TIGERCAT 822 FELLER BUNCHER SERVICE MANUAL – PDF DOWNLOAD

Description

TIGERCAT 822 FELLER BUNCHER SERVICE MANUAL – PDF DOWNLOAD

DESCRIPTION:

TIGERCAT 822 FELLER BUNCHER SERVICE MANUAL – PDF DOWNLOAD

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 822 Feller Buncher serial number 8220114 to
  8220189.
• The operator’s manual will assist the operator with the techniques of proper and safe operation of the 822 Feller
  Buncher. There is also important information regarding the safe operation of the saw head. The service manual
  contains safety and servicing procedures and a preventive maintenance schedule to ensure optimum machine
  performance.
• Section 1 in both the operator’s manual and the service manual contains safety information that must be followed. As
  well, throughout the rest of the manuals, WARNING and CAUTION notices are displayed where necessary, drawing
  attention to possible hazards when performing certain procedures.
• Only trained personnel should be allowed to operate or work on the machine.
• The information contained in this manual is current at time of printing. Improvements to the machine are on-going and
  may not be covered, therefore in these cases contact your Tigercat dealer for the appropriate information.
• The phrase “and up” appearing in this manual after the serial number implies that the related information is current for
  any machine serial number HIGHER than the serial number preceding the “and up”.
• Tigercat reserves the right to make changes to the machine after this manual release date that may not immediately
  appear in this manual.

TABLE OF CONTENTS:

