Tigercat M822 MULCHER OPERATOR'S MANUAL - PDF DOWNLOAD

OPERATOR'S MANUAL Tigercat M822 MULCHER TABLE OF CONTENTS

ISSUE 2.0, SEPTEMBER, 2005

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

822M-OM00

M822 Feller Buncher Available Literature Operator's Manual (This Manual) ........................... Part No. 26804A Service Manual ....................................................... Part No. 26805A Parts Catalog .......................................................... Part No. 26806A

Tigercat

®

Tigercat Industries Inc. P.O. Box 544 Paris, Ontario Canada N3L 3T6 Tel: (519) 442-1000 Fax: (519) 442-1855

ii

Tigercat M822 Mulcher

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 M822 Mulcher serial number 822110191 and up.

The operator's manual will assist the operator with the techniques of proper and safe operation of the M822 Mulcher. 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.

M822-002

iii

Tigercat M822 Mulcher

Introduction

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

IT IS Tigercat POLICY THAT NO CHANGES ARE TO BE MADE TO ITS PRODUCTS INCLUDING DELETIONS OR ADDITIONS OTHER THAN A Tigercat APPROVED OPTION FITTED IN THE FACTORY APPROVED MANNER. Official approval to make changes or install options is only to be undertaken as follows: i)

The relevant options for that product must be shown or listed on current Tigercat documentation or literature such as a printed specification sheet, price list, parts manual, or product literature issued by Tigercat.

ii)

Approved options or product changes authorized in writing by the Tigercat Engineering Manager.

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

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

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

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

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

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

Tigercat Industries Inc.

iv

Tigercat M822 Mulcher

SECTION 1 - SAFETY SEPTEMBER, 2005

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

Read and understand all manuals for any attachment or accessories.

CONTENTS - SECTION 1 BATTERY SAFETY ........................................................................................ 1.6 CAB EXITS ..................................................................................................... 1.7 COOLING SYSTEM ...................................................................................... 1.14 EMERGENCY CAB EXITS .............................................................................. 1.7 ENGINE DOORS .......................................................................................... 1.16 ER BOOM SYSTEM PRECAUTIONS ........................................................... 1.15 EXHAUST FUMES ........................................................................................ 1.16 FIRE PREVENTION ...................................................................................... 1.17 FIRE PREVENTION GUIDELINES ............................................................. 1.17 WHAT ELSE TO DO BEFORE YOU EXPERIENCE A FIRE ...................... 1.18 WHAT TO DO AFTER A FIRE ................................................................... 1.19 WHAT TO DO IN CASE OF A MACHINE FIRE .......................................... 1.18 FLUID LEAKS ............................................................................................... 1.14 HAZARD ZONE .............................................................................................. 1.3 HYDRAULIC PRESSURE HAZARD .............................................................. 1.14 LOOSE CLOTHING HAZARD ........................................................................ 1.14 MULCHING OPERATION SAFETY ............................................................... 1.10 PROTECTIVE CLOTHING ............................................................................... 1.2 SAFETY INTERLOCK SWITCHES ON CAB DOORS ..................................... 1.8 SAFETY PRECAUTIONS, GENERAL ............................................................ 1.3 SAFETY PRECAUTIONS, OPERATING ......................................................... 1.6 SAFETY PRECAUTIONS, SERVICING ........................................................ 1.13 SAFETY SYMBOLS ....................................................................................... 1.2 SIGNAL WORDS ............................................................................................ 1.2 WORKING WITH OIL ...................................................................................... 1.4

Tigercat M822 Mulcher

Safety

GENERAL SAFETY PRECAUTIONS

SAFETY SYMBOLS

Remember that safety is a prime responsibility of all.

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

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

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

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.

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.

WARNING

Do not let untrained persons operate the machine.

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

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.

Tigercat M822 Mulcher

Safety

GENERAL SAFETY PRECAUTIONS continued

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.

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.

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

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

500 FEET

Do not jump off the machine at any time.

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

500 FEET

500 FEET

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

Do not use the machine foot controls as steps.

500 FEET

822M-001

HAZARD ZONE

DANGER 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 the attachment is shut down before advancing to the machine.

Always avoid the discharge side of the attachment. High-velocity discharge of debris requires a safe separation distance.

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

1.3

Tigercat M822 Mulcher GENERAL SAFETY PRECAUTIONS continued

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

Check all fluid levels.

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

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

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

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

Some advice which should be observed: • •

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

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

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

Machine should be washed completely at every major service.

•

• • • • • •

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

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

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 round the machine.

1.4

Avoid contact with oil, particularly heated oil.

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

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

Don't put oily rags in your pockets.

Oil soiled clothing should be changes as soon as possible.

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

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

Avoid breathing in oil fumes.

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

Tigercat M822 Mulcher

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

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

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

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

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

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

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

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

•

If these are found, Do Not Touch!!!

•

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

•

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

•

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

Be aware when performing service and maintenance tasks that surfaces and grab handles in and around the engine and cooling system may

become very hot when the engine has been running. Contact with hot surfaces may cause injury.

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

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

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

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

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.

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

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

1.5

Tigercat M822 Mulcher

Safety

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

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

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

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

To avoid backover accidents: •

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

Wash hands after handling.

• •

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

•

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

•

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

• •

Do not short out battery terminals for any reason.

Serious burns or an explosion can result.

CAUTION

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

Keep reverse* warning alarm in working condition.

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

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

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

Keep windows, mirrors and lights in good condition.

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

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

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

1.6

Tigercat M822 Mulcher

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

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

1.7

Tigercat M822 Mulcher

Safety Secure loose items in the cab.

OPERATING SAFETY PRECAUTIONS continued

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

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

SWITCH

ACTUATOR ON DOOR

••

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

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

••

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

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

822-D02

INTERLOCK SWITCH (FRONT DOOR)

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

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

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

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

Do not turn on attachment until machine is at work site.

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

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

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

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

Use only prearranged and approved signalling practices.

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

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

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

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

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

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

1.8

Tigercat M822 Mulcher

Safety

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

CAUTION Do not open cab doors or window screens when 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.

NEVER travel across a STEEP slope or side hill: •

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

•

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

1.9

Tigercat M822 Mulcher

Safety DANGER ZONES

OPERATING SAFETY PRECAUTIONS continued

Danger exists most prominently to the right side and left side of the mulching head.

MULCHING OPERATION SAFETY

Operate so that the main discharge areas of the mulching head are not directed at people, livestock, buildings or other machines.

Land clearing operations generally involve other machinery and people on the site. Operators must maintain an awareness of all working traffic within 500 feet of the mulching operation.

Throw distance for metal pieces and stones can be many times the distance for wood chips.

Pieces of wood, debris from the ground and even cutting tools separating from the rotor become potentially dangerous projectiles when thrown from these machines.

Danger is greater if the site contains stones or abandoned metal.

Poor maintenance increases the danger.

Thorough timely inspection and replacement of worn cutter tools, fasteners and wear plates.

Always heed warning signs of missing cutter tool parts or sounds of striking rocks and adjust operation to suit the site.

Inspect cutter tools, cutter tool fasteners, rotor and mulching head assembly.

Ensure that all cutter tool retaining bolts are at correct torque value.

Do not operate in a way that throws chips in a direct line at the machine cab.

Replace all worn cutter tools.

Always replace the fastener whenever replacing a cutter tool.

RIGHT SIDE DANGER ZONE Chunks of wood and rock can be thrown from the RIGHT side of the mulching head. This occurs when the mulching head is raised high enough to allow debris to escape the guard chains. No one should be allowed within the HAZARD ZONE. This condition is dangerous, refer to HAZARD ZONE in THIS SECTION. The following precautions should be followed:

Inspect the rotor for weld cracks and other damage.

Check that the rotor does not wobble due to worn shaft bearings.

Never start or use a machine if the rotor has missing cutting tools, missing cutting tool fasteners or a bent rotor.

Shut down the machine immediately if you feel excessive vibration when the rotating cutter is running.

• •

Check that the cutter housing is clear and undamaged.

•

DANGER ROTATING CUTTER

LEFT SIDE DANGER ZONE

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

Danger caused by flying debris. Improper operation of the attachment and failure to follow safety precautions can result in personal injury.

LEFT SIDE DANGER ZONE

A lower volume of projectiles may be experienced on the LEFT side . However, no one should be allowed within the HAZARD ZONE. Refer to HAZARD ZONE in THIS SECTION. The following precautions should be followed: •

RIGHT SIDE DANGER ZONE

•

•

822M-004

Never allow anyone within the HAZARD ZONE of the machine while it is in operation.

Inspect daily for damage or missing guard chains. Replace them before operating.

Be especially careful when the tool is lowered onto new material and when the tool is raised up and out of material it has been working.

DANGER ZONES

Never allow anyone within the HAZARD ZONE of the machine while it is in operation.

Close the mulch door (if equipped) while pullworking to better contain debris. This also increases the fineness of the shredded product.

Be especially careful when the tool is lowered onto new material and when the tool is raised up and out of material it has been working.

DO NOT operate without guards.

1.10

Tigercat M822 Mulcher OPERATING SAFETY PRECAUTIONS continued URBAN PRECAUTIONS Increased safety precautions are required when working: • • • •

Near streets Near highways In parks, on golf courses or other inhabited areas.

Near buildings

Establish Safety parameters that fit the site: • • •

String coloured warning tape to cordon off the area.

Use a traffic director when the hazard zone impinges on pedestrian or vehicular traffic.

Erect barriers.

Safety ANIMAL REMAINS Animal remains such as calf and deer carcasses will plug the machine due to their leathery skin.

Avoid the unpleasant task of removing the remains from the rotor.

AVOID FENCES Do not drive the mulcher into fences, especially chain link fences. Chain link fencing can damage the rotor. Refer to AVOID METAL AND WIRE above.

When operating mulching head properly position head for push working and pull working for safety and improved operation.

When tree toppling always know and control the direction a tree will fall to prevent injury to coworkers or damage other vehicles.

CAUTION

ASSESSING THE POTENTIAL DANGERS OF THE JOB SITE Before working in a new area a visual survey of the area to be worked is helpful in identifying undesirable materials which may be present.

Remove as much of the undesirable materials as is practical before proceeding.

AVOID METAL AND WIRE. Metal can break cutter tools and create a projectile hazard.

Wire wraps itself around the rotor shaft especially near the bearings. Near bearings this can cause wire to enter past the grease seals and cause damage to bearings if it is not removed promptly.

USE CAUTION WITH STRINGY VEGETATION Shredding materials like Palmetto, Bird of Paradise, and yard waste tied with plastic should be approached with caution. Stringy vegetation and plastic ties gravitate toward the bearings. The operator should exercise caution while working with this type of material.

AVOID PLASTICS Hoses, bags, tarps and ropes must be removed as soon as they are seen.

Mattresses, rugs, clothes and cloth will plug the machine immediately.

To prevent component damage, always have deflector door open when preparing to fell standing trees Work within your operating skills, do not attempt to cut down a tree that is too large to handle.

When pull working (moving in reverse), watch for obstacles in your path.

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

Never use this machine to clear an area when other equipment and operator's are also moving in. Pre-plan to work the area 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 rotating cutter before leaving the mulching area. NOTE: The cutter will continue to free wheel for several minutes after the cutter switch has been turned OFF. To stop cutter from rotating, CAREFULLY lower the rotor onto a stump. This should be done gently to prevent unnecessary loading of the rotor, housing and bearings.

Any time is a good time to inspect the rotor for clinging strands.

1.11

Tigercat M822 Mulcher

Safety

SERVICING SAFETY PRECAUTIONS

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

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

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

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

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

1.12

Tigercat M822 Mulcher

Safety DISCONNECT THE TWO MULTI-PIN PLUGS FROM THE ENGINE CPU

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

••

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

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

This machine is equipped with sensitive electronic control equipment, prior to welding:Disconnect the multi-pin plug from the engine anti-stall controller located on the rear inside wall of the cab.

QSC AND QSL9 ENGINES ONLY

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

830-D39

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

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

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

•

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

IQAN DISPLAY DISCONNECT

ENGINE ANTI-STALL DISCONNECT PLUG

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

822-D03

• DISCONNECT THE 42 PIN PLUG FROM THE XP MODULE

DISCONNECT THE TWO MULTI-PIN PLUGS FROM THE ENGINE CPU

••

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

QSC AND QSL9 ENGINES ONLY 830-D38

ENGINE CPU DISCONNECT - LEFT SIDE OF ENGINE

1.13

IQAN XP MODULE DISCONNECT

Tigercat M822 Mulcher

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 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.

Fluid leaks under pressure may not be visible.

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

Wear safety goggles for eye protection.

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

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

Pressure can be maintained in a hydraulic system long after the power source and pump have been shut down. 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.1 & fig.2). Accumulators will self drain within 2 minutes of stopping the engine.

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

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

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

1.14

Tigercat M822 Mulcher SERVICING SAFETY PRECAUTIONS continued WARNING This machine may be equipped with an ER boom system. Because of this, it may behave in an unexpected manner compared to a conventional boom system.

MACHINE MODELS EQUIPPED WITH AN ER BOOM SYSTEM

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

•

Do not use the boom to service other equipment.

•

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

•

Do not modify the boom system.

•

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

•

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

Pay attention to the following when servicing the ER Boom System: Certain hydraulic circuits on this machine are inter-connected in order to provide level head travel and to recirculate hydraulic oil to reduce heat generation and fuel consumption. As a result, disconnecting hydraulic lines from one cylinder may release pressure in different cylinder at the same time. Before attempting to disconnect hydraulic hoses or perform work on the boom system, ensure that:(a) The machine is parked on level ground with the head sitting flat on the ground. (b) The stick cylinders are fully extended (fig. 1) or the hoist cylinder fully collapsed (fig. 2). c) The tip of the stick boom supported . d) Do NOT rely on the attachment to support the boom system during servicing. Slow leakage in the hydraulic components can cause the attachment to move unexpectedly.

