DIGITAL OUT - Fan Reverse).

The speed of fan rotation is controlled by the flow of oil through the proportional solenoid (SV2) valve, which is operated by an electrical signal (CURRENT OUT - OC Fan Prop.) generated by the computer control system.

The computer control system generates a fan speed electrical signal based on the position of the fan control switch (full on, automatic or clean), the air conditioning controls (on/off), hydraulic oil temperature sensor readings, engine coolant temperature sensor readings and charge air cooler temperature sensor readings.

COOLING FAN SWITCH

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

FULL ON POSITION - When the switch is in the FULL ON position, the fan control system is overridden and the fan will run at FULL speed for cooling regardless of charge air, coolant or oil temperatures. Normally the fan control switch is placed in the AUTO position for optimal cooling.

The FULL ON position is intended for use in the event of a temporary failure of the fan control.

CLEAN POSITION - Momentarily pressing the switch to the CLEAN position will start automatic reversing the direction of fan rotation (there is no need to hold the switch down). Reverse rotation is used to clean the charge air cooler, radiator, oil cooler, A/C condenser and air intake door screens. By "reversing" the flow of the fan, air flow is propelled in the opposite direction, thereby forcing dust and debris off of the radiator. Note that the pilot system must be ON to operate the clean cycle.

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

•

822C-14

Oil Cooler and Cooling Fan

REAR CONTROL PANEL

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

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

Note: The CLEAN cycle also operates automatically via the timed purge function of the computer control system (frequency is adjustable). Refer also to COMPUTER ~ INFORMATION MESSAGES and COMPUTER ~DIAGNOSTIC ~ ADJUST FUNCTION PARAMETERS in SECTION 6 of THIS MANUAL. For more information about the computer control system and detailed electrical schematics refer to SECTION 6 of THIS MANUAL.

10.12

Tigercat H822C/LH830C Harvester

•• ••

822C-13

Oil Cooler and Cooling Fan

SERVICE MODE SWITCH

INSTRUMENT PANEL

SERVICE MODE - SWITCH The cooling fan circuit also has a SERVICE MODE SWITCH. The SERVICE MODE SWITCH (with light) has two positions, ON and OFF. OFF is the position the switch should be in to allow the cooling fan to operate in the normal mode. ON is used whenever a Service Technician is in the Engine Service Compartment performing tests with the engine running. Reversing the fan rotation redirects the airflow away from the service technician. Note that one of the three service access doors equipped with sensors (engine side door, pump door or hydraulic tank door) must be open to reverse the fan rotation using the service mode switch.

When service checks are complete place the switch in the OFF position.

10.13

Tigercat H822C/LH830C Harvester

Oil Cooler and Cooling Fan

COOLING FAN CIRCUIT 822C-27

10.14

Tigercat H822C/LH830C Harvester

Oil Cooler and Cooling Fan

FAN SPEED CHECKS

COOLING FAN SWITCH

MINIMUM FAN SPEED WITH A/C "ON" NOTE: A calibrated "electronic photo tachometer" is required for this procedure.

•

1. Park machine on level ground, lower the attachment and stop engine.

Ensure that engine coolant and hydraulic oil temperatures are well below the normal operating temperatures of 195°F coolant, 130°F hydraulic oil and 111°F charge air cooler throughout entire test or fan will rotate and test will be invalid.

2. Place a piece of reflecting tape on the fan hub.

822C-14

REAR CONTROL PANEL

7. With the help of an assistant momentariliy press the cooling fan switch in the CLEAN position and visually check clutch on A/C compressor. It should be disengaged and compressor not running.

5. Place cooling fan switch in AUTOMATIC position.

8. When the CLEAN cycle is complete (15 seconds) the fan automatically returns to normal rotation direction and the clutch on the A/C compressor should engage and the compressor should be running.

6. Place A/C switch in ON position.

FAN FULL ON SPEED

7. Use a photo-tachometer to measure the speed of rotation of the fan blade, it should be 800-1000 rpm.

NOTE: A calibrated "electronic photo tachometer" is required for this procedure.

FAN 'CLEAN' SPEED AND CHECK FOR NO A/C DURING CLEAN MODE

1. Park machine on level ground, lower the attachment and stop engine.

NOTE: A calibrated "electronic photo tachometer" is required for this procedure.

2. Place a piece of reflecting tape on the fan hub.

3. Start the engine.

4. Set engine speed to 1850 rpm.

3. Start the engine.

4. Set engine speed to 1850 rpm.

1. Park machine on level ground, lower the attachment and stop engine.

5. Place cooling fan switch in FULL ON position.

2. Place a piece of reflecting tape on the fan hub.

6. Use a photo-tachometer to measure the speed of rotation of the fan blade, it should be at least 2200 rpm.

CAUTION Before placing the fan switch in the CLEAN position make sure that there are no personnel at the rear of the machine in the area where the fan will expel debris

FAN SPEED - DEFAULT NOTE: A calibrated "electronic photo tachometer" is required for this procedure.

3. Start the engine.

1. Park machine on level ground, lower the attachment and stop engine.

4. Set engine speed to 1850 rpm.

2. Place a piece of reflecting tape on the fan hub.

5. With the help of an assistant momentarily press the cooling fan switch in the CLEAN position.

3. Disconnect wire connections at the fan drive control valve solenoids.

6. Use a photo-tachometer to measure the speed of rotation of the fan blade, it should be 2100 rpm.

5. Set engine speed to 1850 rpm.

4. Start the engine.

6. Use a photo-tachometer to measure the speed of rotation of the fan blade, it should be at least 2200 rpm.

10.15

Tigercat H822C/LH830C Harvester RADIATOR

Oil Cooler and Cooling Fan CHARGE AIR COOLER (CAC) The charge air cooler is the right core section of the side by side heat exchangers in the cooling assembly.

Inspect air intake hoses and pipes for leaks wear or loose connections.

The radiator is the left core section of the side by side heat exchangers in the cooling assembly.

A surge tank is mounted at the top and behind the radiator to provide for overflow protection during high temperatures and make up coolant when the cooling system is cold. The surge tank has 10 Liters drawdown capacity, 2.5 Liters expansion, total capacity is 12.5 liters.

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

A low coolant sensor is installed on the side of the surge tank. The sensor will activate the Low Engine Coolant warning displayed on the PowerView display on the instrument panel in the cab.

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

Slowly loosen cap to first stop to relieve pressure before removing A rad cap mounted on top of the surge tank maintains a 15 psi (104 kPa) pressure on the coolant in the radiator. This pressure provides for over boil protection of the cooling system.

A drain tap located on the bottom of the radiator provides a drain for the engine coolant. It is recommended that the engine coolant (60% antifreeze - 40% distilled water) be changed every two years.

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

10.16

Tigercat H822C/LH830C Harvester

Oil Cooler and Cooling Fan

OIL COOLER A/C CONDENSER

RADIATOR

DEBRIS SCREEN

COOLING FAN SHROUD FINGER GUARD

•

•

•

SURGE TANK

•

•

FAN DRIVE MOTOR

•

••

•• •

• CHARGE AIR COOLER

822C-01

COOLING ASSEMBLY - OVERALL VIEW

10.17

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

Tigercat H822C/LH830C Harvester

Oil Cooler and Cooling Fan

10.18

Tigercat H822C/LH830C Harvester

SECTION 11 - TRACK DRIVE CONTENTS - SECTION 11 BRAKE CIRCUIT DESCRIPTION ................................................................ 11.5 CIRCUIT DIAGRAM, DRIVE SYSTEM ........................................................ 11.9 DRIVE MOTOR DESCRIPTION ......................................................................................... 11.4 START-UP PROCEDURE ........................................................................ 11.7 DRIVE MOTOR AND GEARBOX ASSEMBLY ............................................ 11.3 GEARBOX AND DRIVE MOTOR ASSEMBLY ............................................ 11.3 HYDROSTATIC DRIVE SYSTEM ................................................................ 11.3 IMPORTANT TRACK DRIVE NOTES NEW MACHINE ........................................................................................ 11.2 STRAIGHT TRAVEL ................................................................................. 11.2 TRACK SAG ............................................................................................. 11.2 LEFT TRACK SPEED ADJUSTMENT ....................................................... 11.12 PRESSURE SETTINGS, DRIVE SYSTEM BEGIN OF REGULATION, SET, FOR DRIVE MOTOR .......................... 11.11 CROSSOVER RELIEF VALVES, FOR DRIVE MOTOR ......................... 11.10 RIGHT TRACK SPEED ADJUSTMENT .................................................... 11.15 SCHEMATIC DIAGRAMS DRIVE CIRCUIT ....................................................................................... 11.9 DRIVE MOTOR .................................................................... 11.3, 11.5, 11.6 SET STRAIGHT TRAVEL .......................................................................... 11.15 TRACK COMPONENTS BOTTOM ROLLER RETAINING BOLTS ................................................ 11.18 MEASURING TRACK SAG .................................................................... 11.16 TRACK SAG ADJUSTMENT .............................................................. 11.17 OPERATING THE MACHINE ................................................................. 11.16 TORQUING UNDERCARRIAGE BOLTS ............................................... 11.17 TRACK SHOE RETAINING BOLTS ....................................................... 11.17 WEAR LIMITS BOTTOM ROLLER WEAR ................................................................. 11.19 BUSHING WEAR, OUTSIDE DIAMETER .......................................... 11.19 IDLER WEAR ...................................................................................... 11.20 PIN AND BUSHING WEAR ................................................................ 11.19 TRACK LINK WEAR ........................................................................... 11.18 TRACK SHOE GROUSER HEIGHT WEAR ....................................... 11.18 TRACK SLIDE WEAR ......................................................................... 11.20 TRACK DRIVE ASSEMBLY ......................................................................... 11.2 TRACK SPEED SET-UP PROCEDURE HIGH FORWARD (MOTOR MINIMUM DISPLACEMENT ...................... 11.14 HIGH REVERSE (VALVE FLOW SETTING) .......................................... 11.15 LOW FORWARD (VALVE FLOW SETTING) ......................................... 11.13 SET MOTOR MAXIMUM DISPLACEMENT ........................................... 11.12 SET STRAIGHT TRAVEL ....................................................................... 11.15 SUMMERY OF PROCEDURE ................................................................ 11.15

AUGUST 2006

Tigercat H822C/LH830C Harvester IMPORTANT TRACK DRIVE NOTES

Track drive STRAIGHT TRAVEL

NEW MACHINE

If the machine does not travel straight, the right and left track speeds are not set the same. Refer to TRACK SPEED SET-UP PROCEDURE in THIS SECTION.

Before driving a new machine ensure that track sag is set correctly. Track sag may be set less than specified for shipping purposes. The correct track sag must be adjusted once a machine has been delivered to the job sight and operating in the accumulated soil buildup in the undercarriage.

Check speeds of each track and follow the set-up procedures closely to obtain straight travel.

TRACK SAG The track sag dimension is very important and should be checked regularly. A 50% increase in the life of the track assembly can be realized, particularly in bushing O/D wear and 'track pitch' by maintaining the correct amount of track sag. A track that is too tight will wear out significantly faster due to increased tension in the chain. Refer to MEASURING TRACK SAG in THIS SECTION.

TOP ROLLERS OR SLIDES

ROTARY MANIFOLD

••

IDLER ASSEMBLY

•• UNDERCARRIAGE LOWER HINGED ACCESS COVER

•• UNDERCARRIAGE

••

•• ••

•

•

•

INSPECTION COVERS

•

•

DRIVE MOTOR

•

TRACK DRIVE GEARBOX DRIVE SPROCKET

822-18

•

LOWER ROLLERS

•

TRACK DRIVE ASSEMBLY 11.2

• TRACK ASSEMBLY

TRACK ACCESS COVER

Tigercat H822C/LH830C Harvester

Track drive

HYDROSTATIC DRIVE SYSTEM The hydrostatic drive system is part of the main hydraulic system utilizing a variable displacement piston pump (Pump 2 or main pump) with load sensing and Horse Power (anti-stall) limiting control along with two pressure and flow compensated valve sections on the main Linde valve manifold. Refer to SECTION 4 in THIS MANUAL for a description of the MAIN HYDRAULIC SYSTEM.

valve in the counterbalance valve (G) (Refer to motor schematic) opens and oil pressure builds up behind the motor pistons.

The motor cannot move until the oil pressure shifts the counterbalance spool to permit the oil on the low pressure side of the motor to flow back through the counterbalance valve to the main control valve and then to tank.

A variable displacement swash plate piston motor transmits power to the tracks through a triple reduction planetary gearbox on each track frame.

The gearbox has an integral spring apply, hydraulic-release, multi-disc brake which is released via the brake release manifold whenever the drive foot pedals are activated.

In order to control the vehicle movement in situations where the vehicle may roll down a grade, each motor is equipped with a counterbalance valve. These valves have a spool valve which controls the flow of oil out of the motor, See motor schematic diagram, it is shown in the centre, closed position.

The valve will remain in the closed position as long as there is no oil pressure in the line from the main control valve. When the main control valve spool is shifted and oil flows to the motor, a check 822C-28

TRACK SPROCKET

PLANETARY TRACK DRIVE GEARBOX

•

MOTOR SCHEMATIC DIAGRAM

•

LOWER FRAME

•

TRACK DRIVE MOTOR (AQ019 SHOWN)

• ••

BRAKE ASSEMBLY

BK004-822

TRACK DRIVE MOTOR AND GEARBOX ASSEMBLY 11.3

Tigercat H822C/LH830C Harvester

Track drive block (1) with nine pistons (2) and an output shaft (3) that is splined to the cylinder block.

DRIVE MOTOR DESCRIPTION The drive motor is a variable displacement swashplate design. The motor is interchangeable from side to side.

Supply oil from the drive control valve enters the motor through the cover (4) to the pistons. During operation, high pressure supply oil enters the

The motor rotating group consists of a cylinder SLIPPER

RETAINER

PISTON 2

BALL GUIDE

CYLINDER BLOCK

6

1

SWASHPLATE

PIN

5 SEAL

MAXIMUM DISPLACEMENT PISTON

8

•• ••

SPACER RETAINING RING

••••• ••

••

•• •• • •• ••

9 MINIMUM

•

SHIMS

••

••

4 COVER

•

•• •

SHAFT 3

DISPLACEMENT ADJUSTMENT STOP

••

•

10 MAXIMUM

DISPLACEMENT ADJUSTMENT STOP

WEAR SLEEVE

CROSS SECTION OF DRIVE MOTOR

AQ019-2

BEARING SHELL MINIMUM

7 DISPLACEMENT

SPRING

MINIMUM DISPLACEMENT ADJUSTMENT STOP

BRAKE RELEASE PRESSURE REDUCING VALVE ADJUSTMENT

BEGIN OF REGULATION ADJUSTMENT

9

PISTON CROSSOVER

11 RELIEF VALVES 4 COVER

•

• •

•• ••

•• 'B' PORT

PRESSURE PORTS

•

'A' PORT

• PRESSURE REGULATOR VALVE BLOCK MAXIMUM 10 DISPLACEMENT ADJUSTMENT STOP

•

AQ019-1

COUNTERBALANCE VALVE

11.4

DRIVE MOTOR FRONT COVER

Tigercat H822C/LH830C Harvester piston bores in the cylinder block (1). This forces the pistons against an angled swashplate (5).

Piston sliding action causes the rotating group to turn. The cylinder block is splined to the output shaft (3) which causes the output shaft to turn.

During the second half of the motor rotation, low pressure is discharged as the pistons ride up to a higher position on the swashplate. To reverse rotation, oil flow is reversed. During operation a small amount of supply oil flows through the centre of each piston. This oil lubricates the piston to slipper (6) joint and the slipper to swashplate area.