TIGERCAT 822 FELLER BUNCHER SERVICE MANUAL – PDF DOWNLOAD

822 SERVICE ISSUE 1.0…………………………………. 1
INTRODUCTION……………………………………… 3
NON-APPROVED FIELD PRODUCT CHANGES………………….. 4
SECTION 1 – SAFETY……………………………………. 5
CAB EXITS ……………………………………….. 10
COOLING SYSTEM …………………………………… 17
EFFICIENT REACH (ER) BOOM SYSTEM PRECAUTIONS ………… 18
EMERGENCY CAB EXITS ………………………………. 10
ENGINE DOORS …………………………………….. 19
EXHAUST FUMES ……………………………………. 19
FELLING TREES ……………………………………. 13
FIRE PREVENTION ………………………………….. 21
FIRE PREVENTION GUIDELINES …………………….. 20
WHAT ELSE TO DO BEFORE YOU EXPERIENCE A FIRE …….. 21
WHAT TO DO AFTER A FIRE ……………………….. 22
WHAT TO DO IN CASE OF A MACHINE FIRE ……………. 21
FLUID LEAKS ……………………………………… 17
HYDRAULIC PRESSURE HAZARD …………………………. 17
LOOSE CLOTHING HAZARD …………………………….. 17
parking the machine ………………………………. 14
PROTECTIVE CLOTHING ………………………………. 7
SAFETY INTERLOCK SWITCHES ON CAB DOORS ……………… 11
SAFETY PRECAUTIONS, GENERAL ……………………….. 7
SAFETY PRECAUTIONS, OPERATING ……………………… 10
SAFETY PRECAUTIONS, SERVICING ……………………… 14
SAFETY SYMBOLS …………………………………… 6
SIGNAL WORDS …………………………………….. 6
APPENDIX – USING HIGH SPEED DISC SAWS SAFELY…………….. 23
Comments and instructions………………………….. 23
Direction of throw ……………………………. 29
High angle wrist rotation ability ………………. 30
Recognizing the Dangers ……………………….. 29
Throwing long wood pieces ……………………… 32
Dangers …………………………………………. 25
forward …………………………………………. 24
Be aware of the hazards ……………………….. 24
Other instructions ……………………………. 25
Safe practices ……………………………….. 25
Several types of heads involved ………………… 24
Stored energy ………………………………… 24
HIGH ANGLE WRIST ROTATION CAPABILITY ……………….. 31
Saw Head Don’ts ………………………………….. 37
Type of Housing makes a Difference …………………. 26
SECTION 3 – LUBRICATION & MAINTENANCE…………………… 39
AIR INTAKE CLEAN-OUT COVER PLATE ………………….. 55
AIR INTAKE SEAL …………………………………. 55
APPROVED HYDRAULIC OILS ………………………….. 45
EFFICIENT REACH (ER) BOOM SYSTEM ………………….. 47
EMERGENCY EXITS, CHECK MONTHLY ……………………. 41
ENGINE AIR CLEANER ………………………………. 54
AIR CLEANER MAINTENANCE ………………………. 56
FILTER RESTRICTION INDICATOR ………………….. 55
ENGINE AIR CLEANER UNLOADER VALVE …………………. 54
FILTER AND LUBRICATION SCHEDULE …………………… 46
FILTERS………………………………………….. 39
CHANGING HYDRAULIC RETURN FILTERS ……………… 50
ENGINE AIR FILTER ……………………………. 54
FUEL FILTER/WATER SEPARATOR …………………… 48
FUEL TANK STRAINER …………………………… 49
HYDRAULIC OIL RETURN FILTERS ………………….. 50
HYDRAULIC OIL RETURN STRAINERS/DIFFUSERS ……….. 53
PILOT FILTER ………………………………… 52
REMOVE AND REPLACE …………………………… 48
SERVICING GUIDELINES FOR OIL FILTERS …………… 50
FIRE PREVENTION …………………………………. 41
FUEL SHUT-OFF VALVE ……………………………… 48
GENERAL MAINTENANCE ……………………………… 41
HYDRAULIC OIL FILTERS ……………………………. 50
HYDRAULIC OILS ………………………………….. 45
LUBRICATE GEARBOX LOWER BEARINGS ………………….. 47
LUBRICATION SCHEDULE …………………………….. 46
NEW MACHINE MAINTENANCE ………………………….. 40
FIRST 50-100 HOUR INSPECTION AND SERVICE REPORT …. 40
INITIAL PRE-DELIVERY INSPECTION ……………….. 40
TIGHTENING POINTS ……………………………. 40
Oil lost from leakage ……………………………. 40
PRESSURE SETTING PROCEDURES. See SERVICE MANUAL………. 39
PRESSURE SETTING VALUES. See SERVICE MANUAL………….. 39
PREVENTIVE MAINTENANCE SCHEDULE …………………… 40
RETURN FILTERS ~ HYDRAULIC OIL ……………………. 50
SCHEDULED MAINTENANCE……………………………… 39
Frequently ………………………………….. 42
8 hours …………………………………….. 42
24 HOURS ……………………………………. 42
125 HOURS …………………………………… 42
250 HOURS …………………………………… 43
500 HOURS …………………………………… 43
1000 HOURS ………………………………….. 44
2000 HOURS ………………………………….. 44
SWING DRIVE GEARBOX……………………………….. 39
LUBRICATION OF LOWER BEARING ………………….. 47
TORQUE CHART, GENERAL ……………………………. 59
TORQUE SETTINGS, RECOMMENDED ……………………… 58
SECTION 4 – HYDRAULIC SYSTEM…………………………… 61
FILTERS, HYDRAULIC OIL…………………………….. 61
FILTER SERVICE NOTE …………………………… 65
PILOT, HIGH PRESSURE ………………………….. 65
RETURN FILTERS ……………………………….. 65
STRAINER SERVICE NOTE …………………………. 65
VENT/BREATHER ………………………………… 64
HAND FILL PUMP, HYDRAULIC OIL ……………………… 66
HIGH PRESSURE LIMITING CONTROL VALVE………………… 61
SET LOAD SENSE RELIEF VALVE ……………………. 87
HYDRAULIC OIL TANK………………………………… 61
DESCRIPTION ………………………………….. 64
OIL LEVEL SIGHT GAUGES ………………………… 64
VENT/BREATHER ………………………………… 64
HYDRAULIC PUMPS…………………………………… 61
CLAMPS AND FAN PUMP …………………………… 69
FAN PUMP …………………………………….. 69
MAIN PUMP ……………………………………. 68
MAIN PUMP CONTROL VALVE ……………………. 85
MAIN PUMP WEAR TEST ……………………….. 68
SAW PUMP …………………………………….. 69
HYDRAULIC SYSTEM OPERATION…………………………. 61
CIRCUIT DESCRIPTION …………………………… 75