HOIST CYLINDER FULLY RETRACTED

•

TIP OF STICK BOOM FULLY SUPPORTED 830-08

PARKING BOOM. FIG.2

1.15

Tigercat M822 Mulcher SERVICING SAFETY PRECAUTIONS continued Before performing work under the boom system ensure it is firmly supported.

WARNING

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

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.

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

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

WARNING Always allow the cutter to come to a COMPLETE STOP before approaching the attachment to make adjustments.

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

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

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

Dispose of fluids properly.

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

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

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

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

1.16

Tigercat M822 Mulcher

FIRE PREVENTION

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

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

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

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

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

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

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

Safety 5. Remove debris and blow out dust regularly from the air intake doors, engine radiator, hydraulic oil cooler and A/C condenser core to prevent overheating of the engine and hydraulics. Refer to CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR in SECTION 2 of the OPERATOR’S MANUAL. 6. Blow off all debris and dust accumulated near hot engine exhaust components (turbocharger and exhaust manifold as well as exhaust pipes and muffler) at the completion of each work shift or more frequently depending on logging conditions. Visual inspection after blow off to ensure thorough cleanliness is vital.

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

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

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

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

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

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

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

1.17

Tigercat M822 Mulcher FIRE PREVENTION continued 13. Park the machine at least 50 feet away from other equipment at the end of each shift.

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.

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

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

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

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

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

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

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

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

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

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

WHAT TO DO IN CASE OF A MACHINE FIRE •

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

•

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

•

Activate the fire suppression system*

•

Shut the engine off.

•

Radio or call for help (as appropriate).

•

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

•

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

•

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

•

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

•

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

1.18

Tigercat M822 Mulcher FIRE PREVENTION continued •

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.

•

•

20229A

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

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

Safety •

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.

WHAT TO DO AFTER A FIRE •

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

•

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

•

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

•

Ensure that all extinguishers and water systems 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.

TYPICAL FIRE EXTINGUISHER ACCESS HOLE

•

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

•

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

•

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

1.19

Tigercat M822 Mulcher

Safety

1.20

DANGER USING HIGH SPEED DISC SAWS SAFELY This information is intended to encourage logging organizations and operators to develop and practice additional rules that suit particular terrain conditions and job requirements. It is also intended to assist towards a quicker understanding of how and why things can happen when a high speed disc saw is in use; and hence to assist in development of safe operating practices.

The following information is in addition to any safety instructions or recommended safe operating practices that may already be in circulation.

CONTENTS COMMENTS AND INSTRUCTIONS DIRECTION OF THROW ........................................................ 7 HIGH ANGLE WRIST ROTATION ABILITY ............................ 8 RECOGNIZING THE DANGERS ............................................ 7 THROWING LONG WOOD PIECES .................................... 10 DANGERS ................................................................................. 3 FORWARD ................................................................................. 2 BE AWARE OF THE HAZARDS ............................................. 2 OTHER INSTRUCTIONS ....................................................... 3 SAFE PRACTICES ................................................................. 3 SEVERAL TYPES OF HEADS INVOLVED ............................. 2 STORED ENERGY ................................................................. 2 HIGH ANGLE WRIST ROTATION CAPABILITY ......................... 9 SAW HEAD DON’TS ................................................................ 15 TYPE OF HOUSING MAKES A DIFFERENCE ......................... 4

Tigercat

5211A • R2-1101

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using high speed disc saws safely FORWARD:

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Several types of heads involved Tigercat wheel type feller-bunchers and crawler feller-bunchers can be supplied with several optional makes and models of high speed disc saw tree felling heads. Because each has certain advantages and disadvantages they are chosen where they best do specific types of work.

Stored energy The saw blade stores energy from the hydraulic motor during the times between tree cuts so that it can supply up to 1000 hp during a 1 sec tree cut. However this rotational energy, if misapplied can result in wood materials or other objects being thrown strongly enough to cause damage and to hurt people.

Be aware of the hazards It is important that users of machines with disc saw felling heads are aware of certain safety precautions that need to be taken. In this section some previously unknown, unexpected safety hazards are illustrated and explained . These should be studied before use of the machinery and then reviewed again after use has begun.

FIGURE 1: BROADSIDE SAW CONTACT WITH A LOG COULD PRODUCE A THROW

FIGURE 2: A SUDDEN MACHINE MOVEMENT MAY CAUSE AN UNEXPECTED THROW AT THE CAB

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Safe practices It is understood and expected that logging organizations and operators will develop and practice additional rules that suit (for example) particular conditions of terrain, trees, soil and job requirements. The information given here is intended to assist towards a quicker understanding of how and why things can happen when a high speed disc saw is in use; and hence to assist in development of safe operating practices.

It should not be assumed that all possible dangers have been discovered and described here.

Other instructions It is also understood and expected that all instructions contained in service and operator's manuals for use and maintenance of Tigercat disc saw heads and other disc saw heads installed on Tigercat machines will be followed.

THE DANGERS

There are at least these means by which a rotating disc saw can cause harm by throwing: • The normal throwing of chips from the cut.

• Soil particles are thrown from the ground.

• Loose chunks of wood encountered or produced are tossed by the exposed blade.

• Sticks and debris falling onto the blade or sliding across the blade are struck by the teeth and thrown.

• Metal pieces from the blade or from objects encountered are thrown.

• Wood pieces enter the saw housing and are expelled by the blade.

• In very peculiar cases the saw can throw long lengths of wood as spears.

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TYPE OF HOUSING MAKES A DIFFERENCE Since the configuration of the saw housing can affect the safety of its use we need to identify some particular types of housing shapes and guarding being used.

Figure 3 shows a typical commonly used saw housing plan where there is a continuous skirt around the saw except at a mouth opening where the trees are cut and taken. The skirt extends below the saw enough to intercept tangential throw. There are snouts on both sides of the mouth so that if pushed against the side of a felled tree or log the saw teeth will not contact the wood.

THROW ANGLE

IF A SAW HEAD IS PUSHED AGAINST THE SIDE OF A FELLED TREE, SNOUTS PREVENT SAW TEETH FROM CONTACTING WOOD.

•

•

FIGURE 3: TYPICAL COMMONLY USED SAW HOUSING, CONTINUOUS SKIRT WITH OPENING WHERE TREES ARE CUT. SNOUTS ON BOTH SIDES OF THE MOUTH.

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Figure 4 shows another commonly used plan. It has no blade guarding snouts so that the saw blade teeth do protrude ahead of the housing. This may be preferred over figures 3 and 5 for dexterity in tree getting.

THROW ANGLE

IF A SAW HEAD WITHOUT SNOUTS IS PUSHED AGAINST THE SIDE OF A FELLED TREE, SAW TEETH WILL CONTACT WOOD.

FIGURE 4: ANOTHER COMMONLY USED HOUSING PLAN WITH NO SNOUTS, BLADE TEETH PROTRUDE AHEAD OF THE HOUSING.

In figure 5 there is a much longer snout on the ingoing side of the mouth, i.e., where the teeth of the rotating blade are entering the housing. The broad side of a log, if nudged, will not contact the saw teeth and more thrown material will be intercepted by the extra length of snout.

THROW ANGLE

NUDGED LOG WILL NOT CONTACT SAW TEETH.

• EXTRA LENGTH OF SNOUT WILL INTERCEPT PORTION OF THROWN MATERIAL.

FIGURE 5: HOUSING USES LONGER SNOUT ON IN-GOING SIDE OF MOUTH WHERE ROTATING BLADE ENTERS HOUSING.

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using high speed disc saws safely Housing types cont.

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In figure 6a and 6b there is an additional opening in the housing skirt. Openings in this location are sometimes provided for escape of wood chips produced by the saw teeth in the cut and being taken into the housing.

A CHIP ESCAPE PORT CAN ALLOW THROW BEHIND THE MACHINE

REAR

FRONT

FIGURE 6a

FIGURE 6b

FIGURE 6c

FIGURE 6: ADDITIONAL OPENING IN THE HOUSING SKIRT.

In figure 6c a guard has been added to the chip escape port so that tangential travel of chips and other material is intercepted as soon as it leaves the housing.

Each figure shows a shaded area where normally tangentially thrown material can escape from the saw housing. Deflected and dropped chips escaping below the bottom edge of the housing skirt are not included. The areas and angles are not exact but do show that one head can be different from another.

It is important that the operator familiarize himself with the blade rotation direction, the effectiveness of any snout on the in-going side and which direction any chip escape ports allow material to fly.

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using high speed disc saws safely COMMENTS AND INSTRUCTIONS

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Recognizing the Dangers While it may appear that these illustrated danger areas can be visually recognized on the job by observing how far chips fly during a cut, that is only true for chips and other light weight materials.

Metal parts and wooden spears can be thrown to surprisingly greater distances. Even distant personnel on the ground, in other vehicles, or in buildings are at risk if the throw is in their direction.

Direction of throw The direction of possible tangential throw for metal parts and stones is dependent on the housing configuration and might be expected to be the same as observed for the chips. However, these throws can occur at any time the saw is running, in whichever direction the angle of throw is pointed by boom geometry, not just when a cut is being made.

Throw distance The throw distance for metal pieces and stones, can be many times the distance shown by the pattern for chips. More testing and data collection is needed to pin down a “safe distance” but if someone or something is in a place that can be seen by the operator and in the throw direction of a high speed disc saw, then the operation is not safe regardless of the distance.

Safe operating areas These saw heads must not be used in areas where the logging operation does not have control over the presence and movement of people. In particular, clearing of vegetation in urban and populated areas should not be done with a Tigercat manufactured or supplied high speed disc saw. High speed disc saw heads are intended for high productivity wood harvesting in areas remote from normal habitation. The possible presence of people and property within throw range and the likelihood of encountering scrap metal, wire fencing, steel posts and concrete must be respected.

Assessing the potential dangers on the job site The extent of danger from high speed disc saws on the logging operation has to be assessed on the job site, depending on how much other work activity is in the area and whether the operator can do his job of cutting and bunching with good control of throw patterns. Danger is greater if the saw is equipped with detachable, or fragile, or brittle teeth, or if the site contains stones or abandoned metal.

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using high speed disc saws safely Comments and Instructions cont.

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Regular maintenance Poor saw maintenance increases these dangers. Some designs that might allow fasteners to wear thin or fatigue and suddenly break, need thorough timely replacement procedures. It is important that the warning signs of missing saw tooth parts or the sounds of striking rocks be heeded and the operation adjusted to avoid danger.

High angle wrist rotation ability When a felling machine is equipped with a high speed disc saw head with a high angle wrist rotation ability it should be determined that the limits of the boom, stick, tilt, wrist, upper leveling and any other freedoms, do not permit a direct throw at the operators cab during normal operation, see figure 7a. It is probably essential that the housing have a long snout on the throw side and that if a chip escape port is used it should be guarded.

With these high mechanical freedom arrangements there is a chance that an unforeseeable operator misadventure or equipment failure could result in an accidental direct or deflected throw at the operators cab, refer to figure 2 and 7b. The cab should be capable of resisting such accidental and ricochet throws. The velocity energy of metal or rock pieces leaving the blade is extremely high. The operators cab cannot be considered safe to routinely operate in the chip throw area, even if it has been especially constructed to prevent penetration by accidentally thrown objects.

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FELLING HEAD • WITH A CHIP ESCAPE PORT AND SHORT SNOUT. • SHOWN IN A HIGH ANGLE WRIST ROTATION POSITION, PLACING OPERATOR'S CAB IN DIRECT LINE WITH UNGUARDED CHIP ESCAPE PORT

FIGURE 7a

PLAN VIEW OF MACHINE SHOWING CLOCKWISE AND COUNTERCLOCKWISE BLADE ROTATION

FIGURE 7b FELLING HEAD • WITH LONGER SNOUT ON THROW SIDE OF OPENING AND WITH A GUARDED CHIP ESCAPE PORT.

FIGURE 7: DISC SAW FELLING HEAD WITH HIGH ANGLE WRIST ROTATION CAPABILITY

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using high speed disc saws safely Comments and Instructions cont.

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Throwing long wood pieces Dangers from throws of long wood pieces are illustrated in figures 8 to 11. Tests and experience have shown that when a high speed rotating saw is applied to a loose piece of wood, the wood is either blown or pushed away, without a throw. If the wood is held firmly in all directions and the saw advanced into it at any feed speed, cutting will take place. If the wood is only held against escape from the saw radially, but not held tangentially, then the wood will be both partly cut and partly moved tangentially. In this last case tests have shown that if the piece of wood is backed-up by a solid slippery surface; and if the feed in is very fast; and if the piece of wood is long enough; then the tangential movement is a dangerous spear-like throw.

A SLAB, WHICH COULD LATER BE THROWN, MIGHT HAPPEN WHEN NOT ENOUGH ROOM IN HEAD TO COMPLETELY CUT THE LAST TREE

SLAB

•

SLAB

• FE

ED

IN

FIGURE 8a: HOW A SLAB CAN BE THROWN FROM THE SIDE OF A LOG

TH DIR ROW EC TIO N

SAW HOUSING HAS SKIS, BUT WITHOUT SNOUTS AND BLADE TEETH PROTRUDE AHEAD OF THE HOUSING.