Track drive BRAKE CIRCUIT DESCRIPTION Refer to motor schematic diagram When the foot pedals are activated, pilot oil from the foot pedal valves is directed to the brake release manifold. This oil pressure acts on the brake release valve and causes it to shift, redirecting pilot oil from the pilot manifold through the valve to the track drive brake cylinders. Pilot oil is limited to 500 psi., the brake is fully released by 250 psi. and the maximum pressure the brake can stand without failure is 725 psi.

High pressure supply oil also flows through a tube to lubricate the swashplate to bearing shell area.

Normal leakage and lubrication oil aid in flushing and cooling the motor during drive operation.

The swashplate (5) angle is changed by the minimum displacement piston (7) and maximum displacement piston (8). When supply oil acts on the minimum displacement piston (7), the motor runs at its highest speed. When supply oil acts on the maximum displacement piston (8), the motor runs at its slowest speed. The maximum displacement piston is larger than the minimum piston and will hold the motor in maximum displacement when equal pressure acts on both pistons.

NOTE: Swashplate angle (motor displacement) is limited by the minimum and maximum displacement pistons contacting the minimum (9) and maximum (10) displacement adjustment stops. For minimum displacement, the maximum displacement piston contacts the minimum displacement adjustment stop. For maximum displacement, the minimum displacement piston contacts the maximum displacement adjustment stop.

Refer to front cover illustration; The drive motor cover (4) consists of several components to operate the drive functions.

The minimum displacement adjustment stop (9) limits the minimum angle the swashplate can move. The maximum displacement adjustment stop (10) limits the maximum angle the swashplate can move. The crossover relief valve(s) (11) protects the motor circuit from pressure spikes.

MOTOR SCHEMATIC DIAGRAM The drive speed change valve (H) routes supply oil to the maximum displacement piston to keep the drive motor in the lowest speed. A servo pressure reducing valve controls the pressure of the supply oil entering the drive speed change valve at 2000 psi. maximum.

822C-28

A flushing orifice (I) is located in the flushing circuit to motor case passage. The orifice provides a passage for oil flow from the flushing circuit to the motor case for cooling and flushing during drive operation. When the oil is cold the flow of oil is restricted by the orifice to prevent an excessive build up of pressure in the drive motor case. The orifice also provides a passage to release any residual pressure to the motor case when not driving.

Continued on page 6

11.5

Tigercat H822C/LH830C Harvester

Track drive

Continued from page 5

The drive motor may be operated in two ranges;

For H822C AQ019, MAXIMUM DISPLACEMENT = 105cc/rev.

MINIMUM DISPLACEMENT = app. 50cc/rev.

For LH830C AQ047, MAXIMUM DISPLACEMENT = 135cc/rev.

MINIMUM DISPLACEMENT = app. 50cc/rev.

These two ranges are controlled by a solenoid pilot valve on the pilot manifold which is operated by the TRACK (LOW/DRIVE) switch in the cab.

In the LOW position the solenoid on the pilot valve is energized and the motor is in its maximum displacement mode which will give the slowest speed and maximum tractive effort.

BEGIN OF REGULATION ADJUSTMENT

MINIMUM DISPLACEMENT ADJUSTMENT STOP 'A'

PRESSURE REGULATOR VALVE BLOCK

• • •

•

MOTOR SCHEMATIC DIAGRAM

822C-28

For faster travelling modes the TRACK (LOW/ DRIVE) switch can be put in the DRIVE position and the motor will be in its minimum displacement position which will give the fastest speed. When in this high speed mode the motor will automatically de-stroke in the event that a high load is encountered, e.g. a short grade or obstacle. This de-stroking is controlled by the drive speed change valve. This valve controls the hydraulic pressure signal to the maximum displacement piston. The piston shifts the motor to maximum displacement when the supply oil pressure in the motor is above the drive speed change valve pressure setting.

CROSSOVER RELIEF VALVES 'B'

CYLINDER BLOCK 'J'

COVER 'L'

PRESSURE REGULATOR VALVE BLOCK

PISTON 'I' SWASHPLATE 'E'

• •

MIN. AND MAX. ADJUSTING STOPS 'A' & 'E'

•

BEARING SHELL 'R'

••

•

•

'B' PORT

••

• 'A' PORT

'A' BRAKE RELEASE PRESSURE REDUCING VALVE ADJUSTMENT

AQ019

••

•

SHAFT 'A'

•

'A'

SLIPPER 'F'

MAXIMUM DISPLACEMENT ADJUSTMENT STOP 'E'

DRIVE MOTOR FRONT COVER (AQ019 & AQ47)

••

TUBE

•

COUNTERBALANCE VALVE

CROSS SECTION 'A' 'A' DRIVE MOTOR (AQ019 & AQ047) 11.6

PRESSURE PORTS 'A', 'B'

Tigercat H822C/LH830C Harvester DRIVE MOTOR START-UP PROCEDURE

Track drive

IMPORTANT: The drive motor will be damaged if is not filled with oil before operating the drive function. This procedure must be performed whenever a new drive motor or drive pump is installed or whenever oil has been drained from the motor.

1. Disconnect drive motor drain line on top of motor.

2. Install plug in line to minimize loss of oil.

3. Remove port adapter from motor drain port.

4. Fill motor with oil through the drain port. Add oil slowly until level is to the top of drain port.

5. Re-connect drain line.

6. Run each drive motor slowly with track off the ground for three track revolutions to remove air from the drive circuit.

DRAIN LINE

••

'U' PORT DRAIN CONNECTION GAUGE TEST PORT 'Y1'

••

•

DRIVE MOTOR TOP VIEW

822-D61

PRESSURE REGULATOR VALVE BLOCK

GAUGE TEST PORT Y1 SYSTEM PRESSURE PORT 'A'

BRAKE LINE TO GEARBOX

• MAXIMUM DISPLACEMENT ADJUSTMENT STOP

•

6mm ALLEN KEY 19mm WRENCH

••

SYSTEM PRESSURE PORT 'B'

MINIMUM DISPLACEMENT ADJUSTMENT STOP 6mm ALLEN KEY 19mm WRENCH

••

•

COUNTERBALANCE VALVE

••

'B' SIDE

•• CROSSOVER RELIEF VALVES

'A' SIDE

••

6mm WRENCH 13mm WRENCH

•• 'L' PORT DRAIN CONNECTION (FOR L.H. SIDE)

5mm ALLEN KEY 17mm WRENCH 822-D62

BEGIN OF REGULATION ADJUSTING SCREW

DRIVE MOTOR (AQ019) - R.H. SIDE SHOWN 11.7

••

Tigercat H822C/LH830C Harvester

Track drive

11.8

Tigercat H822C/LH830C Harvester

822C-29

Track drive

TRACK DRIVE CIRCUIT DIAGRAM WITH AQ019 MOTOR 11.9

Tigercat H822C/LH830C Harvester DRIVE SYSTEM PRESSURE SETTINGS FOR DRIVE MOTOR DRIVE MOTOR CROSSOVER RELIEF VALVES Pressure Setting: 4600 - 4800 psi (cracking pressure)

Track drive 12. Set throttle switch to FULL

...

13. Activate LEFT drive foot pedal in FORWARD or REVERSE and temporarily set LS. relief valve to 4700 psi. on gauge at 'P' test port.

TEST PROCEDURE: Place attachment head securely on the ground before performing any service work.

'B' SIDE REVERSE CROSSOVER RELIEF VALVE

'A' SIDE FORWARD CROSSOVER RELIEF VALVE

1. Ensure hydraulic oil is at operating temperature.

••

2. Remove both LEFT and RIGHT drive motor inspection covers.

•

3. Install a 0 to 10,000 psi gauge on 'P' test port on Linde main valve manifold.

'P' GAUGE TEST CONN.

••

HIGH PRESSURE LIMITING CONTROL

L.S. GAUGE TEST CONN.

••

••

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

103-17A

GAUGE TEST PORTS ON MAIN VALVE

DRIVE MOTOR - LEFT SIDE SHOWN 'B' SIDE REVERSE CROSSOVER RELIEF VALVE

'A' SIDE FORWARD CROSSOVER RELIEF VALVE

5mm ALLEN KEY 17mm WRENCH

5mm ALLEN KEY 17mm WRENCH

•• ••

•

MAIN VALVE MANIFOLD

4. Disconnect LEFT brake line at port on final drive gearbox. Plug hose with size 04 JIC plug and cap port adapter on gearbox.

5.

822-D60

Start engine and set throttle speed to above 1500 RPM.

6. From inside the cab close and latch the front door and press the PILOT RESET switch to activate the pilot system.

7. Place ANTI-STALL switch OFF position.

••

822-D62

DRIVE MOTOR - RIGHT SIDE SHOWN 14. With the aid of an assistant; While holding the LEFT drive foot pedal in the FORWARD position loosen locknut on FORWARD crossover relief valve adjusting screw and unscrew slowly until engine begins to lug. Turn adjusting screw 1/8 of a turn in and tighten locknut.

8. Place DRIVE/LOW switch to LOW.

15. Repeat step (14) for the LEFT REVERSE crossover relief valve.

9. Activate LEFT track drive foot pedal in both FORWARD and REVERSE directions to ensure that the track does not move.

16. Repeat steps (4) through (15) for RIGHT track drive motor.

10. With the aid of an assistant, activate LEFT track drive foot pedal in either FORWARD or REVERSE and check pressure reading on gauge at 'P' port. the gauge should show 4300 psi (Main system LS. relief pressure) 11. Loosen locknut on both crossover relief valve adjusting screws and turn both adjusting screws all the way in. Tighten locknuts.

17. Reset the LS. relief valve to 4300 psi. on gauge at 'P' test port. Refer to SET LOAD SENSE RELIEF VALVE in SECTION 4 of THIS MANUAL. 18. Re-connect brake line(s) to both gearboxes.

19. Remove pressure gauge and wipe up any spills.

20. Replace both LEFT and RIGHT drive motor inspection covers.

11.10

Tigercat H822C/LH830C Harvester

Track drive 12. With the aid of an assistant, activate LEFT track drive foot pedal in the FORWARD direction and check pressure reading on gauge at motor gauge test port 'Y1' it should show between 800 and 1,000 psi.

SET BEGIN OF REGULATION (DRIVE SPEED CHANGE VALVE) 1. Ensure hydraulic oil is at operating temperature.

2. Remove both LEFT and RIGHT drive motor inspection covers.

If adjustment is required, loosen locknut on begin of regulation adjusting screw and turn screw in to increase pressure or out to decrease pressure. Tighten locknut.

3. Install a 0 to 10,000 psi gauge on 'P' test port on Linde main valve manifold.

'P' GAUGE TEST CONN.

••

HIGH PRESSURE LIMITING CONTROL

L.S. GAUGE TEST CONN.

••

••

13. Stop engine.

14. Repeat steps (4) through (12) for the right drive motor.

15. Reset the LS. relief valve to 4300 psi. Refer to SET LOAD SENSE RELIEF VALVE in SECTION 4 of THIS MANUAL. 16. Re-connect brake line(s) to both gearboxes.

17. Remove pressure gauge and wipe up any spills.

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

103-17A

GAUGE TEST PORTS ON MAIN VALVE

•• ••

MAIN VALVE MANIFOLD

4. Disconnect LEFT brake line at port on final drive gearbox. Plug hose with size 04JIC plug and cap port adapter on gearbox.

5. Install a 0 to 5,000 psi gauge on drive motor gauge test port 'Y1', size 04JIC quick connect.

6.

Start engine and set throttle to FULL

18. Replace both LEFT and RIGHT drive motor inspection covers. **NOTE For begin of regulation; this pressure setting can be adjusted between 3100 psi and 3600 psi depending on the operator's requirements. The lower the begin of regulation setting the sooner the drive motors will automatically shift to LOW when encountering difficult terrain conditions.

...

7. From inside the cab close and latch the front door and press the PILOT RESET switch to activate the pilot system.

8. Place ANTI-STALL switch to OFF position.

9. Place DRIVE/LOW switch to DRIVE position.

10. Activate LEFT track drive foot pedal in both FORWARD and REVERSE directions to ensure that the track does not move.

11. With the aid of an assistant, activate LEFT drive foot pedal in FORWARD or REVERSE and temporarily set LS. relief valve to 3600 psi.** on gauge at 'P' test port on Linde main valve manifold.

11.11

Tigercat H822C/LH830C Harvester TRACK SPEED SET-UP PROCEDURE

Track drive Machine weight (less attachment):

IMPORTANT: EACH motor maximum displacement setting must be correctly set before making adjustments to the valve spool stops described here in. Refer to the following SET MOTOR MAX. DISPL. (SLOW SPEED) procedure.

LH830C 72000 lbs (32660 kg) 822C 54000 lbs (24490 kg) Refer to attachment manufacturer's manual for correct attachment weight information.

5. Use blocks to firmly support track frame in raised position.

Also note that changes in margin pressure will also affect track speeds.

NOTE: Both left and right track drives have 4 (speed) settings which are dealt with in the following procedures, they are: 1, Forward-Drive 2, Forward-Low 3, Reverse-Drive 4, Reverse-Low. However, there are only 3 adjustments required to accomplish this; 1, Forward flow stop adjusting screw 2, Reverse flow stop adjusting screw 3, Motor minimum displacement adjustment stop

WARNING DO NOT place arms, legs or body under track while in the raised position.

SET MOTOR MAX. DISPL. (SLOW SPEED) NOTE: The motor maximum displacement setting is the SLOW speed setting and is factory set to:

For H822C AQ019, MAXIMUM DISPLACEMENT = 105cc/rev.

For LH830C AQ047, MAXIMUM DISPLACEMENT = 135cc/rev.

NOTE: Turn the screw either IN (clockwise) to speed up or OUT (counterclockwise) to slow down the final drive.

SET TRACK SPEED Low speed 10 rpm**. High speed 28 rpm. **NOTE: This value is dependant on engine HIGH IDLE speed or FULL throttle. 10 rpm is based on 1800 rpm.

6. On LEFT track drive motor, unscrew the MINIMUM DISPLACEMENT ADJUSTING SCREW 6mm ALLEN KEY 19mm WRENCH

1. Park machine on flat hard ground and ensure hydraulic oil is at operating temperature.

2. Remove both left and right final drive inspection covers to access track motors.

•

LEFT TRACK ADJUSTMENT POSITION MACHINE

••

3. Position attachment head in vertical position and swing boom to LEFT side of machine.

4. Use a jack of suitable design and capacity to safely lift the left track clear of the ground.

MAXIMUM DISPLACEMENT ADJUSTING SCREW 6mm ALLEN KEY 19mm WRENCH

822-D60

LEFT TRACK DRIVE MOTOR MAXIMUM DISPLACEMENT ADJUSTING SCREW 6mm ALLEN KEY 19mm WRENCH

•• MINIMUM DISPLACEMENT ADJUSTING SCREW 6mm ALLEN KEY 19mm WRENCH H822C-I01

LIFT LEFT TRACK

822-D61

11.12

••

RIGHT TRACK DRIVE MOTOR

Tigercat H822C/LH830C Harvester maximum displacement adjusting screw all the way OUT.

Track drive CONTROL FORWARD SPOOL VALVE STOP SCREW FOR MANIFOLD LEFT TRACK

7. From inside the cab close and latch the front door and press the PILOT RESET switch to activate the pilot system.

FORWARD SPOOL STOP SCREW FOR RIGHT TRACK

••

••

••

8. Place ANTI-STALL switch to OFF position.

9. Set TRACK (LOW/DRIVE) switch to LOW. 10. Set throttle switch to FULL

B

...