FIGURE 8

THROW ENGAGEMENT DISTANCE FELLING HEAD MOVING INTO SLAB/LOG

®

SLAB

LOG A LONG THROW ENGAGEMENT DISTANCE CAN CAUSE A DANGEROUS SPEAR THROW

• •

FIGURE 8b SIDE VIEW

FEED IN

IF THE SIDE OF A LOG CAN CONTACT THE SAW, THE THROW ENGAGEMENT DISTANCE CAN BE LONG

10

FIGURE 8c TOP VIEW

using high speed disc saws safely Comments and Instructions cont.

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Figures 8 and 9 show two ways that this might happen in the woods if using the saw head of figure 4 (where the throw contact can be long). A slab, still partly attached to a well backed-up tree bole and wet with sap, makes an ideally bad throw situation which could unintentionally occur in woods work. A small log in a pile of other logs might also be propelled out with enough length of continued contact to reach near saw tip speed.

A SMALL LOG IN A PILE OF OTHER LOGS MIGHT ALSO BE PROPELLED OUT WITH ENOUGH LENGTH OF CONTINUED CONTACT WITH THE BLADE TO REACH NEAR SAW TIP SPEED.

• FE

ED

IN

FELLING HEAD MOVING INTO LOG PILE

FIGURE 9a: HOW A LOG CAN BE THROWN LIKE A SPEAR SAW HOUSING WITHOUT SNOUTS AND BLADE TEETH PROTRUDE AHEAD OF THE HOUSING.

SMALL LOG

THROW ENGAGEMENT DISTANCE LOG PILE

FEED IN

•

•

A SAW HOUSING WITHOUT SNOUTS ALLOWS A LONG THROW ENGAGEMENT DISTANCE

FIGURE 9b SIDE VIEW

FIGURE 9c TOP VIEW

IF THE SIDE OF A LOG CAN CONTACT THE SAW, THE THROW ENGAGEMENT DISTANCE CAN BE LONG

FEED IN

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using high speed disc saws safely Comments and Instructions cont.

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Figure 10 shows how a head with snouts does not allow a long throw contact. Although tests show that a short contact length on a long log or tree butt does not result in a spear like throw, this action should nevertheless be avoided because abnormally large chips are sometimes produced and thrown.

UNCUT TREE OR STUMP BACKUP THROW ENGAGEMENT DISTANCE

• WHEN ONLY THE END OF A LOG CAN MAKE CONTACT WITH THE SAW, THERE IS NOT MUCH THROW ENGAGEMENT DISTANCE

FIGURE 10: FELLING HEAD HOUSING WITH SNOUTS DOES NOT ALLOW A LONG THROW CONTACT

FELLING HEAD MOVING INTO LOG

Figure 11 warns that blocks of wood can be tossed in any direction when improvising with a disc saw to trim over-size stumps. A long snout and a slow feed speed lessen danger during stump trimming.

A similar danger of throw may exist when clearing small brush with multiple pass cuts.

FELLING HEAD MOVING INTO STUMP (FEED SPEED)

FIGURE 11: A BLOCK OF WOOD CAN BE TOSSED WHEN TRIMMING STUMPS

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using high speed disc saws safely Comments and Instructions cont.

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Saw blade throw gap Saw blades have gaps between adjacent teeth and holders to permit installation and removal of the teeth and to provide spaces to accumulate chips in the cut, see figure 12. Fallen sticks and debris or sticks and debris sliding across the the saw blade can enter these gaps when the blade is rotating and be struck by the teeth and be tossed or thrown. Larger gaps and lower rotation speeds increase these dangers.

THROW GAP

FIGURE 12: SAW BLADE THROW GAP

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using high speed disc saws safely Comments and Instructions cont.

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Saw housing entrance and exit space To avoid the ingestion of materials into the housing space above the disc (and later ejection) the ingoing entrance for the saw rim of teeth is kept as small as practical. It is important that this high wear area be maintained at its original size and shape. The outgoing opening is large enough to allow the housing to clean itself and will allow most things inside to be thrown out, see figure 13. Its throw direction and angle must be respected. A long snout on the other side reduces this danger.

THE INGOING ENTRANCE OF THE HOUSING FOR THE SAW RIM OF TEETH SHOULD BE SMALL

THE OUTGOING OPENING IS LARGER TO ALLOW THE HOUSING TO CLEAN ITSELF AND WILL ALLOW MOST THINGS INSIDE TO BE THROWN OUT

FIGURE 13: SAW BLADE ENTRANCE AND EXIT SPACE

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using high speed disc saws safely Comments and Instructions cont.

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This information is offered by Tigercat as part of interim action to make saw heads safer. It is based on what has recently been reported from the field and on tests conducted on proving grounds.

Tigercat is continuing to do design and testing of tree felling machinery towards achieving greater safety in the woods. Tigercat would be thankful for written reports describing any unsafe happenings, including near misses, in the use of felling heads and their carriers.

The following are some “SAW HEAD DON’TS” that apply particularly to throw prevention.

Do not point the throw of a disc saw head in a direction towards people, vehicles or buildings at any visible distance.

Do not operate in a way that throws chips in a direct-line at the machine cab.

Do not push hard with the saw against anything except a standing tree to be cut.

Do not mix new sharp teeth with old dull teeth on the same saw.

Do not change the blade rotation from its designed direction in the head.

Do not over speed the blade rpm.

Do not remove or shorten snouts provided by the head manufacturer or installer.

Do not neglect tooth fastening inspection, maintenance and replacement.

Do not neglect to repair worn or damaged saw housings.

Do not neglect to replace any covers removed for service or clean out.

Do not count on skis to give the throw protection that snouts do.

Do not nudge loose short pieces with the front of any type of head.

Do not nudge anything, even long logs, with the front of a head which has no snouts.

Do not cut short small stalks when blade speed is low.

Do not operate a high speed disc saw in a populated area.

Do not assume that visitors and other workers are aware of disc saw dangers.

Do not assume that the operator will spare you, a visitor, from danger.

Do not select and operate heads that throw rearward.

Do not select and operate heads with unnecessarily wide throw angles.

Do not neglect to read and follow all instructions provided by the saw and head manufacturers.

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Tigercat M822 Mulcher SECTION 2 - CONTROLS & OPERATION SEPTEMBER, 2005

CONTENTS - SECTION 2 AIR CONDITIONER/HEATER CONTROLS ................................................ 2.17 AIR INTAKE CLEAN-OUT COVER PLATE ................................................. 2.36 AIR INTAKE SEAL ....................................................................................... 2.36 AM/FM STEREO CASSETTE ...................................................................... 2.25 ANTI-STALL - SWITCH WITH LIGHT ......................................................... 2.14 AUXILIARY POWER OUTLET ..................................................................... 2.19 BATTERY DISCONNECT - SWITCH .......................................................... 2.30 BOOM CONNECTIONS ........................................................... 2.15, 2.49, 2.50 BOOM CONTROLS BOOM, FORWARD/BACK ......................................................................... 2.4 BOOM, UP/DOWN ..................................................................................... 2.4 TILT FUNCTION, FELLING HEAD ............................................................. 2.4 CARE OF THE MACHINE ............................................................................ 2.48 CHANGING THE ATTACHMENT ................................................................ 2.49 CIGARETTE LIGHTER ................................................................................ 2.19 CIRCUIT BREAKERS AND FUSES ............................................................... 2.6 CLEANING A/C CONDENSER AND COOLING ASSEMBLY ...................... 2.37 CLEANING LEXAN WINDOWS ................................................................... 2.48 CONTROL PANEL ....................................................................................... 2.14 COOLING ASSEMBLY - CLEANING ........................................................... 2.37 COOLING FAN - SWITCH ........................................................................... 2.19 CUTTER - SWITCH ..................................................................................... 2.19 EMERGENCY EXITS ESCAPE HATCH ...................................................................................... 2.25 ESCAPE HATCH REMOVAL/REPLACEMENT ....................................... 2.26 MAINTENANCE GUIDE ........................................................................... 2.26 SIDE DOOR ............................................................................................. 2.25 ENGINE AIR CLEANER ............................................................................... 2.35 FILTER RESTRICTION INDICATOR ....................................................... 2.35 ENGINE AIR CLEANER UNLOADER VALVE ............................................. 2.35 ENGINE AIR PRECLEANER ....................................................................... 2.35 ENGINE ANTI-STALL - SWITCH WITH LIGHT .......................................... 2.14 ENGINE HOT WATER SHUT OFF VALVES ............................................... 2.24 ENGINE, STARTING, COLD WEATHER .................................................... 2.44 ENGINE, STOPPING ................................................................................... 2.45 FILTER, FRESH AIR - A/C UNIT ................................................................. 2.23 FILTER, HIGH PRESSURE, PILOT SYSTEM ............................................. 2.34 FILTER, RE-CIRCULATING AIR - A/C UNIT ............................................... 2.23 FILTERS, HYDRAULIC OIL ......................................................................... 2.33 FIRE SUPPRESSION SYSTEM (OPTIONAL) AUTOMATIC OPERATION ...................................................................... 2.20 AVOIDING DAMAGE AND FALSE DISCHARGES DURING MACH ....... 2.23 COMPONENT LOCATIONS .................................................................... 2.23 DISCHARGE OF THE SYSTEM .............................................................. 2.21 IN CASE OF FIRE .................................................................................... 2.21 INSPECTION OF FIRE SUPPRESSION SYSTEM .................................. 2.22 MANUAL OPERATION ............................................................................. 2.20

Tigercat M822 Mulcher

Controls and operation

FOOT PEDALS, LEFT AND RIGHT TRACK DRIVE ..................................... 2.5 FUEL SHUT-OFF VALVE ............................................................................ 2.30 FUEL TANK ................................................................................................. 2.30 CAPACITY ................................................................................................ 2.30 FUEL SHUT-OFF VALVE ......................................................................... 2.30 OPTIONAL BOTTOM FUELLING SYSTEM ............................................. 2.30 FILLING INSTRUCTIONS .................................................................... 2.31 FUSES AND CIRCUIT BREAKERS ............................................................... 2.6 GRAFFITI REMOVAL .................................................................................. 2.48 HAND FILL PUMP, HYDRAULIC OIL .......................................................... 2.34 FILLING HYDRAULIC TANK .................................................................... 2.34 HORN, SAFETY ALERT - SWITCH ............................................................. 2.18 HOT WATER SHUT OFF VALVES (ENGINE) ............................................ 2.24 HYDRAULIC OIL FILTERS .......................................................................... 2.33 HYDRAULIC OIL LEVEL SIGHT GAUGES ................................................. 2.33 HYDRAULIC OIL TANK ............................................................................... 2.32 IGNITION KEY SWITCH .................................................................... 2.14, 2.16 INSTALLING THE ATTACHMENT .............................................................. 2.50 INSTRUMENT PANEL ................................................................................... 2.8 BULB TEST SWITCH ............................................................................... 2.12 COOLANT LOW - WARNING LIGHT AND HORN .................................. 2.11 DIMMER CONTROL, INSTRUMENT PANEL .......................................... 2.12 ENGINE COMPUTER FAULT CODE LIGHTS ......................................... 2.12 ENGINE COOLANT TEMPERATURE - GAUGE AND HORN ................... 2.9 ENGINE DIAGNOSTICS CONNECTION ................................................. 2.13 ENGINE DISPLAY AND DIAGNOSTICS MODULE (MDDM) ..................... 2.8 ENGINE OIL PRESSURE - GAUGE .......................................................... 2.9 ENGINE POWER DOOR - SWITCH .......................................................... 2.8 FILTER BYPASS, HYD. OIL - WARNING LIGHT .................................... 2.11 FUEL LEVEL - GAUGE ............................................................................ 2.10 HYDRAULIC OIL LOW - LIGHT AND HORN ........................................... 2.11 HYDRAULIC OIL TEMPERATURE GAUGE AND HORN ........................ 2.10 LIGHTS, SERVICE - SWITCH ................................................................... 2.8 LIGHTS, WORK - SWITCH ...................................................................... 2.12 MODE SELECT SWITCH ......................................................................... 2.15 PILOT SYSTEM "OFF" LIGHT ................................................................. 2.12 PILOT SYSTEM "ON" LIGHT ................................................................... 2.12 POWER ENGINE DOOR - SWITCH .......................................................... 2.8 SAW "ON" LIGHT ..................................................................................... 2.11 STOP ENGINE - WARNING LIGHT ......................................................... 2.12 TACHOMETER ........................................................................................ 2.10 VOLTMETER ............................................................................................ 2.10 WAIT TO START - WARNING LIGHT ..................................................... 2.13 WARNING - WARNING LIGHT ................................................................ 2.12 WATER IN FUEL - WARNING LIGHT ..................................................... 2.13 INTERIOR LIGHTS ...................................................................................... 2.25

2.2

Tigercat M822 Mulcher

Controls and operation

JOYSTICKS, LEFT AND RIGHT HAND ........................................................ 2.4 JUMPER BAR CABLE CONNECTION ........................................................ 2.30 KEY SWITCH ............................................................................................... 2.16 LIGHTS, INTERIOR ..................................................................................... 2.25 LIGHTS, SERVICE ........................................................................................ 2.8 LIGHTS, WORKING .................................................................................... 2.12 MACHINE PREPARATION .......................................................................... 2.46 SYSTEM TEST AND WARM-UP ............................................................. 2.46 MODE SELECT SWITCH ............................................................................ 2.15 MOVING INSTRUCTIONS ........................................................................... 2.51 OPERATING MACHINE .............................................................................. 2.39 PRE-START CHECKS ............................................................................. 2.39 RESTARTING, AFTER RUNNING OUT OF FUEL .................................. 2.44 STARTING ENGINE ................................................................................. 2.42 SYSTEM TEST AND WARM-UP ............................................................. 2.46 OPERATING TIPS WITH LOAD SENSING ................................................. 2.47 OPERATOR’S SEAT (SEATS INC.) ........................................................... 2.28 PILOT SYSTEM INTERLOCK SWITCH (FRONT DOOR) .......................... 2.17 PILOT SYSTEM "OFF "- PUSH BUTTON SWITCH .................................... 2.17 PILOT SYSTEM RESET - PUSH BUTTON SWITCH .................................. 2.17 POWER ENGINE DOOR - SWITCH ............................................................. 2.8 POWER DOOR LATCH ............................................................................. 2.9 PRECLEANER, ENGINE AIR ...................................................................... 2.35 RETURN FILTERS ~ HYDRAULIC OIL ....................................................... 2.33 SEAT, OPERATOR'S (SEATS INC.) .......................................................... 2.28 SERVICE LIGHTS ......................................................................................... 2.8 STEREO CASSETTE AM/FM RADIO .......................................................... 2.25 STOPPING ENGINE .................................................................................... 2.45 SWING BRAKE - SWITCH WITH LIGHT .................................................... 2.14 SWING CONTROL, JOYSTICK ..................................................................... 2.4 SYSTEM CIRCUIT BREAKERS AND FUSES ............................................... 2.6 SYSTEM TEST AND WARM-UP ................................................................. 2.46 THROTTLE SWITCH ................................................................................... 2.16 TRACK DRIVE, LEFT AND RIGHT ............................................................... 2.5 TRACK, LOW/DRIVE - SWITCH WITH LIGHT ........................................... 2.18 TRAVELLING (BOOM RAISED) .................................................................. 2.47 WINDOWS - CLEANING ............................................................................. 2.48

2.3

Tigercat M822 Mulcher

Controls and operation IMPORTANT

This manual is applicable to factory installed machine functions and controls. It does not take into account any changes or modifications made after shipment. Verify all functions before operating this machine.

CONTROLS - CAB

1 2

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822-D04

822-D05

2. R.H. JOYSTICK CONTROL LEVER

1. L.H. JOYSTICK CONTROL LEVER

FOOT PEDAL

FOOT PEDAL

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

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

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

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

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

Attachment Tilt, Forward/Back Move the joystick right to tilt the attachment forward.

Move the joystick left to tilt the attachment back.

Thumb switch, lower left No factory equipped function.

Thumb switch, lower left No factory equipped function.

Thumb switch, lower right No factory equipped function.

Thumb switch, lower right No factory equipped function.

Thumb switch, upper left No factory equipped function.

Thumb switch, upper left No factory equipped function.

Thumb switch, upper right No factory equipped function.

Thumb switch, upper right No factory equipped function.

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

Move the joystick forward to LOWER the boom.

Trigger switch - Wrist Pull the trigger switch to rotate wrist clockwise.

2.4

Tigercat M822 Mulcher 4

•

Controls and operation

3

••

822-D06 FOOT PEDALS 3. RIGHT FOOT PEDAL - RIGHT TRACK DRIVE

Depress the foot pedal with the toe to drive forward.

Depress the foot pedal with the heel to drive backward.

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

Depress the foot pedal with the heel to drive backward.

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

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

2.5

Tigercat M822 Mulcher

Controls and operation

5. SYSTEM CIRCUIT BREAKERS AND FUSES 2X12 GAUGE FUSIBLE LINK CONNECTIONS

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

BATTERIES

••

FUSIBLE LINKS CUMMINS ENGINE

LH830-26

••

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

Two others are used for the engine grid heater relays.

822-D07

ENGINE DIAGNOSTICS CONNECTION BEHIND COVER

SYSTEM CIRCUIT BREAKERS

• LH830-05

INSTRUMENT PANEL

The engine computer fuses and the engine diagnostics plug are located behind a cover on the left side of the instrument panel. Refer also to ENGINE DIAGNOSTICS CONNECTION in THIS SECTION. IQAN fuses are located directly below the large fuse (or breaker) panel located in the rear of the cab.

IQAN FUSES BEHIND THIS COVER

• LH830-03

FUSES

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

2.6

Tigercat M822 Mulcher

Controls and operation

822-D10

•• • • •

ENGINE BELL HOUSING THREE 60 AMP FUSES

822-D09

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

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

2.7

Tigercat M822 Mulcher

Controls and operation POWER DOOR LATCH

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1

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RIGHT SIDE ACCESS DOOR OPEN

4

POWER DOOR LATCH

822-D19

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

5

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9

4.

8

Not used for this machine configuration.

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6

PUMP DRIVE GEARBOX OIL TEMP. - GAUGE

ALARM (LED) AMBER

•• DATA, LCD

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SHUTDOWN (LED) RED

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10

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SCROLL UP

•• LH830-30

LH830-05

INSTRUMENT PANEL

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

14

SCROLL DOWN

ENGINE DIAGNOSTICS MODULE

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

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

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

ACTIVE ENGINE SERVICE CODES

CAUTION

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

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

Tigercat M822 Mulcher

Controls and operation The following are some of the engine parameters displayed:

•• ••

1 2

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

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6. ENGINE OIL PRESSURE - GAUGE

8

6

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

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

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7

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10

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

•• LH830-05

INSTRUMENT PANEL

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

7. ENGINE COOLANT TEMPERATURE - GAUGE This gauge displays information transmitted by the MDDM diagnostics module in the traditional analog format displaying the current engine coolant temperature.

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

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

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

Also refer to the enclosed MURPHY OPERATION MANUAL for a more detailed explanation of this module and how it should be used.

2.9

Tigercat M822 Mulcher

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

• •

1

This meter indicates the engine speed.

Refer to THROTTLE SWITCH in THIS SECTION for engine speeds.

2

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

4

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

•

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

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9 8

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6

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7

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

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Malfunction in a hydraulic circuit

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Malfunction of hydraulic fan drive system

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Malfunction of engine Anti-Stall system

•

Low hydraulic oil level in reservoir

10

• LH830-05

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

INSTRUMENT PANEL

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

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

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

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

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

2.10

Tigercat M822 Mulcher

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

10

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

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

11

13 14 12

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

23 20 15 18 19

24

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21

25 26

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

15. ATTACHMENT "ON" LIGHT

22

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

•• 830-D07

INSTRUMENT PANEL

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

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

WARNING

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

2.11

Tigercat M822 Mulcher

Controls and operation 20. BULB TEST SWITCH

10

•

This is a two position "momentary" switch.

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

11

13 14 12

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••

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

•• 23

20 15 18 19

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21

24 25 26

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

ENGINE COMPUTER FAULT CODE LIGHTS:

22

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

•• 830-D07

INSTRUMENT PANEL

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

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

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

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

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

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

WARNING

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

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

2.12

Tigercat M822 Mulcher

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

10

•

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

11

13 14 12

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27 ENGINE DIAGNOSTICS CONNECTION BEHIND COVER

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•• 23

LH830-05

20 15 18 19

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21

24 25 26

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• • • •

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

22

•• 830-D07

INSTRUMENT PANEL

INSTRUMENT PANEL

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

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

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

2.13

Tigercat M822 Mulcher 1

Controls and operation 4

3

2

6

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•• 5

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822M-004

••

CONTROL PANEL

CONTROL PANEL

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

1. ANTI-STALL - SWITCH WITH LIGHT

2. SWING BRAKE - SWITCH WITH LIGHT

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

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

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

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

IMPORTANT: It should be noted that this anti-stall system will only allow full main pump flow with the engine running at speeds above:

CAUTION • Turning ON the swing brake while the boom is moving can damage the gearbox

Cummins QSL9 Engine 1700 RPM Cummins QSC Engine 2000 RPM If BOOM, SWING or TRACK DRIVE functions slow down or stop, check to ensure that the engine speed is above the required level listed above for your machine’s engine.

• NEVER operate the tracks with the swing brake ON as boom contact with the ground will damage the swing gearbox 3. FUEL HEATER SWITCH

If engine stalling occurs, check:

This is a two position switch labelled ON /OFF. Placing this switch in the ON position will turn on the FUEL HEATER.

(a) The ANTI-STALL switch is in the ON position.

An automatic thermostat turns the fuel heater on when the fuel temperature drops below 45°F and off when the fuel temperature reaches 75°F.

(b) The 2 amp fuse located in the large fuse (or circuit breaker) panel in the cab. (c) Malfunction of the anti-stall system.

2.14

Tigercat M822 Mulcher

Controls and operation

4. MODE SELECT SWITCH (SAW/MULCHER) MULTIFUNCTION MACHINES SN 822110578 AND UP

FELLER BUNCHER/MULCHER BOOM CONNECTIONS SAW MODE:

NOTE: These Multifunction M822 Machines have the ability to operate with either a Disc Saw Felling Head or a Mulching Head.

When the machine is attached to the Mulching Head, the hydraulic system is connected in such a way that hydraulic oil from both the Saw Pump and Main Pump provide the increased flow required when operating the Mulching Head.

1. Saw Return 2. Wrist Left 3. Wrist Right 4. Clamp Open 5. Accumulator Open 6. Accumulator Closed

When the machine is attached to the Saw Head, the hydraulic system is connected so that the Saw Pump provides hydraulic oil for the Saw Drive and Attachment Pump provides hydraulic oil for the Accumulator Arm and Wrist functions. The Clamp function is run off of the Main pump.

The MODE SELECT SWITCH is a twoposition switch labeled MULCHER, MODE SELECT and SAW. The Mulcher Head requires different pressure settings than the Saw Head functions, this switch sets the proper pressure values for the attached head.

When the switch is in the MULCHER MODE and the cutter is turned on the light on the face of the switch will be turned ON, the IQAN display will also read the mode selected when toggled. The Saw or Mulcher heads will not function properly in the wrong mode. If mulcher mode is selected while the Saw head is attached, the clamps will not function, if the saw mode is selected while the Mulcher head is attached, the head will have low power.

7. Saw Pressure 8. Clamp Closed Pressure 9. Saw Case Drain ATTACHMENT END OF BOOM

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2

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5

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4

Never operate machine in SAW MODE with Mulcher Head attached. In this mode, the head can be activated by the CLAMP CLOSE joystick function.

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7

8

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9

CAB CABSIDE SIDE 822M-006

BOOM CONNECTIONS

MULCHER MODE: 1. Mulcher Return (1)

WARNING

6

2. Wrist Left 3. Wrist Right 4. Mulcher Return (2) 5. Capped

To select SAW MODE press the switch DOWN to the saw mode position.

6. Capped

To select MULCHER MODE push the switch UP to the mulcher mode position.

8. Mulcher Pressure (2)

7. Mulcher Pressure (1)

9. Mulcher Case Drain

The MODE SELECT SWITCH only becomes active when the cutter switch is turned on.

2.15

Tigercat M822 Mulcher 1

Controls and operation 4

3

2

6

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CONTROL PANEL

822M-004

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

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

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

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

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

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

6. THROTTLE SWITCH CUMMINS ENGINE This is a three position "momentary" switch connected into the engine CPU circuit to adjust the engine RPM. between the (IDLE) and

(FULL) throttle set points.

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

2.16

Maintaining Correct Engine RPM. It is most important that the IDLE and FULL RPMs. of the engine be correct at all times: Cummins QSL9 280 HP Engine IDLE 900 to 950 RPM (No Load) FULL 1830 to 1850 RPM max (No Load) RATED WORKING 1800 RPM Cummins QSC 240 HP Engine IDLE 900 to 950 RPM (No Load) FULL 2200 to 2250 RPM max (No Load) RATED WORKING 2200 RPM NOTE: At start-up the engine will always default to IDLE. The above values are with the hydraulic and engine oil at normal operating temperatures and no functions activated and without pilot system engaged. These values are pre-set into the engine CPU (computer) and cannot be adjusted without the proper electronic equipment programming software. Check engine speed regularly with engine diagnostics module.

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

Tigercat M822 Mulcher

Controls and operation

7 8 C

B

9

10

11

12

14

15

A

••

••

•• •

13

••

•• •

••

•

••

••

CONTROL PANEL

822M-005

8. PILOT SYSTEM RESET - PUSH BUTTON SWITCH

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

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

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

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

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

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

ACTUATOR ON DOOR

•

••

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

822-D02

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

INTERLOCK SWITCH (FRONT DOOR)

9. PILOT SYSTEM OFF - PUSH BUTTON SWITCH

Refer also to CHECKING THE AIR CONDITIONING SYSTEM in SECTION 3 of THIS MANUAL. 2.17

This is a push OFF spring return switch. This switch shuts off the pilot system deactivating all operating functions as well as applying the track drive brake and swing brake. The pilot OFF light will be ON and the pilot ON light will be OFF. The pilot system can be REACTIVATED when the PILOT RESET button (item 8) is pressed with the front door closed.

Tigercat M822 Mulcher

Controls and operation

7 8 C

B

9

10

11

12

15

••

••

••

•• ••

••

14

A

•• •

13

•

•

••

CONTROL PANEL The DRIVE position will provide a faster travel 10. TRACK, LOW/DRIVE - SWITCH WITH LIGHT speed range but with a lower driving force.

This is a two position switch labelled LOW and However, when the machine encounters DRIVE. tougher terrain conditions, e.g. stumps, soft IMPORTANT: ground or slopes etc., the drive system will This switch when in DRIVE provides infinitely automatically adjust* to a slower travel speed/ variable travel speeds/torque ranges, unlike higher torque range. similar travel range controls on some types of *This amount of adjustment can be anywhere construction equipment. from a slight reduction in speed to all the way LOW: Placing the switch in the LOW position down to LOW, this will be dependant on the will provide the slowest travel speed but with terrain conditions encountered. increased torque or driving force.