SIDE

•

11. With an assistant depressing LEFT TRACK drive pedal FORWARD, turn maximum displacement screw IN until the end of adjusting screw just makes contact with piston inside the motor.

A SIDE

12. Release drive pedal and turn screw IN an additional 1/4 turn = 105cc or 135 cc.

RETURN MANIFOLD

822-D63A

13. LEFT drive motor maximum displacement (slow track speed) is now set.

14. Turn ‘DRIVE/LOW’ switch to ‘LOW’

REVERSE SPOOL STOP SCREW FOR RIGHT TRACK

MAIN CONTROL VALVE

*NOTE: Refer to TRACK TIMING CHART.

...

16. With an assistant depressing ‘LEFT’ TRACK drive pedal ‘FORWARD’, record track drive sprocket speed.

••

••

Track containing 47 links*: A reading of 11 RPM is desired which equals 1 complete revolution of the track every 22.3 seconds.

LOW FORWARD (VALVE FLOW SETTING)

A TIMING MARK, VISIBLE FROM THE CAB CAN ALSO BE PLACED ON THE TRACK

••

REVERSE SPOOL STOP SCREW FOR LEFT TRACK

Tighten locknut while holding adjusting screw from turning.

15. Set throttle switch to FULL

RIGHT DRIVE VALVE

LEFT DRIVE VALVE

17. To obtain the 10 or 11 RPM value adjust FORWARD spool stop adjusting screw for the LEFT track drive control valve.

SPOOL STOP ADJUSTING SCREW • 19mm WRENCH • 6mm ALLEN KEY

••

••

•• ROTATION

TO RECORD TRACK SPEED, PLACE TIMING MARKS ON TRACK FRAME AND GEARBOX HOUSING

84-18

SET TRACK SPEED 853MV-2

Track containing 45 links*: A reading of 10RPM is desired which equals 1 complete revolution of the track every 23.5 seconds.

VALVE FLOW SETTING TRACK DRIVE MAIN CONTROL VALVE

Turn the screw either IN (clockwise) to slow down or OUT (counterclockwise) to speed up the final drive. Tighten locknut on adjusting screw and re-check sprocket speed.

11.13

Tigercat H822C/LH830C Harvester

Track drive

HIGH FORWARD (motor minimum displacement)

TRACK TIMING CHART

18. Turn ‘DRIVE/LOW’ switch to ‘DRIVE’ 19. Set throttle switch to FULL

...

20. With an assistant depressing ‘LEFT’ TRACK drive pedal ‘FORWARD’, record track drive sprocket speed.

GEARBOX RPM DESIRED LOW

Track containing 45 links*: A reading of 28 RPM is desired which equals 1 complete revolution of the track every 8.4 seconds.

Track containing 47 links*: A reading of 29 RPM is desired which equals 1 complete revolution of the track every 8.5 seconds. *NOTE: Refer to TRACK TIMING CHART. 21. To obtain the 28 or 29 RPM adjust the minimum displacement adjusting screw for the LEFT track drive motor. Turn the screw either IN (clockwise) to slow down or OUT (counterclockwise) to speed up the final drive. Tighten locknut on adjusting screw and re-check sprocket speed.

DESIRED HIGH DO NOT EXCEED

MINIMUM DISPLACEMENT ADJUSTMENT STOP

••

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

822 TRACKCHART.XLS

•• MAXIMUM DISPLACEMENT ADJUSTMENT STOP 822-D60

NUMBER OF TRACK LINKS 45 47 51 TRACK REVOLUTION TIME (SECONDS)

LEFT TRACK DRIVE MOTOR IMPORTANT: DO NOT exceed the recommended track speed specified above, over speeding will damage the drive motor or gearbox input.

11.14

23.48 21.34 19.57 18.06 16.77 15.65 14.67 13.81 13.04 12.36 11.74 11.18 10.67 10.21 9.78 9.39 9.03 8.70 8.39 8.10 7.83 7.57 7.34 7.11 6.91 6.71 6.52 6.35 6.18 6.02 5.87

24.52 22.29 20.43 18.86 17.52 16.35 15.33 14.42 13.62 12.91 12.26 11.68 11.15 10.66 10.22 9.81 9.43 9.08 8.76 8.46 8.17 7.91 7.66 7.43 7.21 7.01 6.81 6.63 6.45 6.29 6.13

26.61 24.19 22.17 20.47 19.01 17.74 16.63 15.65 14.78 14.00 13.30 12.67 12.09 11.57 11.09 10.64 10.23 9.86 9.50 9.18 8.87 8.58 8.32 8.06 7.83 7.60 7.39 7.19 7.00 6.82 6.65

Tigercat H822C/LH830C Harvester HIGH REVERSE (valve flow setting)

Track drive SUMMERY OF PROCEDURE • REMOVE INSPECTION COVERS

22. Repeat steps 18 to 20 to set ‘LEFT’ HIGH REVERSE.

LEFT TRACK ADJUSTMENT • POSITION MACHINE, LEFT track off ground • LOW FORWARD (valve flow setting) • HIGH FORWARD (motor minimum displacement) • HIGH REVERSE (valve flow setting)

23. To obtain 28 or 29 RPM value adjust REVERSE spool stop adjusting screw for the LEFT track drive control valve. Turn the screw either IN (clockwise) to slow down or OUT (counterclockwise) to speed up the final drive. Tighten locknut on adjusting screw and re-check sprocket speed.

RIGHT TRACK ADJUSTMENT • POSITION MACHINE, RIGHT track off ground • LOW FORWARD (valve flow setting) • HIGH FORWARD (motor minimum displacement) • HIGH REVERSE (valve flow setting) • REPLACE INSPECTION COVERS

TRACK SPEED SET-UP PROCEDURE continued; RIGHT TRACK ADJUSTMENT

SET STRAIGHT TRAVEL

845-12

Following completion of TRACK SPEED SETUP PROCEDURE, drive the machine in both forward and reverse directions with the ‘DRIVE/LOW’ switch in ‘DRIVE’ and again with the switch in ‘LOW’ position. Ensure that both DRIVE pedals are equally and fully depressed.

LIFTING RIGHT TRACK

24. Re-position machine to raise RIGHT track.

If the machine continuously drifts to the left or to the right, the above set-up procedure should be reviewed. It is important that the LEFT and RIGHT track speeds are synchronized with each other to prevent unnecessary wear from occurring to the track components.

25. Repeat steps 3 through 13 to set RIGHT drive motor maximum displacement.

LOW FORWARD (valve flow setting) 26. Repeat steps 14 to 17 to set RIGHT TRACK valve flow setting.

HIGH FORWARD (motor minimum displ.)

27. Repeat steps 18 to 21 to set RIGHT drive motor minimum displacement.

HIGH REVERSE (valve flow setting) 28. Repeat steps 22 and 23 to set RIGHT TRACK valve flow setting.

29. Replace final drive inspection covers for both right and left track drives.

11.15

Tigercat H822C/LH830C Harvester TRACK COMPONENTS

Track drive

IMPORTANT: New machine: Before driving a new machine ensure that track sag is set correctly. Track sag may be set less than specified for shipping purposes.

The correct track sag must be adjusted once a machine has been delivered to the job sight and operating in the accumulated soil build-up in the undercarriage.

TRACK SAG NOTE: The track sag dimension is very important and should be checked regularly, 50% increase in the life of the track assembly can be realized, particularly bushing O/D wear and track pitch by maintaining the correct amount of track sag. A track that is too tight will wear out significantly faster due to increased tension in the chain.

H822C-I01

MEASURING TRACK SAG 1. Position attachment head in vertical position and swing boom to side of machine.

2. Use a jack of suitable design and capacity to safely lift the left track clear of the ground.

Use blocks to firmly support track frame in raised position.

Machine weight (less attachment):

Track components operate under varying terrain conditions, most of which cause excessive wear.

Wear to one component can quickly spread to the rest of the track assembly.

To ensure that the track components are always in good running order, a periodic inspection should be made to ensure that components have not come loose, that bolts are at the correct torque, that components are within the specified wear limits (discussed further in this section) and where applicable, check lubrication points.

For a guide on inspection, refer to the PERIODIC MAINTENANCE SCHEDULE in SECTION 3 OF THIS MANUAL.

LH830C 822C

72000 lbs (32660 kg) 54000 lbs (24490 kg)

Refer to attachment manufacturer's manual for correct attachment weight information.

3. Rotate track in forward and reverse several times. Stop the track while in reverse. Do not clean the track.

4. Stop engine.

5. Measure distance between top surface of track shoe at centre of lower surface of track frame.

UNDERSIDE OF TRACK GUARD

SAG DIMENSION

• •

UPPER SURFACE OF TRACK SHOE 853ILL8

OPERATE MACHINE WITH 822C-36 ATTACHMENT HEAD OVER IDLERS OPERATING THE MACHINE Whenever possible the machine should always be operated with the attachment head over the IDLERS and not over the SPROCKETS. Operating over the sprockets will result in overloading of the contact surfaces between the sprocket and the track bushings. Bushings could crack during sprocket impact.

MEASURING SAG DIMENSION

6. This dimension should be between 4" and 6" for normal operations.

NOTE: If track sag is less than specified, track chain wear will be accelerated. If track sag is excessive, it is possible for the track to jump off the sprocket.

11.16

Tigercat H822C/LH830C Harvester IDLER ADJUSTING 4 CYLINDER

Track drive TORQUING UNDERCARRIAGE BOLTS

•

It is important to check the torque values of the track shoe retaining bolts and the bottom roller retaining bolts at the NEW MACHINE MAINTENANCE time period (first 100 hours) and the EVERY 125 HOURS SCHEDULED MAINTENANCE time period.

3

•

DO NOT REMOVE

•

•

CW001-3

• 1

2

When installing new components, all traces of paint and dirt must be removed from all mating surfaces including the contact area under the bolt head and nut.

TRACK ADJUSTMENT TRACK SAG ADJUSTMENT

Both the bolt and the nut on the track shoes should be lightly lubricated with SAE 30 oil and tightened using the Torque-turn method.

To tighten track, attach adjustment fitting adapter (3) onto valve body (1). Connect a grease gun to the grease fitting (2) on the adjustment fitting adapter (3). Add grease until track sag dimension is within recommended limits. Remove adjustment fitting adapter.

The torque-turn method involves torquing the bolt to an initial predetermined value, plus an additional 1/3 turn (not the value shown in the torque charts). This ensures a more accurate and consistent torquing of the bolts, with less likelihood of the bolt/nut coming loose later.

CAUTION: The grease is under very high pressure, DO NOT REMOVE the adjustment fitting valve body (1) from the idler adjusting cylinder (4).

When checking the torque values at the first 100 hours and every 125 hours thereafter use the CHECKING TORQUE values listed in the following paragraphs.

To loosen track, slowly loosen valve body (1) until grease begins to escape via a relief passage in the valve body housing, grease will be seen escaping from around valve body threads. When track sag is correct, tighten valve body.

If loose shoes or under torqued bolts are discovered during the FIRST 100 HOUR check, they should be removed, surfaces cleaned, and reused using the torque-turn method. If the shoe is not loose but a single bolt is low on torque, loosen the bolt and re torque-turn.

CW001-2

If loose or under torqued bolts are discovered any time after the 100 HOUR check, the bolts and nuts must be replaced with NEW ones, surfaces cleaned, and re torque-turned.

TRACK SHOE RETAINING BOLTS Track shoes must be fastened together applying the exact torque values shown below and using the Torque-turn method described in TORQUING UNDER CARRIAGE BOLTS earlier in this section.

TORQUE 1

TRACK COMPONENT TORQUE VALUES 11.17

Tigercat H822C/LH830C Harvester

Track drive

Track shoe bolts and nuts are designed specifically for this purpose and should not be substituted with standard off the shelf hardware.

Only bolts with grade '12.9' or '170' designation forged in the head are approved.

SINGLE GROUSER BERC-9

When checking the torque values at the first 100 hours and every 125 hours thereafter use the checking torque value.

DOUBLE GROUSER BERC-10

Track shoe bolts ~ 3/4" UNF (D6) TORQUE-TURN ............ 220LBF-FT. + 1/3 TURN. CHECKING TORQUE ....................... 450 LBF-FT.

TRIPLE GROUSER

Track shoe bolts ~ M20 (F8) BERC-1

TORQUE-TURN ............ 260LBF-FT. + 1/3 TURN.

GROUSER WEAR (HEIGHT)

CHECKING TORQUE ............... 563-648 LBF-FT.

WEAR LIMITS

Track shoe bolts ~ M24 (FH400)

TRACK SHOE GROUSER HEIGHT WEAR WEAR LIMITS New 75% wear 100% wear Single 2.82"(716.2mm) ... 1.37" (348mm) ........ 0.93" (236.2mm) Double 1.37"(348mm) ...... 0.71" (180.3mm) ..... 0.43" (109.2mm) Triple 1.06"(269.2mm) ... 0.51" (129.5mm) ..... 0.36" (91.4mm)

TORQUE-TURN ............ 340LBF-FT. + 1/3 TURN. CHECKING TORQUE ..................... 1040 LBF-FT. BOTTOM ROLLER RETAINING BOLTS The bottom rollers must be fastened to the lower frame applying the exact torque values shown below.

When installing new rollers, apply "NEVER-SEEZ" to the bolt.

NOTE: Allowable wear for soft ground conditions is 100%. Allowable wear for rocky ground conditions is 75%.

When checking the torque values at the first 100 hours and every 125 hours thereafter use the torque value(s) shown below.

NOTE: Two sizes of bolts have been used to fasten the rollers to the lower frame; 3/4" UNC; and on later machines 7/8" UNC. Bottom roller bolts ~ 3/4" UNC TORQUE ......................................... 310 LBF-FT. Bottom roller bolts ~ 7/8" UNC TORQUE ......................................... 475 LBF-FT. For a complete maintenance check Refer to the PREVENTIVE MAINTENANCE SCHEDULE in SECTION 3 of this manual.

BERC-2

TRACK LINK WEAR (HEIGHT)

TRACK LINK WEAR WEAR LIMITS New link height ........................ 4.78" (121.5mm) 50% wear ................................ 4.60" (116.8mm) 75% wear ................................ 4.48" (113.8mm) 100% wear .............................. 4.34" (110.2mm)

11.18

Tigercat H822C/LH830C Harvester

Track drive

PIN AND BUSHING WEAR

BUSHING WEAR, OUTSIDE DIAMETER

To obtain the track internal wear, i.e., the wear between the pin and the internal diameter of the bushing, measure the track pitch over four sections of track (5 pins).

Use a calliper to measure the wear of the bushing O.D. in three places.

45°

45°

FORWARD SIDE VERTICAL WEAR WEAR BERC-3

MEASURING TRACK PITCH

To take this measurement, 1. Remove slack by placing a steel pin between sprocket and chain, then slowly move machine in reverse to tighten chain.

2. Measure pitch across two four link sections, except section on each side of the master pin, to find average chain wear.

INTERNAL PIN & BUSHING WEAR

ROTATION

MEASURING BUSHING WEAR

BERC-5

NOTE: Bushing outside diameter is measured at three places because of the forward and reverse travel of the machine and a vertical wear that takes place.

WEAR LIMITS New bushing O.D. ........................ 2.62" (66.6mm) 75% worn ..................................... 2.5" (63.5mm) 100% worn ................................... 2.43" (61.7mm) NOTE: Allowable wear in rocky ground is 75% BOTTOM ROLLER WEAR

180° EXTERNAL BUSHING WEAR

REVERSE SIDE WEAR

TURN PIN & BUSHING 180°

Measure the roller diameter on the tread contact surface with a large calliper to obtain the worst wear condition.