NOTE: The operator should be aware that this It is recommended that when operating automatic speed/torque range adjustment will attachment and when travelling on slopes that cause the machine to gradually slow down the range switch be placed in the LOW over a period of 1 to 2 seconds, due in part to position to maximize drive motor life. Low the infinitely variable displacement drive position is indicated by a light on the Track motors used. When travelling on relatively flat Low/drive switch. terrain it is not necessary to place the range switch in the LOW position .

DRIVE: When this switch is in the DRIVE 822M-005

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

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

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

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

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

2.18

Tigercat M822 Mulcher

Controls and operation

12. CUTTER - SWITCH NOTE: Multifunction M822 Machines have the abilty to operate with either a Disc Saw Felling Head or a Mulching Head. Place the MODE SELECT SWITCH in the Mulcher Mode when using a Mulching Head or Saw Mode when using a Disc Saw Felling Head. See page 2.15 item 4 MODE SELECT SWITCH for Details.

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

Place throttle in FULL position before turning cutter ON. NOTE: If the engine has been turned off or the pilot shut off system tripped (Front Door opened) with the cutter switch left in the ON position, the cutter will not start up when the engine is restarted or the front door closed. In this case press the PILOT RESET button and turn the cutter switch OFF and then ON. 13. COOLING FAN - SWITCH This is a two position "momentary" switch. Press and hold this switch in the CLEAN (PURGE) position to run the cooling fan in reverse. With

CAUTION Before placing the fan switch in the CLEAN (PURGE) position make sure that there are no personnel on the RIGHT side of the machine in the area where the fan will expel debris. this switch in the "normal" position the hydraulically driven cooling fan will be turning and drawing cool air through the debris screen and cooling assembly. The air is expelled to atmosphere through the perforated panels that make up the engine enclosure.

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

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

15. CIGARETTE LIGHTER Cigar/Cigarette lighter.

2.19

Tigercat M822 Mulcher

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

16

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

•• ••

"SYSTEM OK" LIGHT

••

FIRE SUPPRESSION SYSTEM

822-D19

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

•• 376-24A

SYSTEM CONTROL PANEL

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

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

RED FIRE BUTTON

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

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

DISCHARGE HOSE

•

To manually operate the system:

PRESSURE GAUGE

1. Safely lower the boom to the ground.

2. Pull locking pin.

•

3. Press red FIRE button.

PRESSURIZED CYLINDER

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

•• •• 822-D20

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

822-D19

ELECTRICAL ACTUATOR

•

"PUSH TO TEST" BUTTON

PRESSURIZED CYLINDER CHECK GAUGE DAILY 2.20

Tigercat M822 Mulcher

Controls and operation

DISCHARGE OF THE SYSTEM When an electrical signal (automatic or manual) is received by the control panel it sends a discharge signal to the electrical actuator located on top of the pressurized cylinder. When activated the electrical actuator extends a control shaft which mechanically opens the agent cylinder valve.

This releases the dry chemical in the discharge area protected by the system. At the same time the control panel will also automatically shut down the engine.

will automatically shutdown either immediately or will be delayed for 10 to 15 seconds if the machine is a leveller.

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

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

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

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

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

CAUTION Wear protective clothing and masks when cleaning up after a discharge Before cleaning up after a discharge, read the AMEREX manual. If water mixes with the dry chemical it becomes corrosive and can seriously damage wiring connections.

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

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

1. Safely lower the boom to the ground.

RED FIRE BUTTON

••

MANUAL ACTUATION SWITCH 2. Pull locking pin.

822-D19

3. Press red FIRE button.

The system will activate the discharge system and the automatic engine shutdown system. There will be a cloud of dry chemical dispersed in the discharge area. The engine 2.21

Tigercat M822 Mulcher

Controls and operation

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

ELECTRICAL ACTUATOR

•

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

•

Check fire suppression electrical network.

•

Ensure thermostats are clean.

PRESSURE GAUGE

• ••

PRESSURIZED CYLINDER

• • PRESSURIZED CYLINDER CHECK GAUGE DAILY

822-D20

TYPICAL THERMOSTAT

378-19A

•• DAILY: •

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

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

•

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

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

"SYSTEM OK" LIGHT

••

"PUSH TO TEST" BUTTON

••

PRESSURE GAUGE 376-24A

••

•

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

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

BI-YEARLY •

822-D21

PORTABLE FIRE EXTINGUISHER CHECK CHARGE GAUGE DAILY

WEEKLY: •

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

•

All components are in place and unobstructed.

2.22

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

Tigercat M822 Mulcher

Controls and operation 17. FILTER, RE-CIRCULATING AIR - A/C UNIT Air in the cab is drawn into the A/C-HEATER unit via this filter and re-circulated. The filter should be inspected and cleaned on a regular basis. The A/C will not cool efficiently if these filters become dirty or plugged.

17

••

RE-CIRCULATING AIR FILTER 18. FILTER, FRESH AIR - A/C UNIT 822-D22

822-03

COMPONENT LOCATIONS

Outside air is continuously drawn into the cab air conditioning unit through this filter and mixed with interior air from the cab. The filter is located on the right side of cab and can be serviced from the outside by removing the

AVOIDING DAMAGE AND FALSE DISCHARGES DURING MACHINE SERVICE: Pay attention to the location of the components of the fire suppression system. Take care not to damage heat sensors or wiring, this includes hitting, cutting, bending, denting, etc. Damage to heat sensors due to shock could cause an accidental discharge of the system. Cut, pinched, or kinked wiring could cause false signals and lead to burnt wiring or an accidental discharge of the system.

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

18

•

822-D23

If any of the components are damaged replace them immediately.

FRESH AIR FILTER

two fasteners holding the hinged cover. The filter should be inspected on a regular basis and cleaned/replaced when dirty or when wet. NEVER operate air conditioner without a filter installed.

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

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

2.23

Tigercat M822 Mulcher

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

••

HOSE TO A/C HEATER UNIT

••

•• •• ••

19 SHUT-OFF VALVES COOLANT FILTER ELEMENT

LH830-D18

••

••

HOSE FROM A/C HEATER UNIT

HOT WATER SHUT OFF VALVE (CUMMINS ENGINE)

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

2.24

Tigercat M822 Mulcher

Controls and operation 20

• 21

•

23

822-D25

• •

22

23. ESCAPE HATCH, EMERGENCY EXIT This is a third cab exit for use if the side exit and the front door exit become blocked. There are two retaining knobs on the inside to allow removal of the hatch. These knobs should only be HAND TIGHTENED, to allow them to be unscrewed in case of an emergency.

•

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

• ••

••

•

INTERIOR LIGHTS, EMERGENCY EXITS

••

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

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

RETAINING KNOB AND CLAMP BRACKET

•

23

21

••

••

822-D26

ESCAPE HATCH, EMERGENCY EXIT

For more information refer to ESCAPE HATCH AND SIDE DOOR EMERGENCY EXIT MAINTENANCE GUIDE in THIS SECTION. 822-D27

AM/FM STEREO CASSETTE/

WARNING

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

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

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

Failure to follow these proper maintenance procedures can result in the exit being unusable in an emergency ESCAPE HATCH REPLACEMENT: NOTE: Do not apply silicone sealant between Escape Hatch and Cab Roof

22

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

•

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

822-D29

SIDE DOOR EMERGENCY EXIT 2.25

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

Tigercat M822 Mulcher

Controls and operation If the escape hatch does not move without excessive force refer to ESCAPE HATCH REMOVAL FOR MAINTENANCE OR REPAIR and ESCAPE HATCH REPLACEMENT in THIS SECTION.

SIDE DOOR AND ESCAPE HATCH EMERGENCY EXIT MAINTENANCE GUIDE Two alternate exit routes are provided on the LH. side and roof of the cab. These are only to be used if the front door cannot be opened.

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

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

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

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

REMOVE BOTH CLAMP BRACKETS

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

••

ESCAPE HATCH REMOVAL ESCAPE HATCH REMOVAL FOR MAINTENANCE OR REPAIR:

822-D31 822-D29 INTERIOR HANDLE

822-D28 EXTERIOR HANDLE

2. Check for proper operation of both handles, latches and hinges. Adjust and/or lubricate any part of the mechanism that requires attention.

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

CHECKING PROCEDURE FOR ESCAPE HATCH: CLAMP BRACKET

UNSCREW RETAINING KNOB FOUR COMPLETE TURNS

WARNING

••

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

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

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

••

822-D30

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

CHECK ESCAPE HATCH

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

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

2.26

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

Tigercat M822 Mulcher

Controls and operation FOAM SEAL

ESCAPE HATCH

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

'C' CHANNEL RUBBER

•

CAB ROOF

• ••

APPLY GREASE TO 'C' CHANNEL RUBBER BETWEEN CHANNEL AND CAB ROOF LH830-06

NYLON INSERT

•

CROSS SECTION OF ESCAPE HATCH SEAL

SKY LIGHT

• CAB

•• WARNING

822-01

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

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

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

NYLON STUD REPLACEMENT

2.27

Tigercat M822 Mulcher

Controls and operation

OPERATOR’S SEAT (SEATS INC.)

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

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

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

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

To Raise Firmly lift up on the height adjustment lever.

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

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

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

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

To Lower Firmly lift up on the height adjustment lever.

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

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

• ••

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

•• ARMREST ADJUSTMENT

SEAT ADJUSTMENTS

332-6 4-WAY LUMBAR VERTICAL ADJUSTMENT

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

•

4-WAY LUMBAR HORIZONTAL ADJUSTMENT

BACK ANGLE ADJUSTMENT KNOB

••

•• RIDE ADJUSTMENT KNOB 332-1B

••

•• ••

VIEW FROM RIGHT REAR OF SEAT

HEIGHT ADJUSTMENT LEVER FORE/AFT SLIDE LEVER

2.28

Tigercat M822 Mulcher

Controls and operation

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

Refer to height adjustment.

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

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

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

2.29

Tigercat M822 Mulcher

ENGINE COMPARTMENT

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

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

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

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

3

••

822-D34

FUEL SHUT-OFF VALVE

••

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

•• FUEL FILLER CAP

822-D48

2

FUEL LEVEL SENDER

FUEL FILLER CAP AND FUEL LEVEL SENDER

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

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

••

LH830-29

JUMPER BAR CABLE CONNECTION

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

2.30

Tigercat M822 Mulcher

Controls and operation CAUTION

INDICATOR LIGHT

••

•• •

QUICK DISCONNECT

LH830-20

ON/OFF SWITCH

CAUTION

BOTTOM FUELLING OPTION

FUEL FILLING PROCEDURE LABEL

BOTTOM FUELLING OPTION FUEL FILLING INSTRUCTIONS

••

1. Park machine with the upper level.

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

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

FUEL FILLING PROCEDURE LABEL

LH830-21

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

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

SOLENOID OPERATED SHUT OF VALVE

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

••

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

8. Turn off fuel transfer pump.

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

LH830-19

10. Turn off service lights.

FUEL FILLING SHUT OFF VALVE

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

•• FUEL FILLER CAP

LH830-22

FUEL LEVEL SENDER

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

•• ••

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

FUEL FLOAT SWTICH

FUEL FILLER CAP AND FUEL LEVEL SENDER - BOTTOM FUELING 2.31

Tigercat M822 Mulcher

Controls and operation

4. HYDRAULIC OIL TANK

IMPORTANT

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).

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 GROUP

RETURN MANIFOLD

•• ••

••

• •• WATER ABSORBING ELEMENT (COLOUR BLUE)

DRIP TRAY

•

822M-016

HYDRAULIC OIL TANK

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

SOME COMPONENTS REMOVED FOR CLARITY BREATHER FILTER

••

TOP OF HYDRAULIC TANK

•• •• H822-03

BREATHER, HYDRAULIC TANK LATER MACHINES HYDRAULIC TANK

5. BREATHER, HYDRAULIC TANK The air space in the top of the hydraulic tank is vented to atmosphere via a spin-on filter. The hydraulic tanks on later machines are not pressurized.

822M-015

2.32

HYDRAULIC COMPARTMENT

Tigercat M822 Mulcher

Controls and operation

6. OIL LEVEL SIGHT GAUGES

7. RETURN FILTERS ~ HYDRAULIC OIL

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

••

FIRST SIGHT GAUGE

SECOND SIGHT GAUGE

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

5 - HYDRAULIC RETURN FILTERS

•

RETURN MANIFOLD

•• ••

••

LOW LEVEL SENDING UNIT, FOR WARNING LIGHT

•• • • ••

••

•• 1 - WATER ABSORBING RETURN FILTER (COLOUR BLUE)

DRIP TRAY

LOW LEVEL SENDING UNIT, FOR WARNING BUZZER

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

The pressures stated are for normal operating conditions and temperatures.

822M-016

422-05 HYDRAULIC OIL LEVEL SIGHT GAUGES Incorporated into the first sight gauge (highest) is a low level sending unit which signals a LOW HYDRAULIC OIL light in the cab to come ON when the oil level reaches the LOW mark. A second sight gauge is used to detect a further loss of oil. Incorporated into this gauge is a sending unit (earlier machines also incorporated a temperature gauge). If the level of oil reaches the bottom of this gauge, the sending unit will signal a buzzer in the cab to sound.