BERC-4 PIN/BUSHING INTERNAL WEAR NOTE: Wear to the pins and bushings only occurs in a small localised area, to extend the life of these components, the pins and bushings may be turned 180° or replaced provided other components are within specified wear limits:

1. Track link wear is 75% or less.

2. Change in track pitch is 32.50:" (825.5mm) per link or less.

3. Bushing external wear less than 100% or 75% or less in rocky ground.

BERC-6

MEASURING BTM. ROLLER WEAR

4. There is at least 0.008" (0.2mm) press fit available between pin and bushing and link.

If accessibility to the rollers is impaired by guards, then concentrate on the front and rear rollers, these will be the most worn.

WEAR LIMITS New length of four sections .............. 32" (813.0mm) 75% worn ......................................... 32.37"(822.2mm) 100% worn ....................................... 32.50"(825.5mm)

WEAR LIMITS New roller. ................................... 8.26" (210.0mm) 75% worn .................................... 7.64" (194.0mm) 100% worn .................................. 7.36" (187.0mm)

NOTE: Allowable wear in rocky ground is 75% NOTE: These wear limits are to be used as a guide for when to turn the pins and bushings. If pins and bushings are not to be turned, the chain can be run past the 100% wear limit, until chain failure.

11.19

Tigercat H822C/LH830C Harvester

Track drive

IDLER WEAR Measure the idler wheel side diameters (tread contact surface) at several points to obtain the worst wear condition. Position a depth gauge or measuring tape as close as possible toward the centre of the idler with the gauge flat on the centre flange and parallel to the idler shaft.

1/8"

845-33A

SUGGESTED MEASURING GAUGE

BERC-7

MEASURING IDLER WEAR

WEAR LIMITS New idler dimension ...................... 0.85"(22.0mm) 100% wear .................................... 1.18"(30.0mm)

TRACK SLIDE WEAR Track slide wear should be checked periodically to ensure that it does not go over the limit and cause damage to the chain link bushings.

the track bushing. Make sure that dirt build-up does not interfere with the reading. Check at several locations. The ends of the track slides tend to wear first. The slides should be replaced if excessive wear is found.

The wear occurs on the top of the track slide as the chain links slide along and this wear will reduce the clearance between the track guide and the chain link bushings. When this clearance disappears the chain link bushings will start to wear.

Since the checking area is not immediately visible, the measuring may be done using a "go/ no go" gauge made from a piece of 1/8" flat bar.

The gauge is inserted down through the holes in the track and placed between the track guide and 'A'

'A'

845-32

TRACK SLIDE WEAR

CHAIN LINK

CHECK THIS DIMENSION

•

• •

CHAIN LINK BUSHING

•

TRACK GUIDE TRACK SLIDE

845-33

SECTION A - A 11.20

Tigercat H822C/LH830C Harvester

SECTION 12 - BOOM FUNCTIONS AUGUST 2006

CONTENTS - SECTION 12 ADJUST OIL FLOW TO CYLINDERS (CYLINDER CYCLE TIMES ............ 12.9 BOOM CONTROL VALVE ........................................................................... 12.3 SEE ALSO SECTION 4 BOOM SYSTEM DESCRIPTION CONVENTIONAL BOOM .......................................................................... 12.2 'ER' BOOM SYSTEM ................................................................................ 12.2 CIRCUIT DIAGRAM 'ER' BOOM SYSTEM ................................................................................ 12.5 COMPUTER CONTROL SYSTEM (IQAN MDM DISPLAY) ELECTRONIC ADJUSTMENT PROCEDURE, TELESCOPIC ............... 12.12 ADJUSTABLE FUNCTIONS CHART .................................................. 12.13 CYLINDER CYCLE TIMES, TYPICAL ....................................................... 12.10 ENGINE ANTI-STALL .................................................................................. 12.3 SEE ALSO SECTION 4 ER BOOM SYSTEM ..................................................................................... 12.6 LOAD SENSING .......................................................................................... 12.3 SEE ALSO SECTION 9 PARKING BOOM ......................................................................................... 12.6 SET MAIN BOOM, STICK AND TELESCOPIC PORT RELIEF VA ............. 12.7 TELESCOPIC BOOM ELECTRONIC ADJUSTMENT PROCEDURE ....... 12.12 TELESCOPIC CYLINDER FLOW ADJUSTMENT ....................................... 12.3

Tigercat H822C/LH830C Harvester BOOM SYSTEM DESCRIPTION CONVENTIONAL BOOM One "hoist" cylinder is used to raise and lower the main boom.

Two identical cylinders are used side by side in the "stick" position.

The optional "telescopic boom" function uses one cylinder.

Boom functions 'ER' BOOM SYSTEM The 'ER' Boom Valve, located on the upper frame at the base of the main boom, connects one of the STICK cylinders with the HOIST boom cylinders circuit in such a way that allows the boom system to be controlled by movement of a single joystick lever.

822C-01.AI

These cylinders receive oil from the main pump via three spool sections on the main hydraulic valve.

Two joystick handles in the cab control the movement of each cylinder by directing pilot oil to the pilot end caps on each end of the appropriate spool sections to shift the spool and move the cylinder(s).

PUSH LEFT JOYSTICK FORWARD TO MOVE ATTACHMENT AWAY FROM MACHINE Simply pushing the LEFT joystick FORWARD moves the boom straight out of pulling back on the joystick moves the head towards the machine.

The right joystick moves the boom system UP or DOWN. 822C-01.AI

PULL LEFT JOYSTICK BACK TO MOVE ATTACHMENT IN TOWARDS THE MACHINE For additional information regarding SAFETY and OPERATING INSTRUCTIONS, Refer to ER BOOM SYSTEM in SECTION 1 of THIS MANUAL and SECTION 2 in the OPERATOR'S MANUAL.

12.2

Tigercat H822C/LH830C Harvester TELESCOPIC 'IN' PORT RELIEF (IF EQUIPPED)

CONTROL VALVE MANIFOLD

STICK 'IN' PORT RELIEF

Boom functions HIGH PRESSURE LIMITING CONTROL

FLOW TANK ADJUSTING PORT 'T3' SCREW FOR PORT 'A' (TYPICAL)

MAIN BOOM 'DOWN' PORT RELIEF

•• ••

••

••

•

••

••

B

B

B

B

B

B

B

A

A

A

A

A

A

A

• LH DRIVE

•• RH DRIVE

•

TELESCOPIC 'OUT' PORT RELIEF (IF EQUIPPED)

•

•

STICK 'OUT' PORT RELIEF

PUMP 2

• MAIN BOOM 'UP' PORT RELIEF

• SWING

MAIN CONTROL VALVE

822-D63

BOOM CONTROL VALVE The boom, stick and telescopic spool sections each have port relief valves with anticavitation features.

These protect the circuit from abnormally high pressures induced by the load.

Adjustable spool travel stops on each pilot end cap of the spool sections can be adjusted to limit spool travel and control the flow of oil to the cylinder, which in turn controls the operating speed of the cylinders.

An additional flow control adjusting screw (restrictor) located on the top of the main valve manifold is used to regulate the flow of return oil from the rod end of the TELESCOPIC BOOM cylinder (if equipped).

• •

• TOP OF CONTROL VALVE MANIFOLD

ADJUSTING SCREW

This adjustment is to compensate for the weight of trees in the harvesting head causing the telescopic boom to move OUT (extend) too fast. Extending the telescopic boom too fast can cause oil to cavitate in the rod end of the telescopic boom cylinder.

For adjusting procedure refer to TELESCOPIC BOOM CYLINDER (ROD END) FLOW ADJUSTMENT in THIS SECTION. To adjust the relief valves, Refer to SET MAIN BOOM, STICK AND TELESCOPIC PORT RELIEF VALVES in THIS SECTION. To adjust oil flow, Refer to ADJUST OIL FLOW TO CYLINDERS in THIS SECTION. LOAD SENSING\ENGINE ANTI-STALL The boom hydraulics along with the swing, pump2 (harvesting) and track drive circuits are all under the control of the load sensing system incorporated into the main hydraulic circuit.

For a full description of the main hydraulic system including load sensing, the main pump and the main control valve, Refer to SECTION 4 in THIS MANUAL. For a full description of the engine anti-stall, Refer to SECTION 9 in THIS MANUAL.

TELESCOPIC 'IN' PILOT END CAP

870B-D16

FLOW CONTROL ADJUSTING SCREW - TELESCOPIC BOOM (IF EQUIPPED)

For a full description of the pilot system including the joystick handles, Refer to SECTION 5 in THIS MANUAL. 12.3

Tigercat H822C/LH830C Harvester

Boom functions

12.4

Tigercat H822C/LH830C Harvester

Boom functions

'ER' BOOM SYSTEM - HARVESTER WITH TELESCOPIC BOOM CIRCUIT DIAGRAM 822C-30

12.5

Tigercat H822C/LH830C Harvester ER BOOM SYSTEM 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.

Boom functions HOIST CYLINDER FULLY COLLAPSED HEAD

•

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 machines 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.

•• 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:

•

ROTATOR

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:(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.

12.6

Tigercat H822C/LH830C Harvester SET MAIN BOOM, STICK AND TELESCOPIC PORT RELIEF VALVES

Boom functions increase the engine RPM sufficiently to prevent the engine from stalling.

NOTE: Constant loosening and tightening of the locknut (sealnut) on the port relief valve adjusting screws will eventually cause the seal in the nut to break down and leak.

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

SPOOL TRAVEL STOP • 19mm WRENCH • 6mm ALLEN KEY

LINDE MAIN VALVE MANIFOLD

••

•

PORT RELIEF VALVE

•

MAIN VALVE BODY

•• L.S. GAUGE TEST PORT

90744-3

'P' GAUGE TEST PORT

• •

LOCKNUT • 17mm WRENCH

HIGH PRESSURE LIMITING CONTROL

••

•

ADJUSTING SCREW • 5mm ALLEN KEY

1. With hydraulic oil at operating temperature,

PILOT END CAP

•

•

MAIN VALVE PORT RELIEF VALVE

4. From inside the cab close and latch the front door and press the PILOT RESET switch to activate the pilot system.

LS PRESSURE ADJUSTMENT P2

•• LINDE MAIN VALVE MANIFOLD 2. Connect a 0-5000 psi pressure gauge on 'P' test port of Linde main valve manifold.

103-17A

3. Start engine and place throttle control in IDLE position. NOTE; It may be necessary to TELESCOPIC 'IN' PORT RELIEF (IF EQUIPPED)

CONTROL VALVE MANIFOLD

STICK 'IN' PORT RELIEF

HIGH PRESSURE LIMITING CONTROL

FLOW TANK ADJUSTING PORT 'T3' SCREW FOR PORT 'A' (TYPICAL)

MAIN BOOM 'DOWN' PORT RELIEF

• •

•

822-D63

••

•

•

B

B

B

B

B

B

B

A

A

A

A

A

A

A

•• LH DRIVE

•

• RH DRIVE

••

TELESCOPIC 'OUT' PORT RELIEF (IF EQUIPPED)

••

••

STICK 'OUT' PORT RELIEF

PUMP 2

MAIN CONTROL VALVE 12.7

•• MAIN BOOM 'UP' PORT RELIEF

•• SWING

Tigercat H822C/LH830C Harvester 5. Place ANTI-STALL switch in OFF position.

6. Turn port relief valve adjusting screws for functions being set fully IN (clockwise). Do not overtighten or breakage will result.

7. With the aid of an assistant, bottom out the cylinder of the function being set and adjust L.S. pressure relief valve on Linde main valve manifold to 4700 psi on pressure gauge at 'P' port. Tighten locknut on adjusting screw.

MAIN BOOM PORT RELIEFS: NOTE: When making these relief adjustments, the upper should be positioned with the boom in the straight ahead position between the tracks.

WARNING When adjusting the port relief valves, the boom will fall if the relief adjusting screw is unscrewed (counterclockwise) out too far.

8. With an assistant holding R.H. joystick in MAIN BOOM UP position (fully extended), loosen locknut on the main boom UP port relief valve cartridge and slowly unscrew adjusting screw (counterclockwise) until oil can be heard (hissing noise) flowing through the relief valve or engine begins to lug slightly.

Boom functions 13. Slowly raise setting (clockwise) until hissing noise stops or until engine stops lugging.

NOTE: Observe the pressure gauge at 'P' port when making these adjustments, it will fall and rise as the adjusting screw is being turned and should show 4700 psi as the hissing sound begins to subside or until engine stops lugging.

14. Tighten locknut on adjusting screw taking care NOT to turn the adjusting screw at the same time.

15. Check setting again by ensuring that the hissing noise is still absent after tightening the locknut.

STICK AND TELESCOPIC PORT RELIEFS 16. Repeat steps 8 thru' 15 to set the port relief valves for the STICK 'IN' and 'OUT' and the TELESCOPIC 'OUT' and 'IN' functions.

17. Readjust L.S. pressure relief valve on Linde main valve manifold to read 4300 psi on pressure gauge at 'P' port (4000 psi at 'LS' port). Refer to SET LOAD SENSE RELIEF VALVE in SECTION 4 of THIS MANUAL. 18. Stop engine, remove all gauges and reinstall plugs and caps.

9. Slowly raise setting (clockwise) until hissing noise stops or until engine stops lugging.

NOTE: Observe the pressure gauge at 'P' port when making these adjustments, it will fall and rise as the adjusting screw is being turned and should show 4700 psi as the hissing sound begins to subside or until engine stops lugging.

10. Tighten locknut on adjusting screw taking care NOT to turn the adjusting screw at the same time.

11. Check the setting again by ensuring that the hissing noise is still absent after tightening the locknut.

12. With an assistant holding R.H. joystick in MAIN BOOM DOWN position (fully retracted), loosen locknut on the main boom DOWN port relief valve cartridge and slowly unscrew adjusting screw (counterclockwise) until oil can be heard (hissing noise) flowing through the relief valve or engine begins to lug slightly.

12.8

Tigercat H822C/LH830C Harvester

Boom functions

ADJUST OIL FLOW TO CYLINDERS (CYLINDER CYCLE TIMES)

STICK BOOM CYLINDER; 8. Repeat steps (5), (6) and (7) using STICK BOOM joystick lever.

NOTE: Constant loosening and tightening of the locknut (sealnut) on the adjusting screws will eventually cause the seal in the nut to break down and leak. Because of this it is best to keep the adjusting procedure brief.

TELESCOPIC CYLINDER; NOTE: Before the TELESCOPIC cylinder cycle times can be recorded, the rod end flow control adjusting screw must first be set correctly.

1. Ensure hydraulic oil is at operating temperature.

See TELESCOPIC CYLINDER (ROD END) FLOW ADJUSTMENT in THIS SECTION.

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

9. Repeat steps (5), (6) and (7) using TELESCOPIC controls.

3. From inside the cab close and latch the front door and press the PILOT RESET switch to activate the pilot system.

** When extending or retracting cylinders to record the time, stop the cylinder just before it gets to the end of it's stroke rather than let it bottom out and impose unnecessary loads on the cylinder parts and boom structures.

4. Place ANTI-STALL switch in OFF position.

MAIN BOOM CYLINDER(S); 5. Fully retract cylinder(s).

6. Place MAIN BOOM joystick lever in 'FULL UP' position and fully ** extend cylinders. Record cycle time from stop to stop.

7. Place MAIN BOOM joystick lever in 'FULL DOWN' position and fully ** retract cylinders.

Record cycle time from stop to stop.