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

FILTER SERVICE NOTE

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

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

2.33

Tigercat M822 Mulcher

Controls and operation RETURN MANIFOLD

•

• ••

RETURN MANIFOLD PORT

CONNECT THE QUICK DISCONNECT TO THE RETURN MANIFOLD PORT

HIGH PRESSURE PILOT FILTER 822-D47 8. HIGH PRESSURE PILOT FILTER

FILLING HYDRAULIC TANK tank. A male quick disconnect port is provided on the return filter manifold and mates with a female quick disconnect attached to the outlet hose on the hand pump. This ensures that any hydraulic oil added is filtered prior to entering the hydraulic tank.

822-D40

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.

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

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

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

FEMALE QUICK DISCONNECT

••

••

SUCTION HOSE

822-D46

HAND FILL PUMP

10. HYDRAULIC HAND FILL PUMP The hydraulic hand fill pump, on the rear left door, is used for adding oil to the hydraulic 2.34

Tigercat M822 Mulcher

Controls and operation

11. ENGINE AIR PRECLEANER

EXHAUST SYSTEM

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

PRECLEANER TO TURBO CHARGER

•• ••

••

AIR CLEANER

• AIR CLEANER UNLOADER VALVE

••

AIR CLEANER AIR CLEANER UNLOADER VALVE

354-15

DISCHARGE PORT AREA

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

13. FILTER RESTRICTION INDICATOR

218-21B

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

PRECLEANER

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

FILTER RESTRICTION INDICATOR

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

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

••

822-D42

FILTER RESTRICTION INDICATOR

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

2.35

Tigercat M822 Mulcher

Controls and operation

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

•

421-15A

AIR INTAKE CLEAN-OUT COVER

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

••

CHECK CONDITION OF SEAL

•• 822-D58

PRECLEANER

AIR INTAKE SEAL

2.36

Tigercat M822 Mulcher

Controls and operation A/C CONDENSER

DEBRIS SCREEN

OIL COOLER RADIATOR COOLING FAN SHROUD FINGER GUARD

••

••

SURGE TANK FAN DRIVE MOTOR

• ••

• •• •

••

•

•

CHARGE AIR COOLER

LH830-01

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

COOLING ASSEMBLY - OVERALL VIEW

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

PROCEDURE: 1. Shut down as per instructions in OPERATING MACHINE SECTION. 2. Open rear right side engine door.

3.

Slide the debris screen out.

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

5.

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

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

2.37

Tigercat M822 Mulcher

Controls and operation

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

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

Always use personal protective equipment to guard against flying debris avoid the risk of fire caused by debris contacting hot surfaces. Care must be taken not to set the pressure too high otherwise damage to the components could result.

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

COOLING ASSEMBLY LH830-08

A/C CONDENSER OIL COOLER/ RADIATOR/CAC ASSEMBLY

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

••

•• ••

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

SLIDE DEBRIS SCREEN OUT AND REMOVE

COOLING ASSEMBLY LH830-09

• NUTS A/C CONDENSER

• HINGES

WARNING

•• •

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

LH830-10

2.38

SWING OUT A/C CONDENSER

Tigercat M822 Mulcher OPERATING MACHINE

Controls and operation ENGINE OIL DIPSTICK

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

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

BEFORE YOU BEGIN: PRE-START CHECKS 1. Ensure ignition key switch and cutter switch are in the OFF position.

2. Check fire extinguisher is sufficiently charged.

CHECK ENGINE OIL LEVEL (CUMMINS ENGINE)

LH830-11

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

EXHAUST SYSTEM

PRESSURE GAUGE

PRECLEANER TO TURBO CHARGER

•• ••

•

••

AIR CLEANER

822-D21

•

PORTABLE FIRE EXTINGUISHER CHECK CHARGE GAUGE

AIR CLEANER UNLOADER VALVE

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

••

354-15

6.

LH830-05

INSTRUMENT PANEL

AIR CLEANER

Check air cleaner unloader valve.

FILTER RESTRICTION INDICATOR

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

••

••

•

UPPER SIGHT GAUGE

822-D42 FILTER RESTRICTION INDICATOR 7. Check air filter restriction indicator.

422-05A

CHECK HYDRAULIC OIL LEVEL 2.39

Tigercat M822 Mulcher

Controls and operation

AIR INTAKE AREA

DISCHARGE PORT AREA

• TOP SEAL 218-21B

UNDER SIDE OF PRECLEANER

CHECK AIR INTAKE PRE-CLEANER 8. Check air intake pre-cleaner and top seal.

822-D50

CHECK CONDITION OF ENGINE BELTS 11. Check condition of engine belts. Cover should be removed to check tension of belts every 250 hours.

822-D51

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

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

WATER SEPARATOR BOWL

DRAIN TAP

822-D53

• • FUEL LINE WATER SEPARATOR

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

822-D54 CHECK ENGINE COOLANT LEVEL 12. Check the engine coolant level.

WATER SEPARATOR

DRAIN TAP

•• ••

LH830-12

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

2.40

Tigercat M822 Mulcher

Controls and operation 17. Check and tighten all of the fasteners retaining the cutter teeth to the proper torque level.

A/C CONDENSER OIL COOLER/ RADIATOR/CAC ASSEMBLY

18. Replace all worn cutter teeth or rotate worn teeth to align fresh cutting tips.

19. Replace the tooth fastener whenever replacing a tooth.

••

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

•• •• SLIDE DEBRIS SCREEN OUT AND REMOVE

LATER MACHINE SHOWN

LH830-09

CLEAN A/C CONDENSER AND COOLING ASSEMBLY

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

22. Check that the cutter housing is clear and undamaged.

23. Shut down the machine immediately if you feel a vibration when the cutter is running.

13. Clean A/C condenser and cooling assembly.

Refer to CLEANING A/C CONDENSER AND COOLING ASSEMBLY in THIS SECTION.

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

14. Check all exits.

CRACKING

BENT

WARN HOLES EDGE WEAR

EDGE WEAR BROKEN EDGE 830-02

CHECK CONDITION OF TRACK SHOES

15. Check condition of track shoes.

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

MEASURING SAG DIMENSION

16. Check track chain tension.

2.41

Tigercat M822 Mulcher STARTING ENGINE

Controls and operation

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

4

2

LH830-23

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

LH830-25

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

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

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

CAUTION

3

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.

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

LH830-23

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

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

3

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

LH830-24

2.42

Tigercat M822 Mulcher

Controls and operation

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

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

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

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

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

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

2.43

Tigercat M822 Mulcher COLD WEATHER STARTING

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

CUMMINS ENGINE

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

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

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

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

RESTARTING AN ENGINE THAT HAS RUN OUT OF FUEL If the engine runs out of fuel, the fuel line must be primed:

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

1. Refill fuel tank completely.

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

3

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

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

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

WAIT TO START WARNING LIGHT

Bleed the system according to engine manual procedures.

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

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

• WARNING

LH830-24

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

2.44

Never use a liquid staring aid to start an engine.

Tigercat M822 Mulcher STOPPING ENGINE

Controls and operation

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

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

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

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

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

5. Do not race engine before shut-off.

6. Activate PILOT SHUT OFF switch.

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

8. Attachment must have stopped before you exit.

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

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

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

2.45

Tigercat M822 Mulcher

Controls and operation (m) Observe all boom operations. If any operations are not operating as they should, take the necessary steps to correct the problem.

MACHINE PREPARATION SYSTEM TEST AND WARM-UP

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

Before commencing mulching operations, follow steps (a) through (q) to accomplish the following; •

Warm up the hydraulic system.

•

Test all systems for proper operation.

•

Inspect for hydraulic oil leaks.

WARNING Ensure that the cutter has stopped rotating before leaving the cab.

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

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

Assuming machine was parked on level ground at last shutdown:

WARNING

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

Never use your bare hand to check for fluid leaks.

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.

(d) Press Pilot reset button (e) Place the anti-stall switch in the OFF position. (f) Increase engine speed to approximately 1300 rpm (Cummins QSL9 engine) or 1500 rpm (Cummins QSC engine). (g) Slowly raise and lower the stick boom and the main boom, check for proper operation.

(p) Leave the cab and visually check hose connections and cylinders for leaks. Check under the machine for oil leaks.

With the attachment raised slightly off the ground: (h) Operate the debris door and check for proper operation. (i) Tilt the attachment forward and back and check that it is operating correctly. (j) Swing the upper to the left and right. (k) When cold weather conditions exist, continue the process of warming up the hydraulic system by repeating steps (g) through (j) several times. If the FILTER BYPASS warning lights come on decrease engine speed immediately and continue warming the system.

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

(l) Turn the attachment on.

2.46

Tigercat M822 Mulcher TRAVELLING (BOOM RAISED) 1. Select the appropriate drive range.

Place the track switch in the LOW or DRIVE position.

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

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

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

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

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

3. Move throttle control to the HIGH idle position.

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

2.47

Tigercat M822 Mulcher

Controls and operation

CARE OF THE MACHINE

REMOVING HAIRLINE SCRATCHES

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

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

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

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

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

SOME IMPORTANT DON’TS

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

DO NOT use abrasive or highly alkaline cleaners on LEXAN sheet products.

5. Do not apply load to a cold engine.

6. Close and secure all doors and access covers.

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

8. Always operate attachment in LOW driving range.

9.

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

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

1. Rinse with lukewarm water.

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

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

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

Compatible Cleaning Agents Aqueous Solutions of Soaps and Detergents Formula 409 Top Job Freon T.F. VM&P grade Naphtha Joy Windex with Ammonia D Palmolive Liquid GRAFFITI REMOVAL (A) Butyl Cellosolve (For removal of paints, marking pen inks, etc.) The use of masking tape, adhesive tape or lint removal tools works well for lifting off old weathered paints.

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

3. Rinse with clean lukewarm water.

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

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

2.48

Tigercat M822 Mulcher Controls and operation CHANGING THE ATTACHMENT - MULTIFUNCTION OPTION TOOLS REQUIRED 1. Drain Pan and Cloth Rags 2. 1 1/8" Socket and Ratchet.

3. 1 3/8", 1 1/2", 1 3/4" and 2 3/4" Combination Wrenches 4. Torque Wrench (to 500 lb.ft.)

1

2

4

3

10 11

•

WARNING

9

Before performing any work on the attachment, ensure that the attachment is lowered and firmly supported on level ground. Failure to do so could result in serious injury or death from crushing.

5

1. REMOVING THE ATTACHMENT

6

7

822M-007 822M-012

Ensure that the attachment is lowered and firmly supported on level ground.

1

2

8

FELLING HEAD INSTALLATION 3

4

10 11

Shut engine off.

If the attachment being removed is a Disc Saw Felling Head be sure to install the SAW GUARD and blade LOCK BOLT as outlined in the SAW OPERATING AND SERVICE MANUAL. Remove the hose cover on the boom and clean the attachment, boom and hoses of all debris and dirt.

9

5

6

822M-006 822M-011

7

8

MULCHING HEAD INSTALLATION

3. REMOVE THE BOOM AND LINK PINS Remove the bolt (1), washer (2), spacer (3) and link pin (4) attaching the link to the wrist boom adapter.

Remove the bolt (5), washer (6), spacer(7), nut (9), nut (11) spacer (10) and pin (8) attaching the boom to the wrist boom adapter.

822M-012

FELLING HEAD

Close cab door, start the engine, press pilot reset switch, slowly raise boom and back machine away from the attachment.

822M-009

MULCHING HEAD

2. DISCONNECT HOSES Install a drain pan under hose fittings.

Disconnect and remove hoses from tubes.

Plug and cap hose and tube ends to prevent debris and moisture from entering hydraulic system.

NOTE: Hose connections and tube ends are stamped with a number from 1 to 9. Mate these numbers when reconnecting hoses to the tubes.

See INSTALLING THE ATTACHMENT for procedure to connect alternate attachment. Refer to FELLER BUNCHER/MULCHER BOOM CONNECTIONS in this section.

2.49

Tigercat M822 Mulcher Controls and operation INSTALLING THE ATTACHMENT - MULTIFUNCTION OPTION 1

2

4

3

Tighten the hose fittings to the specification shown in FELLER BUNCHER/MULCHER BOOM CONNECTIONS AND TORQUE SPECIFICATION.

10 11

FELLER BUNCHER/MULCHER BOOM CONNECTIONS AND TORQUE SPECIFICATION

•

SAW MODE: 9

1. Saw Return (110 lbft. - 150 Nm) 2. Wrist Left (85 lbft. - 115 Nm)

5

6

7

8

3. Wrist Right (85 lbft. - 115 Nm) 4. Clamp Open (110 lbft. - 150 Nm)

822M-007 822M-012

5. Accumulator Open (85 lbft. - 115 Nm)

FELLING HEAD INSTALLATION

6. Accumulator Closed (85 lbft. - 115 Nm) 1

2

3

4

10 11

7. Saw Pressure (110 lbft. - 150 Nm) 8. Clamp Closed Pressure (110 lbft. - 150 Nm) 9. Saw Case Drain (85 lbft. - 115 Nm) ATTACHMENT END OF BOOM

9

1

3

2 5

6

822M-006 822M-011

7

8

••

•

5

•• •

4

6

•

7

8

• • •• ••

9

MULCHING HEAD INSTALLATION

3. INSTALLING THE BOOM AND LINK PINS Carefully move the machine up to the alternate attachment and align the boom and link with the attachment wrist boom adapter pin holes.

Install the boom pin (8), spacer (10), nut (11), washer (6), bolt (5), spacer (7) and nut (9).

Tighten nut (11) to obtain zero end play of pin (8). Torque nut (9) to 282-312 lbft.

Align the link with the pin hole in the wrist boom adapter. Install link pin (4), bolt (1), washer (2), and spacer (3).

Torque bolt (1) to 282-312 lbft.

2. CONNECT HOSES Refer to FELLER BUNCHER/MULCHER BOOM CONNECTIONS for hose connection location reference.

Install the hoses on the tubes matching the numbers on the hose ends with the numbers on the tube ends.

CAB CABSIDE SIDE 822M-006

BOOM CONNECTIONS

MULCHER MODE: 1. Mulcher Return (110 lbft. - 150 Nm) 2. Wrist Left (85 lbft. - 115 Nm) 3. Wrist Right (85 lbft. - 115 Nm) 4. Mulcher Return (110 lbft. - 150 Nm) 5. Capped (85 lbft. - 115 Nm) 6. Capped (85 lbft. - 115 Nm) 7. Mulcher Pressure (110 lbft. - 150 Nm) 8. Mulcher Pressure (110 lbft. - 150 Nm) 9. Mulcher Case Drain (85 lbft. - 115 Nm) NOTE: Can also use (F.F.W.R.) Flats From Wrench Resistance method. Tighten hose fitings 1/3 to 1/2 flat .

2.50

Tigercat M822 Mulcher

Controls and operation

17714B R

2.51

Tigercat M822 Mulcher

Controls and operation

2.52

Tigercat M822 Mulcher SECTION 3 - LUBRICATION & MAINTENANCE SEPTEMBER, 2005

CONTENTS - SECTION 3 AIR CONDITIONING CHECKING THE SYSTEM ...................................................................... 3.12 AIR INTAKE MAINTENANCE ..................................................................... 3.20 APPROVED HYDRAULIC OILS ................................................................... 3.8 CHECKING THE AIR CONDITIONING SYSTEM ....................................... 3.12 EMERGENCY EXITS, CHECK MONTHLY ................................................... 3.3 ENGINE AIR CLEANER MAINTENANCE .................................................. 3.20 ER BOOM SYSTEM .................................................................................... 3.11 FILTER AND LUBRICATION SCHEDULE .................................................... 3.9 FILTERS CHANGING HYDRAULIC RETURN FILTERS ........................................ 3.16 ENGINE AIR FILTER .............................................................................. 3.20 FUEL FILTER/WATER SEPARATOR ..................................................... 3.14 FUEL TANK STRAINER .......................................................................... 3.15 HYDRAULIC OIL RETURN FILTERS ..................................................... 3.16 HYDRAULIC OIL RETURN STRAINERS/DIFFUSERS .......................... 3.19 PILOT FILTER ......................................................................................... 3.18 REMOVE AND REPLACE ....................................................................... 3.14 SERVICING GUIDELINES FOR OIL FILTERS ....................................... 3.16 FILTERS, HYDRAULIC OIL ........................................................................ 3.17 FIRE PREVENTION ...................................................................................... 3.3 GENERAL MAINTENANCE .......................................................................... 3.3 HYDRAULIC OIL FILTERS ......................................................................... 3.17 HYDRAULIC OILS ........................................................................................ 3.8 LUBRICATION SCHEDULE .......................................................................... 3.9 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 PREVENTIVE MAINTENANCE SCHEDULE ................................................ 3.2 RETURN FILTERS ~ HYDRAULIC OIL ...................................................... 3.16 SCHEDULED MAINTENANCE FREQUENTLY .......................................................................................... 3.4 8 HOURS ................................................................................................... 3.4 24 HOURS ................................................................................................. 3.5 125 HOURS ............................................................................................... 3.5 250 HOURS ............................................................................................... 3.6 500 HOURS ............................................................................................... 3.6 1000 HOURS ............................................................................................. 3.7 2000 HOURS ............................................................................................. 3.7 SWING DRIVE GEARBOX LUBRICATION OF LOWER BEARING ................................................... 3.10 TORQUE CHART ....................................................................................... 3.23 TORQUE CHART, GENERAL .................................................................... 3.24

Tigercat M822 Mulcher

Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE FOR M822 MULCHER 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 Engine mounting bolts Pump mounting bolts

IMPORTANT

Track shoe bolts Track roller retaining bolts

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

Track sprocket retaining bolts

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

Track drive gearbox mounting bolts Track drive motor mounting bolts

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

Swing gearbox mounting bolts Cab securing bolts

OIL LOST FROM LEAKAGE

Any other loose nut, bolt or fitting LEAKAGE RATE ONE DROP IN 10 SECONDS ONE DROP IN 5 SECONDS ONE DROP PER SECOND THREE DROP PER SECOND DROPS BREAK INTO STREAM

3.2

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

Tigercat M822 Mulcher

Lubrication and Maintenance

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

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

Clean up all spills immediately.

Always use clean oil and containers.

Drain dirty oil while still warm.

Do not exceed recommended fluid levels.

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

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

Before welding on machine be sure the negative battery terminal is disconnected and the anti-stall controller and all multi pin connectors from the engine are unplugged.

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

Clean away all branches, bark and chips.

Clean up all traces of oil to avoid fires.

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

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

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

Always have a fire extinguisher at hand.

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

Clean fire suppression system sensors.

CHECK EMERGENCY EXITS, MONTHLY:~ Two alternate exit routes are provided: rear window emergency exit and skylight/emergency exit. These are only to be used if the side door cannot be opened.

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

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

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.

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

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

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

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

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

3.3

Tigercat M822 Mulcher

Lubrication and Maintenance

SCHEDULED MAINTENANCE FREQUENTLY:~

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

• Check engine cooling air intake screens for possible restriction.

• ‡ Boom joints:

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

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

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

• ‡ Cylinders; boom, stick & tilt; Standard Boom; 8-fittings - purge ER Boom System; 10-fittings - purge

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

‡ Lubricating cylinder pins and boom joints:1. Ensure machine is on level ground 2. Completely tilt attachment back 3. Fully extend stick boom cylinder 4. Force attachment onto ground 5. While in this position lubricate all cylinder retaining pins and boom joints NOTE: This procedure will allow grease to flow to the normally "loaded side" of the pin/bearing surfaces.

• Perform "frequently" maintenance

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

And in addition:~

• Remove potentially damaging limbs or sticks.

• Check engine coolant level

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

EVERY 8 HOURS:~

• Check engine oil level • Drain water from fuel/water separator • Check air intake precleaner operation

• For loose nuts, bolts and fittings.

• Check air cleaner unloader valve

• Condition and tension of fan belts.

• Check air filter restriction indicator

• Visually check condition of tracks.

• Check hydraulic oil level

• Exhaust system for leaks.

• Conduct an overall visual inspection.

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

3.4

Tigercat M822 Mulcher

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 24 HOURS :~ • Perform "frequently" maintenance

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

EVERY 125 HOURS:~

Make repairs immediately Visually inspect for:~ • Frayed electrical wiring and hydraulic hoses 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 • Check pilot filter restriction indicator (when fitted) with engine running at high idle and oil flow

Clean/replace:~ • Inspect for debris buildup between A/C condenser and cooling assembly • Air conditioner re-circulation filter

• Check track drive gearbox oil level with one level plug at 6 O'Clock and the other at 9 O'Clock

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

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

3.5

Tigercat M822 Mulcher

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 250 HOURS:~

EVERY 500 HOURS:~

• Perform "frequently" maintenance

• Perform "frequently" maintenance

• Perform 8 hour maintenance

• Perform 8 hour maintenance

• Perform 24 hour maintenance

• Perform 24 hour maintenance

• Perform 125 hour maintenance

• Perform 125 hour maintenance

And in addition:~

• Perform 250 hour maintenance

• Check all hydraulic pressures

And in addition replace:~

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

• Air intake safety element.

• Hydraulic oil return filters. † • Hydraulic oil high pressure pilot filter. †

‡ 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.

Lubricate:~ • Power door hinges; 2 fittings - 1 shot • Door cylinder pins apply oil liberally • Other door hinges; apply oil liberally Check:~ • Torque on swing bearing and swing gearbox retaining bolts.

• Check condition and tension of fan belts.

• Torque on track drive gearboxes and motor mounting bolts.

• Replace engine oil and filter.

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

• Replace engine fuel filter(s).

• Replace filter in fuel filter/water separator.

• Replace air intake primary element.

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

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

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

3.6

Tigercat M822 Mulcher

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 1000 HOURS:~ • Perform "frequently" maintenance • Perform 8 hour maintenance • Perform 24 hour maintenance • Perform 125 hour maintenance • Perform 250 hour maintenance • Perform 500 hour maintenance And in addition check:~ • Fuel in-tank strainer • Replace air cleaner unloader valve

EVERY 2000 HOURS:~ • Replace turbocharger rubber inlet elbow and coupling - High temperatures in this area can cause the rubber to harden • Check ALL air intake tubing, rubber couplings and band clamps for signs of wear and leakage • Drain and refill hydraulic oil tank with recommended hydraulic oil. See "approved hydraulic oils" It is strongly recommended that a program of regular oil testing be used. Oil change intervals can be established from oil test results

3.7

Tigercat M822 Mulcher

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.

3.8

Tigercat M822 Mulcher

Lubrication and Maintenance Tigercat® Model M822 FILTER AND LUBRICATION SCHEDULE

CHK

2

ENGINE OIL/FILTER

CHK

3 4 5

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

DRN

6

AIR INTAKE PRECLEANER

CHK

7

AIR INTAKE PRIMARY ELEMENT

8

AIR INTAKE SAFETY ELEMENT

9

HYDRAULIC TANK

10

RETURN FILTERS

CHK

11

PRESSURE FILTER, PILOT*

CHK

12

TRACK DRIVE GEARBOX; ‡ CHECK OIL WITH LEVEL PLUGS AT 6 O'CLOCK AND 9 O'CLOCK POSITIONS

CHK D/R ‡

13

TRACK ROLLERS AND IDLERS CHECK FOR OIL LEAKAGE

14

SWING BEARING ***

15

SWING PINION

16

SWING GEARBOX LOWER BEARING *REFER TO 250 HOURS SCHEDULED MAINTENANCE FOR DETAILS BOOM,STICK AND TILT JOINTS: - STANDARD - STANDARD W/TILT LINK - EFFICIENT REACH SYSTEM

17

18

19 20 21

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

57

15

QTY

2000

1000

CHANGE COOLANT EVERY 2 YEARS REP

REMARKS/LUBRICANT USG

COOLING SYSTEM

CAPACITY LITRE

1

500

250

DESCRIPTION

125

SERVICE EVERY

8

SERVICE POINT NO.

REFER TO Tigercat OPERATOR'S MANUAL FOR FURTHER INFORMATION

60/40 ANTIFREEZE **

25.5 6.75

REP REP

SEE ENGINE MANUFACTURER’S SERVICE MANUAL 1 1

CHK 1 REP

1 REP

CHK

1

D/R 134

1

DRAIN AND REFILL AS REQ’D

BY SEASONAL OIL CHANGE SEE APPROVED HYDRAULIC OILS* *Tigercat RECOMMENDS REGULAR USE OF AN OIL TESTING PROGRAM

REP

5 1

REP †

2

5 STANDARD FILTERS 1 WATER ABSORBING FILTER (COLOUR BLUE) *CHECK RESTRICTION INDICATOR ON LATER MACHINES FILL WITH S 75W-90 (SPEC) SYNTHETIC GEAR OIL RECOMMENDED FOR SEVERE DUTY APPLICATIONS IF LEAKING REMOVE AND REPAIR FILL WITH SAE 30 OR 40

CHK LUB 24HR *** LUB LUB*

LUB

35

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.

6

1.5

1

7.6

2

1

10 SHOTS

1

10 SHOTS

1

5 SHOTS EACH FITTING PURGE

2

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

LUB PURGE PURGE

8 10

POWER DOOR HINGES LUB 2 LITHIUM BASE EP2 GREASE 1 SHOT DOOR CYLINDER PINS LUB APPLY OIL LIBERALLY LUB ATTACHMENT SEE MANUFACTURER'S MAINTENANCE SCHEDULE LITHIUM BASED EP2 GREASE CONTAINING MOLYBDENUM DISULFIDE LEGEND: CHK = CHECK ** ANTIFREEZE MUST MEET GM 6038M SPECIFICATIONS DRN = DRAIN SEE ENGINE MANUFACTURER'S MAINTENANCE MANUAL D/R = DRAIN AND REFILL LUB = LUBRICATE † Use of filters other than genuine Tigercat replacement filters is not recommended.

REP = REPLACE

M822 LUBCHART.XLS MAY/2005

3.9

Tigercat M822 Mulcher LUBRICATION OF SWING DRIVE GEARBOX

Lubrication and Maintenance HOIST CYLINDER FULLY RETRACTED

•

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

LOWER BEARING LUBRICATION Ensure that the boom is properly parked for service (see fig. 1 & fig. 2) and engine is shut off before performing this procedures.

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

LUBE FITTINGS

• ••

LH830-31

LATER MACHINES LUBRICATE GEARBOX LOWER BEARINGS The lube fittings are remotely mounted for easy access.

Using a hand grease gun, pump 5 shots of grease into each grease fitting. Follow the lubricating procedure on the label located beside the grease fittings and also refer to SCHEDULED MAINTENANCE - 250 HOURS in THIS SECTION. For additional information refer to SECTION 15 in the SERVICE MANUAL

3.10

TIP OF STICK BOOM FULLY SUPPORTED 830-08

PARKING BOOM. FIG.2

Tigercat M822 Mulcher ER BOOM SYSTEM

Lubrication and Maintenance HOIST CYLINDER FULLY RETRACTED

WARNING

•

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

TIP OF STICK BOOM FULLY SUPPORTED

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

830-08

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. 1 & fig. 2) and engine is shut off before disconnecting any hydraulic lines.

PARKING BOOM. FIG.2

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.