TELESCOPIC 'IN' PORT RELIEF (IF EQUIPPED)

CONTROL VALVE MANIFOLD

STICK 'IN' PORT RELIEF

HIGH PRESSURE LIMITING CONTROL

FLOW TANK ADJUSTING PORT 'T3' SCREW FOR PORT 'A' (TYPICAL)

MAIN BOOM 'DOWN' PORT RELIEF

• •

•

822-D63

••

•

•

B

B

B

B

B

B

B

A

A

A

A

A

A

A

•• LH DRIVE

•

• RH DRIVE

••

TELESCOPIC 'OUT' PORT RELIEF (IF EQUIPPED)

••

••

STICK 'OUT' PORT RELIEF

PUMP 2

MAIN CONTROL VALVE 12.9

•• MAIN BOOM 'UP' PORT RELIEF

•• SWING

Tigercat H822C/LH830C Harvester TYPICAL CYLINDER CYCLE TIMES The chart below lists typical cylinder cycle times and is based on recommended factory settings and with hydraulic oil at operating temperature. It should be noted that over adjusting to provide faster cycle times will increase the stress on boom components and the hydraulic system.

To adjust cycle times; Loosen locknut on spool adjusting screw on main control valve and turn adjusting screw IN (clockwise) to slow down and OUT (counterclockwise) speed up. Tighten locknut on adjusting screw and re-check times.

Boom functions PORT CONNECTIONS: The 'A' ports (bottom ports) are connected to the base end of the cylinders and the 'B' ports (top ports) are connected to the rod end of the cylinders.

To adjust the flow rate at 'A' PORTS, adjust spool travel stop adjusting screw located at TOP of valve and vice-versa for 'B' ports. See figure 822D63.

BOOM FUNCTIONS MAIN BOOM UP MAIN BOOM DOWN BOOM OUT BOOM IN TILT FORWARD TILT BACK TELESCOPIC STICK OUT TELESCOPIC STICK IN

CYCLE TIMES - 822, H822, L830, LH830 ER BOOM TIME W/STD TILT TIME W/4-LINK 5 sec.

5 sec.

8 sec.

8 sec.

4.5 sec.

4.5 sec.

4.5 sec.

4.5 sec.

3.8 sec.

4.0 sec.

3.8 sec.

4.0 sec.

4 sec. n/a 4 sec. n/a

BOOM FUNCTIONS MAIN BOOM UP MAIN BOOM DOWN STICK BOOM OUT STICK BOOM IN TILT FORWARD TILT BACK TELESCOPIC STICK OUT TELESCOPIC STICK IN

CONVENTIONAL BOOM TIME WITH HEAD TIME NO HEAD 7.0 sec.

5.4 sec.

8.9 sec.

16.0 sec.

6.1 sec.

5.3 sec.

5.9 sec.

10.9 sec.

4.0 sec.

3.8 sec.

3.8 sec.

3.8 sec. n/a n/a n/a n/a

12.10

TIME NO HEAD 5 sec.

12 sec.

4.5 sec.

4.5 sec.

3.8 sec.

3.8 sec.

4 sec.

4 sec.

Tigercat H822C/LH830C Harvester TELESCOPIC CYLINDER (ROD END) FLOW AND SPEED ADJUSTMENT This adjusting screw restricts the flow of oil leaving the rod end of the TELESCOPIC cylinder when telescoping OUT (extending).

• •

• TOP OF CONTROL VALVE MANIFOLD

ADJUSTING SCREW

870B-D16

Boom functions 6. Raise boom and place the telescopic boon in the fully TELELSCOPIC IN (cylinder fully retracted).

7. Loosen locknut on restriction adjustment screw. While holding telescopic control in the fully IN position, observe pressure gauge and record the TELESCOPIC boom travel speed from stop to stop**. Use the restriction adjustment screw to adjust the speed and use the spool travel stop adjustment on the main control valve to maintain 800-1000 psi pump pressure.

If the TELESCOPIC speed is too fast, screw restriction adjustment screw IN. If the TELESCOPIC speed is too slow, screw the restriction adjustment screw OUT.

TELESCOPIC 'OUT' PILOT END CAP

If the pump pressure reading is too low increase flow by screwing TELESCOPIC spool travel stop adjusting screw (bottom adjuster) OUT. Or if the pressure is too high, decrease the flow by screwing the adjusting screw IN.

FLOW CONTROL ADJUSTING SCREW When correctly set, this restriction will prevent cylinder damage.

1. Ensure hydraulic oil is at operating temperature.

LINDE MAIN VALVE MANIFOLD

NOTE: The Telescopic restriction and (to a lesser extent) the spool travel stop adjustment both affect the TELESCOPIC OUT speed. Similarly, the TELESCOPIC restrictor has a small affect on the pump pressure. Alternate between adjustments making moderate changes until the desired speed and pressure ranges are achieved.

HIGH PRESSURE LIMITING CONTROL

• ••

••

•• L.S. GAUGE TEST PORT

8. Tighten locknut on restriction adjustment screw taking care NOT to turn the adjusting screw at the same time.

9. Check the pressures again after tightening the locknut.

'P' GAUGE TEST PORT

10. Stop engine and remove gauge.

LS PRESSURE ADJUSTMENT P2

•• 103-17A

LINDE MAIN VALVE MANIFOLD

2. Connect a 0-5,000 psi pressure gauge on 'P' test port of Linde main valve manifold.

3. Start engine and place throttle control in FULL. 4. From inside the cab close and latch the front door and press the PILOT RESET switch to activate the pilot system.

5. Place ANTI-STALL switch in OFF position.

12.11

Tigercat H822C/LH830C Harvester TELESCOPIC BOOM ELECTRONIC ADJUSTMENT PROCEDURE Adjustments to the telescopic boom through the PROPERTIES MENU of the IQAN control system electronically adjust the performance of these functions to suit operating conditions . Refer also to COMPUTER ~ (PROPERTIES) MENU OPERATION in SECTION 6 of THIS MANUAL.

Boom functions 4. Press the bottom of the MENUS SWITCH to display the IQAN-MDM diagnostic and function adjustment menus.

PROCEDURE: For best results ensure hydraulic oil is at operating temperature before doing any adjustments. In addition, the function(s) being adjusted should be operated at a rate similar to normal operation to ensure that the coil is at a typical operating temperature. Due to the nature of the electrical connections some signals will vary with temperature and should always be adjusted at normal operating temperature to improve the accuracy of adjustments for operating conditions and operator preference.

822C-56

Press Escape button then scroll UP/DOWN to display PROPERTIES. Press OUTPUTS (F2) and use the UP/DOWN scroll buttons to scroll though the menus to PWM OUT. Press SELECT(F1) to go to SELECT. FUNCTION menu.

1. Ensure no other personnel are in the area during this procedure.

2. Start engine and set throttle speed to HIGH IDLE. 3. Close cab door and press PILOT RESET switch to activate pilot system.

630C-105B

A SELECT FUNCTION screen will appear.

Use the UP/DOWN scroll buttons to scroll through to the Telescopic function.

12.12

Tigercat H822C/LH830C Harvester

Boom functions

H822C-09

H822C-09

5. At the Tele-Attachmt screen press SELECT(+) (F1).

You are then able to scroll through the following adjustments: • • • • •

H822C-10

Min MR Max MR Startslope Stopslope Fine Control

Each SELECT FUNCTION screen displays the current reading for MR (modulation ratio) with an option of selecting SELECT (+) (F1) or SELECT (-) (F2) function directions. Selecting positive (+) controls the valve spool shift in one direction, and negative (-) controls the valve spool shift in the other direction.

Refer to the ADJUSTABLE FUNCTIONS chart below for function direction information and factory default setting information for each of the adjustable functions. The following example demonstrates the adjustment procedure for the telescopic boom function.

ADJUSTABLE FUNCTIONS H822C/LH830C Function

Fa ctory de fa ult va lue s

PW M OUT Pum p2 - A ttac hmt 3 Tele-A ttachmt 2

(+ ) not used ex tend

(-) on retrac t

Min MR (%) 30 50

12.13

Ma x MR (%) 100 95

Sta rt slope (Ms) 500 100

Stop slope (Ms) 250 250

Fine control (%) 0 0

Tigercat H822C/LH830C Harvester

Boom functions

DETERMINE MINIMUM MR VALUE

H822C-12 H822C-11

Temporarily reduce the maximum MR value to zero.

At the MAX MR screen press SELECT (F1).

Use the SCROLL DOWN button to reduce the value to zero. Do NOT press OK (F1).

6. Temporarily set the minimum MR value to zero.

At the MIN MR screen press SELECT (F1).

Use the SCROLL DOWN button to reduce the value to zero and press OK (F1).

H822C-12X H822C-11X

Activate and hold the function being adjusted, in the direction being adjusted. (In this example, (+) Tele-Attachmt, operate the telescopic EXTEND function.)

Press ESCAPE button to return to the SELECT FUNCTION screen. (This step is necessary to ensure that the zero setting is recognized by the computer control system. If this step is skipped the control system will not allow the operator to lower the MAX MR setting to zero as required for this procedure)

H822C-13

There should be no movement (notice that the value shown in brackets at the top right of the screen indicates the actual output to the control valve). Begin increasing the Max MR value, while still holding the function. Use the scroll UP button.

H822C-09

Select the same function and direction again.

Scroll to the Max MR adjustment screen.

12.14

Tigercat H822C/LH830C Harvester

Boom functions ADJUST MAXIMUM MR

H822C-13X H822C-12B

Once the function just begins to move, press OK (F1). Release the function control. and make note of (or remember) this number.

7. The maximum MR is an adjustment of the maximum function speed.

Scroll to the MAX MR adjustment screen.

Increase the maximum MR value to the desired level for maximum function speed.

At the MAX MR screen press SELECT (F1).

Use the SCROLL UP button to increase the value, press F1 (OK)]

H822C-11X

Scroll down to the MIN MR adjustment screen and adjust the MIN MR value to be the number determined above.

At the MIN MR screen press SELECT (F1).

Use the SCROLL UP button to increase it to the number determined above and press OK (F1).

H822C-12

For the telescopic function this value is typically about 95% MR, however will vary slightly from machine to machine (due to slight differences in the coils, spool cut on the valve, and various manufacturers) – and of course, the largest factor in this case is operator preference.

H822C-11

The MIN MR setting is now adjusted to the proper level. This level provides just enough spool shift for the function to begin to move.

For the telescopic function this value is typically about 50% MR, however will vary slightly from machine to machine (due to slight differences in the coils, spool cut on the valve, and various manufacturers)

12.15

Tigercat H822C/LH830C Harvester

Boom functions Use UP/DOWN buttons to scroll to STOP SLOPE. Press SELECT (F1).

Use UP/DOWN buttons to set to desired value and press OK (F1) to save new value.

Note that an excessively long start slope can give the operator a poor feel for the head, as if the function is always overshooting its intended target. The purpose for making this adjustable is to accommodate the various preferences of different operator’s for the “feel” of functions.

H822C-15

ADJUST START SLOPE 8. The start slope is an adjustment for the amount of time that it takes for the function to ramp from the Minimum value to the Maximum value. If either the min MR or max MR values are improperly adjusted, the startslope may not produce the desired results.

The standard setting for the start slope on the telescopic function is 100ms (1/10 of a second).

Increasing this value will make the start acceleration smoother.

Decreasing this value will make the start acceleration more harsh (additional stresses ).

Use UP/DOWN buttons to scroll to START SLOPE. Press SELECT (F1).

Use UP/DOWN buttons to set to desired value and press OK (F1) to save new value.

H822C-16

ADJUST FINE CONTROL 10. In this H822C/LH830C application, the fine control is not typically used. Fine control is a feature that becomes very useful when using a proportional type input. In this case, the standard inputs from the joystick are all digital switches.

Fine Control should be set to 0% for this application.

11. Repeat steps 6 to 10 for the (-) TeleAttachment function.

H822C-14

ADJUST STOP SLOPE 9. The stop slope is an adjustment for the amount of time that it takes for the function to ramp from the Maximum value to the Minimum value. If either the min MR or max MR values are improperly adjusted, the stopslope may not produce the desired results.

The standard setting for the stop slope on the telescopic function is 250ms (1/4 of a second).

Increasing this value will make the deceleration smoother.

Decreasing this value will make the deceleration more harsh (additional stresses ).

12.16

Tigercat H822C/LH830C Harvester

SECTION 13 - LEVELLING AUGUST 2006

CONTENTS - SECTION 13 CIRCUIT DIAGRAM ..................................................................................... 13.3 ENGINE ANTI-STALL ................................................... SEE ALSO SECTION 4 LEVELLING CONTROL VALVE .................................... SEE ALSO SECTION 4 LEVELLING SYSTEM DESCRIPTION ........................................................ 13.2 LOAD SENSING ..................................................................... SEE SECTION 9 LUBRICATING CYLINDERS AND PINS ................................. SEE SECTION 3 UNDERCARRIAGE ASSEMBLY, LEVELLING ............................................ 13.2

NOTE: COMPLETE INFORMATION IS NOT AVAILABLE AT THE TIME OF PRINTING, ADDITIONAL INFORMATION WILL BE ADDED TO THIS SECTION AT THE NEXT UPDATE.

Tigercat H822C/LH830C Harvester LEVELLING SYSTEM DESCRIPTION

Levelling is equipped with a counterbalance valve for crossline relief and load holding.

The levelling function is operated by thumb switches on the joysticks. The thumb switches provide input signals for the IQAN Control Module. The IQAN Control Module then transmits output signals to the XT2 and XP2 Modules and out to the electro-hydraulic spool actuators on the levelling control valve. The levelling control valve then directs oil to the two levelling cylinders.

NOTE: All tilt directions (left, right, forward and backward) in this section refer to direction of tilt when the operator is facing the front of the machine (toward the idler).

For additional information regarding SAFETY and OPERATING INSTRUCTIONS, Refer to SECTION 1 of THIS MANUAL and SECTION 2 in the OPERATOR'S MANUAL.

Two levelling cylinders are used to operate the levelling function. The left levelling cylinder retracts while the right cylinder extends to tilt LEFT. To tilt RIGHT, the right levelling cylinder retracts while the left cylinder extends. Both cylinders extend at the same time to tilt FORE or retract at the same time to tilt AFT. Each cylinder

ROTARY MANIFOLD LH LEVELLING CYLINDER

UNDERCARRIAGE

LEVELLING ASSEMBLY IDLER ASSEMBLY RH LEVELLING CYLINDER

•

•

•

•

• •

• •

•

• • •

DRIVE MOTOR

TRACK GUARDS 860-70

LOWER ROLLERS

•

INSPECTION COVERS

• •

TRACK GUARDS

TRACK DRIVE GEARBOX DRIVE SPROCKET

LEVELLING UNDERCARRIAGE ASSEMBLY

13.2

•

TRACK ASSEMBLY

Tigercat H822C/LH830C Harvester

822C-35

Levelling

LEVELLING CIRCUIT DIAGRAM 13.3

Tigercat H822C/LH830C Harvester

Levelling

13.4

Tigercat H822C/LH830C Harvester

SECTION 15 - SWING AUGUST 2006

CONTENTS - SECTION 15 ADJUST OIL FLOW TO SWING MOTOR(SWING MOTOR SPEED) ............. 15.7 CIRCUIT DIAGRAM ....................................................................................... 15.3 PARKING BOOM .......................................................................................... 15.5 SET SWING MOTOR SPEED ....................................................................... 15.7 SWING DRIVE SWING HYDRAULICS ............................................................................... 15.2 SET CROSSLINE RELIEF VALVES ...................................................... 15.6 SWING DRIVE GEARBOX LOWER BEARING LUBRICATION ............................................................. 15.5 LUBRICATION OF SWING PINION AND SWING BEARING ...................... 15.5 SUN GEAR INSTALLATION ...................................................................... 15.9 UPPER GEARING LUBRICATION ............................................................. 15.5 SWING MOTOR REMOVAL FROM GEARBOX ............................................ 15.8

Tigercat H822C/LH830C Harvester MOTOR

R.H. ROTATION

CROSSLINE RELIEF VALVES

•• •••

•

L.H. ROTATION

SWING BRAKE

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

ALTERNATE BRAKE RELEASE PORT 'Z' (PLUGGED)

STEEL DISC FRICTION DISC

FLUSHING PORT 'T'

1/16" DIA. ORIFICE CONNECTOR PORT 'U'

• ••

FLUSHING PORT 'U'

• •

••

• •

GEARBOX

CONNECTOR/ ORIFICE 0.062" DIA

• BRAKE RELEASE PORT 'Y'

•• 845B-D32

SWING DRIVE GEARBOX BK005-8

CROSS SECTION OF SWING BRAKE

SWING DRIVE -SWING HYDRAULICS

CONNECTOR/ ORIFICE 0.062" DIA

The swing function is controlled by the left joystick valve which sends proportional pilot signals to the main valve which, in turn, supplies oil to the swing motor.

SWING BRAKE

•

The swing motor is a piston motor with crossline relief valves mounted on the input end. The crossline relief valves provide a cushion to the high forces that occur during start and stop of the swing.

FROM BRAKE RELEASE PILOT

Power is transmitted from the motor to a double reduction planetary gearbox which has a springapplied, hydraulic-release, multi-disc brake on the input shaft. This brake is normally ON. Placing the swing brake switch in the OFF position energizes the swing brake solenoid pilot valve on the pilot manifold and allows pilot oil pressure to flow to the swing brake via port 'Y', to release the swing brake.

•

• CROSS LINE RELIEF VALVES

PRESSURE LINES FROM MAIN CONTROL VALVE

WARNING Never drive machine with swing brake applied. If attachment makes contact with an immoveable object, forces could damage swing drive gearbox.

GEARBOX FLUSHING OIL SUPPLY FROM OIL COOLER BYPASS/ RETURN MANIFOLD

830-16

Port 'Z' contains an internal orifice but the port is plugged and not used.

In the event that electrical power to the solenoid pilot valve or hydraulic pressure to the pilot valve is lost, the swing brake will engage (ON) automatically.

15.2

SWING DRIVE MOTOR SCHEMATIC

Tigercat H822C/LH830C Harvester

Swing

SWING DRIVE CIRCUIT 822C-31

15.3

Tigercat H822C/LH830C Harvester

Swing

15.4

Tigercat H822C/LH830C Harvester

Swing

LUBRICATION OF SWING DRIVE GEARBOX

HOIST CYLINDER FULLY COLLAPSED HEAD

UPPER GEARING LUBRICATION

•

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'.

••

•• TIP OF STICK BOOM FULLY SUPPORTED

H822-01

NOTE: FULLY RETRACT TELESCOPIC STICK BOOM IF EQUIPPED

PARKING BOOM FIG.5

HOIST CYLINDER FULLY RETRACTED

• LUBE FITTINGS

•• •

TIP OF STICK BOOM FULLY SUPPORTED 830-08

PARKING BOOM. FIG.6

LUBRICATION OF SWING PINION AND SWING BEARING

LH830-31

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

•

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

250 24

20065A R0

The lube fittings are remotely mounted for easy access.

Using a hand grease gun, pump 5 shots of grease into each grease fitting. DO NOT OVERGREASE, make sure machine is warmed up in winter or lower seal can be damaged. 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

•• 250 8

20065A R0

860C-032

SWING PINION & BEARING FITTINGS To lubricate the swing bearing, apply 10 shots grease while swinging every 24 hours to one of the two grease fittings located on the seat pedestal in the operator's cab. To lubricate the swing pinion (or teeth) apply 10 shots grease every 8 hours while swinging to the other grease fitting located on the seat pedestal. The grease fittings are clearly labelled.

For lubrication schedule, refer to SCHEDULED MAINTENANCE in SECTION 3 of THIS MANUAL.

15.5

Tigercat H822C/LH830C Harvester

Swing

SET CROSSLINE RELIEF VALVES 1. Ensure that the hydraulic oil is at operating temperature.

2. Install a 0-5000 psi pressure gauge in the 'L.S.' test port on the back of the main valve manifold.

LINDE MAIN VALVE MANIFOLD

HIGH PRESSURE LIMITING CONTROL

• •

••

•• L.S. GAUGE TEST PORT

'P' GAUGE TEST PORT

103-17A MAIN VALVE MANIFOLD 3. Start engine and place throttle control in FULL.

4. Turn anti-stall switch OFF and the swing brake ON. 5. While operating the L.H. joystick lever fully in both the LEFT and RIGHT directions, loosen locknut on each crossline relief adjusting screw and turn adjusting screw until the reading on pressure gauge in 'L.S.' test port is 3000 psi for each direction.

If pressure gauge is installed in 'P' test port, reading on gauge would be 3300 psi.

CROSSLINE RELIEF VALVES L.H. ROTATION

•• ADJUSTING SCREWS 111-6

••••

R.H. ROTATION

• • •• • CROSSLINE RELIEF

6. Retighten locknut on each adjusting screw taking care not to disturb adjusting screw and recheck pressure setting before removing pressure gauge.

7. Stop engine, remove gauge and reinstall plug.

15.6

Tigercat H822C/LH830C Harvester

Swing

ADJUST OIL FLOW TO SWING MOTOR (SWING MOTOR SPEED)

SPOOL TRAVEL STOP • 19MM WRENCH • 6MM ALLEN KEY

NOTE: Constant loosening and tightening of the locknut (sealnut) on the adjusting screws will eventually cause the seal in the nut to break down and leak. Because of this it is best to keep the adjusting procedure brief.

PILOT END CAP

•

MAKE UP VALVE

1. Ensure that the hydraulic oil is at operating temperature.

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

•

MAIN VALVE BODY

3. Raise attachment off ground and place L.H. joystick lever in 'FULL LEFT' position and rotate the upper. Record time for one complete revolution.

• 90919-1

4. Repeat step (3) with L.H. joystick lever in 'FULL RIGHT' position.

MAIN VALVE SPOOL TRAVEL STOP

5. To adjust swing speed; (Refer to main valve photo and fig. 90919-1) Loosen locknut on spool travel stop adjusting screw and turn adjusting screw IN (clockwise) to slow down and OUT (counterclockwise) speed up. Tighten locknut on adjusting screw and re-check times.

The recommended factory setting is between 6 and 7 RPM. It should be noted that over adjusting to provide a faster swing speed increases the stress on boom components and increases the heat load in the hydraulic system.

CONTROL VALVE MANIFOLD

•

HIGH PRESSURE LIMITING CONTROL

••

FLOW ADJUSTING SCREW FOR PORTS ON 'A' SIDE OF VALVE (TYPICAL)

FLOW ADJUSTING SCREW FOR SWING LEFT

•

•

•• B

B

B

B

B

B

B

A

A

A

A

A

A

A

••

••

•

•

•

••

•• LH DRIVE 822-D63

RH DRIVE

TELESCOPIC BOOM

STICK

PUMP 2

MAIN CONTROL VALVE 15.7

MAIN BOOM

FLOW ADJUSTING SCREW FOR SWING RIGHT

TANK PORT 'T3'

•

Tigercat H822C/LH830C Harvester

•

SWING DRIVE MOTOR M16 HEX. HD. RETAINING BOLTS TORQUE TO 150 LBF/FT (205 NM) SWING BRAKE ASSY.

CROSS LINE RELIEF HOUSING

•

Swing PROCEDURE: 1. Remove the swing drive motor from the swing drive gearbox.

SUN GEAR M12 HEX. HD. RETAINING BOLTS TORQUE TO 62 LBF/FT

• •

ALIGNMENT MARKS

•

••

GEARBOX

• •

AQ009-4

2. Make alignments mark on the sun gear and brake housing to facilitate reassembly of the sun gear back into the swing drive gearbox.

These alignment marks should guarantee that both the brake disc and the first stage planetary gear teeth will be in alignment with the sun gear splines and bottom gear teeth, provided nothing has moved.

SWING PINION

• BK010-2

SWING DRIVE ASSEMBLY

DISASSEMBLY AND ASSEMBLY OF SWING MOTOR FROM GEARBOX When the swing drive motor is removed from the swing drive gearbox for inspection or repair, there is a possibility that the sun gear may not mesh properly with the first stage planetary gears when it is reinstalled. This will cause premature failure of the swing drive gearbox.

Installing the sun gear involves lining up all of the brake discs so that the outer splines on the sun gear can slide through the brake discs allowing the bottom gear teeth to mesh properly with the first stage planet gears.

BRAKE HOUSING WITH MOTOR REMOVED

3. Remove the sun gear from the swing drive gearbox and inspect the gear teeth at the bottom of the sun gear for abnormal damage or wear.

If there is no visible damage to the gear teeth, proceed to step (6). If there is visible damage to the sun gear, it must be replaced, proceed to step (4).

4. If the sun gear in step (3) has visible signs of damage, then the first stage planetary gears must also be inspected. Remove the brake assembly and inspect the first stage planetary gears for visible damage. If there is no visible damage, proceed to step (5). If there is visible damage to the first stage planetary gears, then the entire swing drive gearbox should be replaced.

5. Assuming that there is no visible damage to the first stage planetary gears, reassemble the brake assembly back onto the swing drive gearbox and secure it by reusing the six M12x30mm hex head bolts. Torque each hex head bolt to 62 lbf/ft (84 Nm).

15.8

Tigercat H822C/LH830C Harvester M12 HEX. HD. RETAINING BOLTS

SUN 'O' RING BRAKE HOUSING GEAR

Swing

MOTOR MOUNTING SURFACE

MOTOR

• •

•

• 1-5/16" ± 1/16"

• • 'O' RING

• • • BRAKE DISCS

FIRST STAGE PLANETARY GEARS (3)

• BOTTOM GEAR TEETH ON SUN GEAR

BK005-6

VERIFY SUN GEAR IS FULLY INSTALLED 6. Reinstall the sun gear into the swing drive gearbox using the alignment marks made in step (2). Verify that the sun gear is properly and fully engaged into the swing drive gearbox, i.e.; That the outer splines on the sun gear have passed through all of the brake discs.

This can be done by measuring the distance between the swing motor mounting surface and the top of the flat surface of the sun gear (1 5/16” ± 1/16”).

7. Verify that the O-ring is properly seated and secured on the swing motor. If there is any difficulty in securing it in place, use a small amount of petroleum jelly on the O-ring for assistance.

8. Center the spacer ring on top of the sun gear and install the swing drive motor. Torque the two M16 mounting bolts to 150 lbf/ft (205 Nm).

15.9

Tigercat H822C/LH830C Harvester

Swing

15.10

Tigercat H822C/LH830C Harvester SECTION 17 - ATTACHMENT DRIVE AUGUST 2006

CONTENTS - SECTION 17 ATTACHMENT CONTROL VALVES ........................................................... 17.4 ATTACHMENT PILOT MANIFOLD .......................................................... 17.6 MAIN CONTROL VALVE, PUMP 2 ........................................................... 17.7 PILOT SUPPLY MANIFOLD ..................................................................... 17.4 PUMP 1 VALVE SECTION ....................................................................... 17.4 ATTACHMENT HEAD .............. SEE ORIGINAL MANUFACTURERS MANUAL CIRCUIT DESCRIPTION ............................................................................. 17.8 CIRCUIT DIAGRAM ..................................................................................... 17.9 COMPUTER CONTROL SYSTEM (IQAN MDM DISPLAY) ELECTRONIC ADJUSTMENT PROCEDURE, PUMP 2 ......................... 17.14 ADJUSTABLE FUNCTIONS CHART .................................................. 17.15 ENGINE ANTI-STALL .................................................................................. 17.7 LOAD SENSING .......................................................................................... 17.7 MAIN CONTROL VALVE ............................................................................. 17.7 PRESSURE SETTINGS ............................................................................ 17.10 PUMP 1 (ATTACHMENT PUMP) ................................................................ 17.2 PUMP 2 (MAIN PUMP) ........................................................... SEE SECTION 4 PUMP 2 ELECTRONIC ADJUSTMENT PROCEDURE ............................. 17.14 SET PUMP 2 PORT RELIEF VALVES ..................................................... 17.12

Tigercat H822C/LH830C Harvester

Attachment drive

PUMP 1 (ATTACHMENT PUMP) Pump 1 (attachment pump) is an axial-piston variable displacement pump controlled by a pressure compensator. The pressure compensator is mounted directly onto the pump and has a STANDBY pressure adjustment and a P.O.R. adjustment.

The STANDBY adjusting screw is screwed completely in and is NOT used for this application. The P.O.R. is adjusted to operate at 3600 psi.

Until system pressure reaches 3600 psi, the compensator valve will be in the "return" position blocking oil flow to the swashplate control piston leaving the pump at maximum displacement.

ATTACHMENT PUMP

822-17X

Pump 1 is mounted and driven off the end of pump 2 (main pump) attached to the bell housing of the engine.

PUMP 1 (ATTACHMENT PUMP) SCHEMATIC

A separate fixed displacement pump is mounted on the back of pump 1 for the attachment rotate and cooling fan functions.

ROTATE/FAN PUMP (DOUBLE GEAR PUMP)

PUMP 1 PUMP 1 (ATTACHMENT ) PRESSURE (PISTON PUMP) COMPENSATOR

PILOT SUPPLY MANIFOLD

•• •• ••

•• •• •• ••

PUMP 2 PUMP 2 (MAIN PUMP) CONTROLLER (PISTON PUMP) (LS. CONTROL)

••

PILOT FILTER

••

COOLING FAN CONTROL VALVE PILOT SUPPLY VALVE

822C-136

HYDRAULIC PUMPS 17.2

Tigercat H822C/LH830C Harvester

•

Attachment drive

PUMP 1 PRESSURE COMPENSATOR VALVE

INPUT SHAFT CONNECTION TO PUMP 2 (MAIN PUMP)

•

AP098

PUMP 1 (ATTACHMENT PUMP) ~ SIDE VIEW

17.3

Tigercat H822C/LH830C Harvester

Attachment drive

ATTACHMENT CONTROL VALVES

PUMP 1 VALVE SECTION The pump 1 valve section is part of the attachment valve, , located above the Linde main valve bank. It consists of an open center spool section and an inlet section containing a relief valve.

PILOT SUPPLY MANIFOLD

•• PUMP 1 SOLENOID

Two other spool sections along with one mid inlet section control other attachment functions. The first section controls the attachment rotate function and the second has no factory installed standard function. Each spool section is pilot operated.

••

An outlet section directs return oil back to tank.

PILOT SUPPLY MANIFOLD

822C-136

For further description of attachment valve refer to SECTION 20 of THIS MANUAL.

PILOT SUPPLY MANIFOLD The pilot supply manifold, is located in the pump compartment.

PUMP 1 VALVE OPERATING DESCRIPTION Oil (system pressure) enters the end inlet section of the attachment valve. When the spool is centered (at rest) the oil is allowed to pass through the pump 1 spool section into a common tank passage of the rotate and no function spool sections and back to tank via the outlet section.

From the tank passage, the oil leaves the valve through the outlet section and returns to tank.