Before attempting to disconnect hydraulic hoses or perform work on the boom system, ensure that:(a) The machine is parked on level ground with the head sitting flat on the ground. (b) The stick cylinders are fully extended (fig. 1) or the hoist cylinder fully collapsed (fig. 2). c) The tip of the stick boom supported . d) Do NOT rely on the attachment to support the boom system during servicing. Slow leakage in the hydraulic components can cause the attachment to move unexpectedly.

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

3.11

Tigercat M822 Mulcher CHECKING THE AIR CONDITIONING SYSTEM

Lubrication and Maintenance CAUTION

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

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

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

Always use personal protective equipment to guard against flying debris

A/C SYSTEM TOTAL CAPACITIES R134a REFRIGERANT

PAG OIL (polyalkylene glycol)

3 LBS. 0 OZ.

7 OZ.

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

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

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

OIL COOLER/ RADIATOR/CAC ASSEMBLY

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

CHECK A/C CONDENSER CORE

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

Run air conditioning system for 3 - 5 minutes.

IMPORTANT

••

•

• SLIDE DEBRIS SCREEN OUT AND REMOVE

LH830-09

CHECK A/C CONDENSER CORE

b. Check the condenser core for dirt and debris.

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

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

3.12

Check to see that compressor clutch will engage.*

Tigercat M822 Mulcher 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.

3.13

Tigercat M822 Mulcher FILTERS - REMOVE AND REPLACE

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

6. Wearing face protection (in case of a fuel squirt) turn OFF the fuel shut-off valve and

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

FUEL SHUT-OFF VALVE

•

IMPORTANT Filters that are an integral part of the engine (fuel and lubricating oil) should be serviced and replaced according to the engine manufacturer's operation and maintenance manual.

FUEL FILTER/WATER SEPARATOR

822-D34

unscrew the old filter. The fuel shut off valve is located beside the main hydraulic control valve at the rear left corner of the machine.

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

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

••

FUEL SHUT-OFF VALVE

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

8. Remove the water sediment bowl from the bottom of the old filter. Discard this gasket also. Dispose of old filter and any fuel properly.

PRIMING PUMP

9. Clean the water sediment bowl.

10. Check the seating area for the gaskets on the filter head and the water sediment bowl and wipe clean.

WATER SEPARATOR BOWL

11. Lubricate gasket for bottom of filter and water sediment bowl with clean engine oil and carefully hand tighten the water sediment bowl onto the new filter. It is plastic and will break if over tightened. Close the water drain valve.

DRAIN TAP

822-D53

• • FUEL FILTER/WATER SEPARATOR

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

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

2. Open engine enclosure doors fully.

3. Turn battery disconnect switch to the OFF position.

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

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

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

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

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

3.14

Tigercat M822 Mulcher

Lubrication and Maintenance

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

STRAINER INSIDE FUEL TANK

•

CLEANOUT COVER

•• DRAIN PLUG

••

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

822-D56

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

822-D55

FUEL TANK CLEANOUT COVER

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

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

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

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

9. Reinstall the strainer using the hex on end.

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

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

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

REMOVE THE LIGHT HOUSING/STEP DOOR AND ADJACENT CORNER PANEL

•

830-D41

••

ACCESS TO FUEL TANK

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

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

3.15

Tigercat M822 Mulcher

HYDRAULIC FILTER SERVICING GUIDELINES

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

The oil from the 3 return lines passes through return strainers located inside the hydraulic tank.

IMPORTANT

NEVER PRE-FILL 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.

5 - HYDRAULIC RETURN FILTERS RETURN MANIFOLD

•• ••

•• • •• ••

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.

•• 1 - WATER ABSORBING RETURN FILTER (COLOUR BLUE)

DRIP TRAY

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

The pressures stated are for normal operating conditions and temperatures.

822M-016

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 felling head resting on the ground. Stop engine.

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

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

3.16

Tigercat M822 Mulcher

Lubrication and Maintenance

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

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

Tighten filter an additional 3/4 turn.

••

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

HYDRAULIC OIL FILTERS

••

DRIP TRAY

DRAIN HOSE 822-D69

FILTER HEAD

•

• •

DRIP TRAY DRAIN HOSE

GASKET

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

6. The new Tigercat filter is supplied with two gaskets enclosed, examine the filter head closely to determine which gasket should be used and follow the instructions to ensure proper installation.

• FILTR_SEALS

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 prefill the filter*. Screw on new filter until gasket makes contact.

• GASKET

•

Tighten filter until top edge makes metal to metal contact with filter head. (approximately 1 1/2 additional turns after gasket contact)

FILTER ELEMENT

SQUARE SECTION GASKET INSTALLATION

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

FILTR_SEALS

'O' RING GASKET INSTALLATION

z 'O' Ring Gasket

FILTER HEAD

•

FILTER ELEMENT

Square Section Gasket Remove used gasket and clean groove in head.

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

Apply clean oil to new gasket surfaces.

9. Start the engine and check for leaks.

Install new gasket into groove in filter head.

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

11. Recheck oil level. *Refer to HYDRAULIC FILTER SERVICING GUIDELINES on PREVIOUS PAGE.

3.17

Tigercat M822 Mulcher

Lubrication and Maintenance

HYDRAULIC HIGH PRESSURE PILOT FILTER

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

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

822M-016

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.

3. 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.

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

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.

5. Place rags below to catch any spilt oil.

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

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

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

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

9. DO NOT pre-fill the filter*. Lubricate any new o-rings and seals with clean hydraulic and install the new filter element. *Refer to HYDRAULIC FILTER SERVICING GUIDELINES on PREVIOUS PAGE.

3.18

Tigercat M822 Mulcher

Lubrication and Maintenance

HYDRAULIC OIL RETURN STRAINERS/DIFFUSERS

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.

'O' RING ROUND ACCESS COVER

••

• •

••

ACCESS COVER

• •

409-04

HYDRAULIC OIL TANK DRAIN PLUG

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

822-06

•

DRAIN PLUG (ONLY ACCESSIBLE WITH MAIN CONTROL VALVE REMOVED)

HYDRAULIC OIL TANK

5. 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.

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

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

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

2. Stop engine.

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

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

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

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

9. 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).

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

11. Reinstall the strainers using the hex on end.

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

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

13. Connect sensor wires to sensors on access cover.

14. Refill and check for leaks.

3.19

Tigercat M822 Mulcher AIR INTAKE MAINTENANCE

Lubrication and Maintenance EXHAUST SYSTEM

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

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

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

PRECLEANER TO TURBO CHARGER

•• •

•

AIR CLEANER

•• AIR CLEANER UNLOADER VALVE

CONT AMINANTS ARE BLOWN CONTAMINANTS OUT OF SPECIAL DISCHARGE POR TS BY HIGH VELOCITY PORTS VELOCITY,, AIR POWERED R OTOR RO

•

354-15

•

AIR CLEANER OUTLET TUBE

•

PRIMARY ELEMENT

•

•

•

•

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

SAFETY ELEMENT

ONLY THE PURIFIED AIR GOES TO THE AIR FILTER

PRECLEANER OPERATION AIRCLEANER

AIR FILTER ELEMENTS

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

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

DISCHARGE PORT AREA

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

218-21B

PRECLEANER

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

OVER SERVICING Filter elements increase in dust cleaning efficiency as dust builds up on the media. Looks can be deceiving. A filter that looks dirty is actually more efficient than one that is clean. A filter with dust build up on the media reaches nearly 100% dust cleaning efficiency. Only when a filter is so clogged with dirt that air restriction goes beyond engine manufacturer’s guidelines, should a filter be replaced.

NOTE: This does not apply to oil filters.

3.20

Tigercat M822 Mulcher

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.

Continued on page 22

3.21

Tigercat M822 Mulcher

Lubrication and Maintenance

Continued from page 21

••

CHECK CONDITION OF SEAL

•• 822-D58

PRECLEANER

AIR INTAKE SEAL

AIR INTAKE SEAL Periodically check to ensure seal on top of precleaner is making proper contact with the sealing surface of the inside top of the power door.

Hot air leakage at this seal will reduce engine power.

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

RUBBER ELBOWS AND TUBING

• • ••

822-D58

INTAKE TUBING AND JOINTS

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

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

3.22

Tigercat M822 Mulcher

Lubrication and Maintenance

TORQUE CHART LOCATION

THREAD DIAMETER

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

TORQUE (LUBRICATED) lbf-ft Nm

M18

6980 270

9460 367

M16

4159 126

5640 171

Cylinder pin retaining bolts

M20

380

515

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

M20

400

530

1" UNC

475

625

7/8" UNC

450-500

620-680

M16

200

275

rear front

M24 M22 M12 M16

675 540 80 200

925 725 110 275

rear front

M24 M22 M12 M12

675 540 80 80

925 725 110 110

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

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

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

Cab securing bolts Swing bearing Swing bearing bolts Swing gearbox mounting bolts Engine mounting Cummins QSL9 Engine Bolts, bracket/mount to chassis Bolts, bracket/mount to chassis Bolts, bracket to engine, front Bolts, bracket to engine, rear Cummins QSC Engine Bolts, bracket/mount to chassis Bolts, bracket/mount to chassis Bolts, bracket to engine, front Bolts, bracket to engine, rear Undercarriage Track shoe bolts (D6) Track shoe bolts (FH400) Idler bolts Idler bolts Roller mounting bolts Roller mounting bolts Sprocket bolts Gearbox mounting bolts Drive motor mounting bolts

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

Torque values pertaining to the engine and attachment are provided in the appropriate manuals.

822T2TORQUECHART.XLS

3.23

Tigercat M822 Mulcher

Lubrication and Maintenance

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

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

IMPERIAL

GRADE 5 BOLTS

GRADE 8 BOLTS

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

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

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

DRY LUBRICATED COARSE lbf-ft Nm lbf-ft Nm THREAD 1/4" - 20 7- 8 10 - 11 8 - 10 11 - 13 5/16" - 18 14 - 18 19 - 24 38275 13 - 20 3/8" - 16 31 - 34 42 - 46 23 - 25 31 - 34 7/16" - 14 49 - 54 66 - 73 37 - 41 50 - 55 1/2" - 13 75 - 83 102 - 112 57 - 63 77 - 85 9/16" - 12 109 - 120 148 - 162 82 - 90 111 - 122 5/8" - 11 150 - 165 204 - 223 113 - 124 152 - 168 3/4" - 10 266 - 293 360 - 397 200 - 220 271 - 298 7/8" - 9 394 - 433 535 - 586 296 - 326 402 - 441 1" - 8 591 - 649 802 - 879 443 - 489 601 - 663 1 1/8" - 7 794 - 873 1077 - 1183 596 - 656 808 - 889 1 1/4" - 7 1120 - 1232 1519 - 1670 840 - 924 1139 - 1252 FINE DRY LUBRICATED lbf-ft Nm lbf-ft Nm THREAD 1/4" - 28 9 - 10 12 - 13 9 - 10 12 - 13 5/16" - 24 17 - 22 23 - 29 16 - 20 21 - 27 3/8" - 24 35 - 39 48 - 53 26 - 29 35 - 39 7/16" - 20 55 - 61 75 - 83 41 - 45 56 - 61 1/2" - 20 85 - 94 116 - 127 64 - 70 87 - 95 9/16" - 18 121 - 133 164 - 180 91 - 100 124 - 135 5/8" - 18 170 - 187 231 - 253 128 - 141 174 - 191 3/4" - 16 297 - 327 403 - 443 223 - 245 303 - 332 7/8" - 14 434 - 477 589 - 646 326 - 359 442 - 486 1" - 12 646 - 711 876 - 965 484 - 534 657 - 724 1 1/8" - 12 891 - 980 1208 - 1328 668 - 735 906 - 996 1 1/4" - 12 1240 - 1364 1682 - 1849 931 - 1024 1262 - 1387

METRIC

METRIC BOLT TORQUE SPECIFICATIONS SIZE

CLASS 4.8 LUBRICATED Nm lbf-ft Nm

DRY lbf-ft

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

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

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

M6 M8 M10

4.8 12.0 23.0

3.5 8.5 17.0

6.0 15.0 29.0

4.5 11.0 21.0

9.0 22.0 43.0

6.5 16.0 32.0

11.0 28.0 55.0

8.5 20.0 40.0

13.0 32.0 63.0

9.5 24.0 47.0

17.0 40.0 80.0

12.0 30.0 60.0

15.0 37.0 75.0

11.5 28.0 55.0

19.0 47.0 95.0

14.5 35.0 70.0

M12 M14 M16

40.0 63.0 100.0

29.0 47.0 73.0

50.0 80.0 125.0

37.0 60.0 92.0

75.0 120.0 190.0

55.0 88.0 140.0

95.0 150.0 240.0

70.0 110.0 175.0

110.0 175.0 275.0

80.0 130.0 200.0

140.0 225.0 350.0

105.0 165.0 225.0

130.0 205.0 320.0

95.0 150.0 240.0

165.0 260.0 400.0

120.0 190.0 300.0

M18 M20 M22

135.0 190.0 260.0

100.0 140.0 190.0

175.0 240.0 330.0

125.0 180.0 250.0

260.0 375.0 510.0

195.0 275.0 375.0

330.0 475.0 650.0

250.0 350.0 475.0

375.0 530.0 725.0

275.0 400.0 540.0

475.0 675.0 925.0

350.0 500.0 675.0

440.0 625.0 850.0

325.0 560.0 460.0 800.0 625.0 1,075.0

410.0 580.0 800.0

M24 M27 M30

330.0 490.0 675.0

250.0 360.0 490.0

425.0 625.0 850.0

310.0 650.0 450.0 950.0 625.0 1,300.0

M33 900.0 M36 1,150.0

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

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

3.24