A pump 1 electrical signal from the attachment control module (wire 442) is sent to the IQAN computer control system (VOLTAGE IN - Pump 1 Input). The IQAN computer control system sends an electrical signal (PWMOUT - Pump 1 Attachment) out to the pump 1 solenoid in the pilot supply manifold. When energized the pump 1 solenoid shifts the spool and directs pilot oil to one end of the spool section of the pump 1 valve.

The pump 1 spool section has a self centering, three position spool which is open centered. A spring in the spool end cap holds the spool in the center neutral position.

Refer to SECTION 5 of this manual for a more complete description the pilot supply manifold and its operation.

RELIEF VALVE PORT 'A'

SEAL GROOVES

A

RELIEF VALVE PORT 'B'

B

SPOOL CENTERING SPRINGS

•

• • •

•

•

•

• •

•

• PILOT END CAP

AT047IL2

•

•

•

• SPOOL TANK PASSAGE

PARALLEL PASSAGE

LOAD CHECK VALVE

THRU' NEUTRAL PASSAGE

WORK PORT BRIDGE

CROSS SECTION OF SPOOL SECTIONS 17.4

TANK PASSAGE

PILOT END CAP

Tigercat H822C/LH830C Harvester

Attachment drive

The spool is shifted by pilot pressure being applied to one end of the spool from the pilot valve. Shifting the spool directs oil from pump 1 to the attachment motor.

The relief valve installed in the pump 1 inlet section of the attachment valve is set higher than the pump1 (attachment pump) compensator pressure setting and will limit the pressure should a pump regulator or "swashing" failure occur.

The pump 1 spool section is equipped with port relief valves which are NOT used in this application. These port relief valves must be screwed IN completely for proper operation of the attachment circuit.

The relief valve diverts oil to tank via the tank passages in the spool sections and the outlet section of the attachment valve. It also functions as an anti-cavitation relief valve.

PILOT END CAPS

PUMP 1 SECTION

MAIN (MID) RELIEF VALVE

• GAUGE TEST PORT (FOR PUMP 1 ONLY) OUTLET SECTION

••

•• PUMP1

•• ••

ROTATE

•

•

MID INLET SECTION

••

GAUGE TEST PORT (FOR ROTATE) END INLET SECTION (PUMP 1)

H822C-17

ATTACHMENT CONTROL VALVE (WITH ROTATE SECTION) 17.5

Tigercat H822C/LH830C Harvester

Attachment drive

ATTACHMENT PILOT MANIFOLD The attachment pilot manifold is located in the hydraulic tank compartment at the rear left corner of the upper frame.

The attachment pilot manifold supplies pilot oil to the pump 2 valve section.

A pump 2 electrical signal from the attachment control module (wire 443) is sent to the IQAN computer control system (VOLTAGE IN - Pump 2 Input). The IQAN computer control system sends an electrical signal (PWMOUT- Pump 2 Attachment) out to the pump 2 solenoid on the attachment proportional pilot manifold. When energized the pump 2 solenoid in the attachment pilot manifold valve to shifts the spool and directs pilot oil to one end of to one end of the pump 2 valve section.

Refer to SECTION 5 of this manual for a more complete description the pilot supply manifold and its operation.

822C-137

17.6

ATTACHMENT PILOT MANIFOLD

Tigercat H822C/LH830C Harvester

Attachment drive

MAIN CONTROLVALVE

LOAD SENSING\ENGINE ANTI-STALL

The pump 2 spool section has port relief valves with anticavitation features.

The pump 2 hydraulics along with the boom, swing, track drive and levelling circuits are all under the control of the load sensing system incorporated into the main hydraulic circuit.

These protect the circuit from abnormally high pressures induced by the load.

For a full description of the main hydraulic system including load sensing, the main pump and the main control valve, Refer to SECTION 4 in THIS MANUAL.

Adjustable spool travel stops on each pilot end cap of the spool section can be adjusted to limit spool travel and control the flow of oil from pump 2 to the attachment.

For a full description of the engine anti-stall, Refer to SECTION 9 in THIS MANUAL.

To adjust the relief valves, Refer to SET PUMP 2 PORT RELIEF VALVES in THIS SECTION.

For a full description of the pilot system, refer to SECTION 5 in THIS MANUAL.

The IQAN computer controls the speed at which the spools are shifted to reduce harsh starts and stops. The IQAN computer can also be used to adjust pump 2 if required.

CONTROL VALVE MANIFOLD

HIGH PRESSURE LIMITING CONTROL

•

FLOW ADJUSTING FLOW ADJUSTING SCREW FOR SCREW FOR PUMP 2 PORTS ON 'A' SIDE OF VALVE (TYPICAL)

TANK PORT 'T3'

••

• ••

• B

B

B

B

B

B

B

A

A

A

A

A

A

A

•• LH DRIVE 822-D63

• RH DRIVE

•• TELESCOPIC BOOM

STICK

PUMP 2

MAIN CONTROL VALVE 17.7

••

••

••

MAIN BOOM

•• • SWING

Tigercat H822C/LH830C Harvester ATTACHMENT CIRCUIT DESCRIPTION Oil flow to the attachment motor is supplied primarily by Pump 1 (attachment pump) and additional flow is made available on demand by Pump 2 (main pump). The signals to operate both Pump 1 and Pump 2 are sent via the attachment control module. The control module and motor type will vary depending on the manufacturer and model of attachment in use.

For explanation of attachment control module and motor, refer to attachment manufacturers manual.

Pump 1 is a variable displacement pump. Refer also to PUMP 1 in THIS SECTION. Oil flow from Pump 1 to the attachment motor is controlled by the pump 1 section of the attachment control valve. The pump 1 valve section is pilot operated. A relief valve is installed in the inlet section of the attachment valve.

A solenoid operated pilot valve located in the pilot supply manifold controls the flow of pilot oil to the end of the spool in the pump 1 valve section.

A pump 1 electrical signal from the attachment control module (wire 442) is sent to the IQAN computer control system (VOLTAGE IN - Pump 1 Input). The IQAN computer control system sends an electrical signal (PWMOUT - Pump 1 Attachment) out to the pump 1 solenoid in the pilot supply manifold.

When there is no pump 1 signal (pump 1 OFF), the solenoid operated pilot valve is in the deenergized position preventing pilot oil flow from shifting the spool in the pump 1 valve section.

With the pump 1 valve section spool in this neutral position, the hydraulic oil is directed through the open centre of the attachment valve and back to tank. This prevents the Pump 1 from generating system pressure, it also causes the Pump 1 to shift to maximum displacement.

When there is a pump 1 signal from the attachment control module ( pump 1 ON) via the IQAN computer control system, the solenoid operated pump 1 pilot valve will be placed in the energized position directing pilot oil to shift the spool in the pump 1 valve section. This will direct oil from the Pump 1 to the attachment motor.

Attachment drive control valve. The pump 2 section of the main control valve is pilot operated.

A solenoid on the attachment proportional pilot manifold controls the flow of pilot oil to the pump 2 section of the main control valve.

A pump 2 electrical signal from the attachment control module (wire 443) is sent to the IQAN computer control system (VOLTAGE IN - Pump 2 Input). The IQAN computer control system sends an electrical signal (PWMOUT- Pump 2 Attachment) out to the pump 2 solenoid on the attachment proportional pilot manifold.

When there is no pump 2 signal (pump 2 OFF), the solenoid operated pilot valve is in the deenergized position preventing pilot oil flow from shifting the spool in the pump 2 valve section.

When there is a pump 2 signal from the attachment control module ( pump 2 ON) via the IQAN computer control system, the solenoid operated pump 2 pilot valve will be placed in the energized position directing pilot oil to shift the spool in the pump 2 valve section. This will direct oil from the Pump 2 to the attachment motor.

NOTE: The attachment will not operate with pilot system OFF. The attachment will not function properly with low pilot pressure.

If the engine has been turned off or the pilot shut off system tripped (door opened) with the saw switch left in the ON position, the attachment will not start up when the engine is restarted or the door closed. In this case press the PILOT RESET button and turn the saw switch OFF and then ON. IMPORTANT: To maximize pump and motor life, do not shut the engine off until the attachment has come to a complete stop.

The attachment motor adjusts its displacement in response to system pressure, this is only true with variable displacement motors.

Return oil from the attachment motor is directed back to tank through a return line with a 1 psi check valve installed at the tank connection.

Pump 2 (main pump) is a Linde HPR, axialpiston, variable-displacement pump with load sensing, and horsepower limiting controls. Refer also to PUMP 2 (MAIN PUMP) in SECTION 4 of THIS MANUAL. Oil flow from Pump 2 to the attachment motor is controlled by the pump 2 section of the main 17.8

Tigercat H822C/LH830C Harvester

822C-32

Attachment drive

ATTACHMENT CIRCUIT 17.9

Tigercat H822C/LH830C Harvester

Attachment drive

PRESSURE SETTINGS:

STANDBY VALVE

P.O.R. VALVE

Pressure settings for a harvesting attachment will vary depending on the manufacturer and model of attachment in use. Refer to attachment manufacturer's service and installation information.

•

PUMP 1 AND PUMP 1 CONTROL VALVE 1. Park machine on level ground, lower the attachment to the ground, engage the swing brake and stop engine.

217-21

PRESSURE COMPENSATOR VALVE PUMP 1 PRESSURE COMPENSATOR

2. Block attachment from operating as per method outlined in attachment manufacturer’s manual.

••

3. Ensure that the hydraulic oil is at operating temperature.

PUMP 1

4. Install a 0-5000 PSI pressure gauge on pump 1 valve gauge test port.

•

5. On the pump 1 compensator valve; •

Slacken jamnut on P.O.R. adjusting screw, and turn adjusting screw all the way in.

CAUTION: Do not use excessive force; stop when the resistance increases sharply. Tighten the jamnut.

•

The STANDBY valve adjusting screw is screwed fully IN (factory set) and must remain this way. This portion of the compensator is NOT USED.

OUTLET SECTION

•

822-D74

PUMP 1 (ATTACHMENT PUMP)

•

LEFT

ROTATE

RIGHT

NO FUNCTION MID INLET SECTION

• PUMP 1

•

•

GAUGE TEST PORT (FOR PUMP 1)

AT097-1

PUMP 1 MAIN RELIEF (4000 PSI)

ATTACHMENT VALVE (WITH ROTATE AND NO FUNCTION SECTIONS) 17.10

Tigercat H822C/LH830C Harvester

Attachment drive

6. On attachment control valve, loosen locknut and on pump 1 main relief valve and turn adjusting screw OUT until spring pressure is relieved.

7. Start the engine** and put throttle control to the IDLE position. **CAUTION: Before starting engine, ensure pump 1relief valve is unscrewed as stated in step 6, otherwise damage could occur to the piston pump.

8. Reset pilot system and turn the pump 1 power switch ON. NOTE: Attachment will not operate with pilot system OFF. Attachment will not function properly with low pilot pressure.

NOTE: If the engine has been turned off or the pilot shut off system tripped (door opened) with the pump 1 power switch left in the ON position, the attachment will not start up when the engine is restarted or the door closed. In this case press the PILOT RESET button and turn the pump 1 power switch OFF and then ON. 9. Set the pump 1 main relief pressure to 4000 psi by slowly screwing the relief valve adjusting screw in until the required pressure reading is obtained.

10. Re-tighten locknut, taking care not to turn the adjusting screw.

11. Set P.O.R. on pump1 compensator to 3200 psi. (or to attachment manufacturers recommended value, which ever is lower) by slowly screwing the relief valve adjusting screw out until the required pressure reading is obtained.

IMPORTANT: Pump 1 main relief valve must be set at least 400 psi. above Pump 1 P.O.R. to avoid generation of excessive heat.

12. Re-tighten jamnut, making sure adjusting screw does not turn.

13. The adjusting screw on the STANDBY valve must remain screwed fully IN. 14. Remove all pressure gauges.

Refer to attachment manufacturer's information for recommended pressure settings and safe procedures for adjusting pressures.

17.11

Tigercat H822C/LH830C Harvester

Attachment drive

SET PUMP 2 PORT RELIEF VALVES

2. Connect a 0-5000 psi pressure gauge on 'LS' test port of Linde main valve manifold.

NOTE: Constant loosening and tightening of the locknut (sealnut) on the port relief valve adjusting screws will eventually cause the seal in the nut to break down and leak.

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

3. Start engine and place throttle control in FULL position.

4. Turn anti-stall switch OFF.

WARNING

1. With hydraulic oil at operating temperature, LINDE MAIN VALVE MANIFOLD

The attachment will be operating during this procedure. Operator must ensure that no one is near the attachment during this procedure.

The swing brake should be applied at all times during this procedure.

HIGH PRESSURE LIMITING CONTROL

• ••

••

••

5. With an assistant operate the pump 2 control, loosen locknut pump 2 port relief valve cartridge and adjust to 3600 psi. on gauge at 'LS' port.

L.S. GAUGE TEST PORT 'P' GAUGE TEST PORT LS PRESSURE ADJUSTMENT P2

•• MAIN VALVE MANIFOLD

103-17A

CONTROL VALVE MANIFOLD

HIGH PRESSURE LIMITING CONTROL

•

FLOW ADJUSTING FLOW ADJUSTING SCREW FOR SCREW FOR PUMP 2 PORTS ON 'A' SIDE OF VALVE (TYPICAL)

TANK PORT 'T3'

••

•• ••

• B

B

B

B

B

B

B

A

A

A

A

A

A

A

• LH DRIVE 822-D63

•• RH DRIVE

• TELESCOPIC BOOM

STICK

•

••

• PUMP 2

MAIN CONTROL VALVE 17.12

MAIN BOOM

•• • SWING

Tigercat H822C/LH830C Harvester SPOOL TRAVEL STOP • 19mm WRENCH • 6mm ALLEN KEY

• • •

LOCKNUT • 17mm WRENCH

•

PORT RELIEF VALVE

90744-3

PILOT END CAP

•

ADJUSTING SCREW • 5mm ALLEN KEY

MAIN VALVE BODY

Attachment drive

•

MAIN VALVE PORT RELIEF VALVE

6. Tighten locknut on adjusting screw taking care NOT to turn the adjusting screw at the same time.

7. Check the setting again.

8. Stop engine, remove all gauges and reinstall plugs and caps.

Refer to attachment manufacturer's information for recommended pressure settings and safe procedures for adjusting pressures.

17.13

Tigercat H822C/LH830C Harvester

Attachment drive

PUMP 2 ELECTRONIC ADJUSTMENT PROCEDURE Adjustments to pump 2 through the PROPERTIES MENU of the IQAN control system electronically adjust the performance of this function to suit operating conditions . Refer also to COMPUTER ~ (PROPERTIES) MENU OPERATION in SECTION 6 of THIS MANUAL.

4. Press the bottom of the MENUS SWITCH to display the IQAN-MDM diagnostic and function adjustment menus.

PROCEDURE: For best results ensure hydraulic oil is at operating temperature before doing any adjustments. In addition, the function(s) being adjusted should be operated at a rate similar to normal operation to ensure that the coil is at a typical operating temperature. Due to the nature of the electrical connections some signals will vary with temperature and should always be adjusted at normal operating temperature to improve the accuracy of adjustments for operating conditions and operator preference.

822C-56

Press Escape button then scroll UP/DOWN to display PROPERTIES. Press OUTPUTS (F2) and use the UP/DOWN scroll buttons to scroll though the menus to PWM OUT. Press SELECT(F1) to go to SELECT. FUNCTION menu.

1. Ensure no other personnel are in the area during this procedure.

2. Start engine and set throttle speed to HIGH IDLE. 3. Close cab door and press PILOT RESET switch to activate pilot system.

630C-105B

A SELECT FUNCTION screen will appear.

Use the UP/DOWN scroll buttons to scroll through to the Pump 2 function.

17.14

Tigercat H822C/LH830C Harvester

Attachment drive

H822C-09

H822C-10

5. At the Pump 2-Attachmt screen press SELECT(-) (F1).

You are then able to scroll through the following adjustments: • • • • •

H822C-10

Min MR Max MR Startslope Stopslope Fine Control

Each SELECT FUNCTION screen displays the current reading for MR (modulation ratio) with an option of selecting SELECT (+) (F1) or SELECT (-) (F2) function directions. Selecting positive (+) controls the valve spool shift in one direction, and negative (-) controls the valve spool shift in the other direction.

Refer to the ADJUSTABLE FUNCTIONS chart below for function direction information and factory default setting information for each of the adjustable functions. The following example demonstrates the adjustment procedure for the pump 2 function.

ADJUSTABLE FUNCTIONS H822C/LH830C Function

Fa ctory de fa ult va lue s

PW M OUT Pum p2 - A ttac hmt 3 Tele-A ttachmt 2

(+ ) not used ex tend

(-) on retrac t

Min MR (%) 30 50

17.15

Ma x MR (%) 100 95

Sta rt slope (Ms) 500 100

Stop slope (Ms) 250 250

Fine control (%) 0 0

Tigercat H822C/LH830C Harvester

Attachment drive

DETERMINE MINIMUM MR VALUE

H822C-12 H822C-11

Temporarily reduce the maximum MR value to zero.

At the MAX MR screen press SELECT (F1).

Use the SCROLL DOWN button to reduce the value to zero. Do NOT press OK (F1).

6. Temporarily set the minimum MR value to zero.

At the MIN MR screen press SELECT (F1).

Use the SCROLL DOWN button to reduce the value to zero and press OK (F1).

H822C-12X H822C-11X

Activate and hold the function being adjusted, in the direction being adjusted.

Press ESCAPE button to return to the SELECT FUNCTION screen. (This step is necessary to ensure that the zero setting is recognized by the computer control system. If this step is skipped the control system will not allow the operator to lower the MAX MR setting to zero as required for this procedure)

H822C-13

There should be no movement (notice that the value shown in brackets at the top right of the screen indicates the actual output to the control valve). Begin increasing the Max MR value, while still holding the function. Use the scroll UP button.

H822C-10

Select the same function and direction again.

Scroll to the Max MR adjustment screen.

17.16

Tigercat H822C/LH830C Harvester

Attachment drive ADJUST MAXIMUM MR

H822C-13X H822C-12B

Once the function just begins to move, press OK (F1). Release the function control. and make note of (or remember) this number.

7. The maximum MR is an adjustment of the maximum function speed.

Scroll to the MAX MR adjustment screen.

Increase the maximum MR value to the desired level for maximum function speed.

At the MAX MR screen press SELECT (F1).

Use the SCROLL UP button to increase the value, press F1 (OK)]

H822C-11X

Scroll down to the MIN MR adjustment screen and adjust the MIN MR value to be the number determined above.

At the MIN MR screen press SELECT (F1).

Use the SCROLL UP button to increase it to the number determined above and press OK (F1).

H822C-12

For the pump 2 function this value is typically about 100% MR, however will vary slightly from machine to machine (due to slight differences in the coils, spool cut on the valve, and various manufacturers) – and of course, the largest factor in this case is operator preference.

H822C-11

The MIN MR setting is now adjusted to the proper level. This level provides just enough spool shift for the function to begin to move.

For the pump 2 function this value is typically about 30% MR, however will vary slightly from machine to machine (due to slight differences in the coils, spool cut on the valve, and various manufacturers)

17.17

Tigercat H822C/LH830C Harvester

Attachment drive Use UP/DOWN buttons to scroll to STOP SLOPE. Press SELECT (F1).

Use UP/DOWN buttons to set to desired value and press OK (F1) to save new value.

Note that an excessively long start slope can give the operator a poor feel for the head, as if the function is always overshooting its intended target. The purpose for making this adjustable is to accommodate the various preferences of different operator’s for the “feel” of functions.

H822C-15

ADJUST START SLOPE 8. The start slope is an adjustment for the amount of time that it takes for the function to ramp from the Minimum value to the Maximum value. If either the min MR or max MR values are improperly adjusted, the startslope may not produce the desired results.

The standard setting for the start slope on the pump 2 function is 500ms (1/2 of a second).

Increasing this value will make the start acceleration smoother.

Decreasing this value will make the start acceleration more harsh (additional stresses ).

H822C-16

ADJUST FINE CONTROL 10. In this H822C/LH830C application, the fine control is not typically used. Fine control is a feature that becomes very useful when using a proportional type input. In this case, the standard inputs from the joystick are all digital switches.

Use UP/DOWN buttons to scroll to START SLOPE. Press SELECT (F1).

Use UP/DOWN buttons to set to desired value and press OK (F1) to save new value.

Fine Control should be set to 0% for this application.

H822C-14

ADJUST STOP SLOPE 9. The stop slope is an adjustment for the amount of time that it takes for the function to ramp from the Maximum value to the Minimum value. If either the min MR or max MR values are improperly adjusted, the stopslope may not produce the desired results.

The standard setting for the stop slope on the pump 2 function is 250ms (1/2 of a second).

Increasing this value will make the deceleration smoother.

Decreasing this value will make the deceleration more harsh (additional stresses ).

17.18

Tigercat H822C/LH830C Harvester

SECTION 20 - ROTATE AUGUST 2006

CONTENTS - SECTION 20 ATTACHMENT VALVE - ROTATE SECTION ............................................. 20.4 CIRCUIT DESCRIPTION ............................................................................. 20.6 CIRCUIT DIAGRAM ..................................................................................... 20.7 CONTROL VALVE ....................................................................................... 20.4 PRESSURE SETTINGS .............................................................................. 20.8 AIR IN PILOT END CAPS ......................................................................... 20.8 ROTATE PUMP (ROTATE/FAN PUMP) ...................................................... 20.3

Tigercat H822C/LH830C Harvester

Rotate

20.2

Tigercat H822C/LH830C Harvester

Rotate

ROTATE/FAN PUMP

THRUST PLATES

This is a two cartridge dual gear pump driven off the power take-off of the Pump 1 (Attachment pump) . The input drive shaft is connected to the Pump 1 (Attachment pump) drive shaft by a drive coupling.

DRIVE GEAR ON INPUT SHAFT

DRIVE GEAR ON INPUT SHAFT

CONNECTING SHAFT

• • •

•

One of the two cartridges in the rotate/fan pump provides hydraulic oil flow to the attachment rotate function*. The second cartridge provides hydraulic oil flow to the cooling fan circuit.

THRUST PLATES

• • •

•

•

* NOTE: This description of functions applies only to standard factory installed features, it does not take into account any changes or modifications made after shipment.

INPUT DRIVE SHAFT (CONNECTED TO PUMP 1)

The operation of a typical external gear pump (so called because the gear teeth are on the external surface of the hub) is shown in Figure gear1.

AP179

•

• GEAR HOUSINGS

PORT PLATE, REAR

ROTATE/FAN PUMP

ROTATE/FAN PUMP

•

A gear pump carries oil from the inlet to the outlet in the spaces between gear teeth. The pumping chamber is formed by the gears, the pump housing, and thrust plates. One of the two gears, called the drive gear, will be connected to the drive shaft. The other idler gear is driven by the drive gear.

PUMP 1 (ATTACHMENT PUMP)

••

822-D73

PUMP ASSEMBLY

OUTLET DRIVEN (IDLER) GEAR

DRIVE GEAR

•

•

INLET GEAR1

20.3

TYPICAL GEAR PUMP

Tigercat H822C/LH830C Harvester

Rotate

CONTROL VALVES

common to all three sections and returns oil to the hydraulic tank.

For a detailed description of the attachment pilot manifold and joystick controls refer to SECTION 5 of THIS MANUAL.

Oil enters the mid inlet section and is allowed to pass through the two spool sections (rotate/no function) and back to tank via the outlet section.

Each of the spool sections has a self centering 3position spool which is open center. A spring in the spool end cap holds the spool in the center neutral position. The spool is shifted by pilot pressure being applied to either end of the spool.

Shifting the spool directs oil to operate any one of the two functions (or all at the same time if required but with reduced flow to each). The rotate valve section is equipped with adjustable spool stops.

ATTACHMENT VALVE - ROTATE SECTION The attachment valve consists of three open center spool sections, an end inlet section, a mid inlet section and an outlet section. The inlet (end) section feeds a single spool which is used for the pump 1 function. The mid inlet section feeds the remaining two spools which are used for the rotate and no factory function functions. Each spool is pilot operated. The outlet section is

ADJUSTABLE SPOOL STOP

••

PUMP 1 SECTION

MAIN (MID) RELIEF VALVE

PILOT END CAPS

•• GAUGE TEST PORT (FOR PUMP 1 ONLY) OUTLET SECTION

••

•• PUMP1

•• ••

ROTATE

•

•

MID INLET SECTION

GAUGE TEST PORT (FOR ROTATE)

ADJUSTABLE SPOOL STOP

END INLET SECTION (PUMP 1)

•

H822C-17

••

ATTACHMENT CONTROL VALVE (WITH ROTATE SECTION) 20.4

Tigercat H822C/LH830C Harvester

Rotate procedures for adjusting pressures.

To protect components and hoses when the valve is closed, each work port in the valve sections have a PORT RELIEF VALVE with an anti-cavitation function.

A MAIN RELIEF VALVE is also installed in the end inlet section of the pump 1 section. This relief valve is set higher than the pump 1 compensator pressure setting and will limit the pressure should a pump regulator or "swashing" failure occur.

A main relief valve is installed in the mid inlet section of the valve. It controls the pressure to the two spool sections and is set lower than the PORT RELIEF VALVES. Refer to attachment manufacturer's information for recommended pressure settings and safe

OUTLET SECTION

ADJUSTABLE SPOOL STOP

•

• LEFT

RIGHT

ROTATE NO FUNCTION

MID INLET SECTION

•

•

MID INLET MAIN RELIEF

PUMP 1

•

• GAUGE TEST PORT (FOR PUMP 1)

PUMP 1 MAIN RELIEF

ATTACHMENT VALVE (WITH ROTATE AND NO FUNCTION SECTIONS)

AT097-2

RELIEF VALVE PORT 'A'

RELIEF VALVE PORT 'B'

SEAL GROOVES

A

B

SPOOL CENTERING SPRINGS

•

• • •

•

•

•

• •

•

• PILOT END CAP

AT047IL2

•

•

•

• SPOOL TANK PASSAGE

PARALLEL PASSAGE

LOAD CHECK VALVE

THRU' NEUTRAL PASSAGE

WORK PORT BRIDGE

CROSS SECTION OF SPOOL SECTIONS 20.5

TANK PASSAGE

PILOT END CAP

Tigercat H822C/LH830C Harvester

Rotate 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.

ROTATE CIRCUIT DESCRIPTION The rotate function is operated by the right hand joystick*. Moving the joystick left and right directs pilot to the rotate spool section of the attachment control valve, to shift the spool. The spool directs oil from the rotate/fan pump to either end of the cylinder and from the cylinder back to tank. * NOTE: This description of functions applies only to standard factory installed features, it does not take into account any changes or modifications made after shipment.

Refer to attachment manufacturer's information for recommended pressure settings and safe procedures for adjusting pressures.

20.6

Tigercat H822C/LH830C Harvester

822C-33

Rotate

ROTATE CIRCUIT DIAGRAM 20.7

Tigercat H822C/LH830C Harvester

Rotate

PRESSURE SETTINGS WARNING:. Ensure that no one is near the attachment during this procedure. The swing brake should be applied at all times during this procedure.

IMPORTANT: Avoid blowing oil over the relief for longer than 5 seconds, as this will cause excessive heating of the hydraulic fluid and possible damage to the pump.

WARNING Operator must ensure that no one is near the attachment during these procedures.

7. With the aid of an assistant. Lift the attachment off the ground and press and hold the rotate control in the ROTATE RIGHT position, check gauge pressure reading.

If less than 1450 psi, turn rotate right port relief adjusting screw in until 1450 psi is obtained on the gauge.

Air in pilot end caps

Air accumulation in the pilot end caps of the rotate control valve can cause the rotate function to behave in a sluggish manor. To bleed the air: Pressurize the hydraulic tank to approximately 5 psi and loosen the suspected pilot end cap fitting to release the air. After completion, tighten the fittings and re-adjust the pressure in the hydraulic tank.

SET ROTATE RELIEF VALVES Mid inlet main relief valve setting*........1300 psi Rotate left port relief setting*................1450 psi Rotate right port relief setting*..............1450 psi *Note: Pressure values given are factory settings.

Refer also to attachment manufacturer's information for recommended pressure settings and safe procedures for adjusting pressures.

1. Park machine on level ground, lower the attachment to the ground, engage the swing brake and stop engine.

2. Ensure that hydraulic oil is at operating temperature.

IMPORTANT: During these procedures, Do Not hold thumb switch in the ON position for longer than 5 seconds.

IMPORTANT: Approach the gauge reading slowly and deliberately by turning adjusting nut in a little at a time. The pressure setting must not exceed the above value.

8. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

9. Press and hold the rotate control in the ROTATE LEFT position, check gauge pressure reading.

If less than 1450 psi turn rotate left port relief adjusting screw in until 1450 psi is obtained on the gauge.

10. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

11. Repeat steps 7 and 9 to verify settings.

3. Connect a 0 - 5000 psi pressure gauge to the rotate control valve test port. The control valve is accessed through the left hand rear enclosure door and is mounted above the hydraulic tank cleanout cover.

RESET MID INLET MAIN RELIEF VALVE

4. Loosen locknut on the mid inlet main relief valve and turn main relief adjusting screw all the way IN, tighten locknut.

13. Press and hold the rotate control in the ROTATE RIGHT position, check gauge pressure reading.

5. Turn both port relief valve adjusting screws on the rotate spool sections of the control valve OUT until spring pressure is relieved and then turn adjusting screws one full turn IN. 6. Start the engine and set throttle to IDLE. NOTE: It may be necessary to increase the engine speed sufficiently to prevent the engine from stalling.

12. With throttle control in the FULL position; Loosen the locknut on the mid inlet main relief and unscrew adjusting screw 3 full turns.

If less than 1300 psi, turn mid inlet main relief adjusting screw in until 1300 psi is obtained on the gauge.

14. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

15. Repeat step 13 to verify setting.

20. Stop engine and remove pressure gauge.

20.8

Tigercat H822C/LH830C Harvester

OUTLET SECTION

ADJUSTABLE SPOOL STOP

Rotate

•

• LEFT

ROTATE

RIGHT

NO FUNCTION MID INLET SECTION

•

•

MID INLET MAIN RELIEF

PUMP 1

•

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GAUGE TEST PORT (FOR PUMP 1)

AT097-2

PUMP 1 MAIN RELIEF

ATTACHMENT VALVE (WITH ROTATE AND NO FUNCTION SECTIONS)

SUMMARY 1. Ensure that hydraulic oil is at operating temperature.

3. Connect gauge to the rotate control valve.

4. Turn mid inlet main relief all the way in.

5. Turn both rotate sections out and then one full turn in.

6. Start the engine and set throttle to IDLE. 7. Set ROTATE RIGHT port relief.

8. Set ROTATE LEFT port relief 9. Set throttle to FULL. 10. Reset main relief.

20.9

Tigercat H822C/LH830C Harvester

Rotate

20.10