CLAMPS AND ACCUMULATING ARMS CIRCUIT ……………. 62
FAN DRIVE SYSTEM ……………………………… 63
FLOW ON DEMAND and LOAD COMPENSATION ……………. 75
MAIN HYDRAULIC SYSTEM; BOOM, SWING, WRIST, DRIVE …. 62
MARGIN PRESSURE ………………………………. 69
MARGIN PRESSURE, SET ………………………….. 85
PILOT CIRCUIT ………………………………… 63
PRESSURE GAUGE CONNECTIONS …………………….. 86
SAW CIRCUIT ………………………………….. 63
SWING SYSTEM …………………………………. 62
TRACK DRIVE SYSTEM ……………………………. 62
HYDRAULIC TANK …………………………………… 64
LOAD SENSING……………………………………… 61
BASIC DESCRIPTION …………………………….. 71
BASIC PRINCIPLES ……………………………… 70
OPERATING TIPS ……………………………….. 73
SET LOAD SENSE RELIEF VALVE ……………………. 87
SET MARGIN PRESSURE …………………………… 85
MAIN CONTROL VALVE/MANIFOLD………………………… 61
CONTROL SPOOL SECTIONS ………………………… 76
CONTROL VALVE SECTIONS ………………………… 77
CONTROL VALVE SPOOL OPERATION ………………….. 79
HIGH PRESSURE LIMITING CONTROL VALVE ……………. 84
MAIN CONTROL VALVE DESCRIPTION …………………. 76
PORT RELIEF AND ANTICAVITATION VALVE ……………. 78
ADJUSTING PROCEDURE ……………………….. 78
SWING AND DRIVE MOTOR SPOOL SECTIONS ……………. 76
PILOT FILTER, HIGH PRESSURE ……………………….. 65
PRESSURE SETTINGS ……………………………….. 88
SCHEMATIC DIAGRAMS………………………………… 61
HIGH PRESS. LIMITING CONTROL …………………… 84
LOAD SENSING (FLOW ON DEMAND) ………………….. 70
LOAD SENSING SYSTEM CIRCUIT DIAGRAM …………….. 74
MAIN PUMP ……………………………………. 68
MAIN VALVE WITH HIGH PRESS. LIMITING CONTROL …….. 76
SECTION 5 – PILOT SYSTEM………………………………. 89
ACCUMULATOR………………………………………. 89
CHARGING …………………………………….. 98
CHECK PRE-CHARGE PRESSURE ……………………… 98
GENERAL DESCRIPTION …………………………… 93
TESTING DEVICE ……………………………….. 98
CIRCUIT dESCRIPTION ………………………………. 96
CIRCUIT DIAGRAM ………………………………….. 95
ELECTRICAL CIRCUIT ……………………………….. 94
PILOT MANIFOLD …………………………………… 90
PILOT SYSTEM COMPONENTS……………………………. 89
ACCUMULATOR ………………………………….. 93
GENERAL DESCRIPTION …………………………… 90
HIGH PRESSURE FILTER ………………………….. 91
JOYSTICKS AND FOOT PEDALS ……………………… 94
PILOT MANIFOLD ……………………………….. 92
PILOT SHUT OFF VALVE ………………………….. 92
PILOT SUPPLY VALVE ……………………………. 91
PRESSURE SETTINGS ………………………………… 97
SECTION 6 – ELECTRICAL, GAUGES AND ALARMS……………….. 99
ELECTRICAL INSTALLATION – CAB ………………………105
ELECTRICAL SCHEMATIC DIAGRAM ……………………….100
GAUGES AND ALARMS …………………………………106
CHART ………………………………………..106
REAR ELECTRICAL PANEL ……………………………..104
SOLENOID DRIVERS ………………………………….106
SWITCH AND SENSOR LOCATIONS ………………………..107
wire colour code chart …………………………….104
SECTION 7 – ENGINE START AND STOP……………………….109
CIRCUIT DESCRIPTION ……………………………….110
ENGINE START CIRCUIT ………………………………110
SCHEMATIC DIAGRAM………………………………….109
START CIRCUIT – AT REST ………………………..112
START CIRCUIT – BATTERY DISCONNECT SWITCH ‘ON’ ……113
START CIRCUIT – RUN ……………………………115
START CIRCUIT – RUN, PILOT RESET SWITCH ‘OFF’ …….117
START CIRCUIT – RUN, PILOT RESET SWITCH ‘ON’ ……..116
START CIRCUIT – START ………………………….114
SECTION 9 – ENGINE ANTI-STALL…………………………..119
CONTROL MODULE IN CAB ……………………………..120
CONTROL MODULE PIN CONNECTIONS ……………………..122
ENGINE ANTI-STALL CURVE ……………………………122
FAULT FINDING procedure ~ Anti-stall Quick Check ……..123
FAULT FINDING procedures, additional ………………..124
HORSEPOWER LIMITING CONTROL…………………………119
GENERAL DESCRIPTION ……………………………120
LOAD SENSE; SET MARGIN PRESSURE See SECTION 4…………119
MAIN PUMP CONTROLLER (LS CONTROL) …………………..120
SCHEMATIC DIAGRAMS…………………………………119
ENGINE ANTI-STALL CIRCUIT ………………………123
LOAD SENSING SYSTEM CIRCUIT DIAGRAM ……………..121
SET PILOT PRESSURE See SECTION 5…………………….119
SPEED SENSOR, ADJUSTING ……………………………122
SPEED SENSOR ON ENGINE …………………………….120
verify ANTI-STALL SETTING See SECTION 4………………119
SECTION 10- OIL COOLER AND COOLING FAN…………………..127
CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR……….127
COOLING ASSEMBLY – OVERALL VIEW …………………128
cooling FAN ………………………………………132
COOLING FAN CIRCUIT DESCRIPTION …………………….136
COOLING fan circuit DIAGRAM ………………………..137
fan drive motor INSTALLATION ……………………….133
FAN MOTOR ………………………………………..133
FAN PUMP (CLAMPS/FAN PUMP) …………………………132
FAN SPEED ADJUSTMENT ………………………………138
hydraulic tank ……………………………………129
main control valve See SECTION 4…………………….127
main pump See SECTION 4…………………………….127
OIL COOLER ……………………………………….128
oil cooler bypass/ return manifold ………………….128
OIL COOLER CIRCUIT DESCRIPTION ……………………..130
OIL COOLER CIRCUIT DIAGRAM …………………………131
return manifold/ return filters …………………….128
SECTION 11 – TRACK DRIVE……………………………….141
BRAKE CIRCUIT DESCRIPTION ………………………….145
CIRCUIT DIAGRAM, DRIVE SYSTEM ………………………148
DRIVE MOTOR……………………………………….141
DESCRIPTION …………………………………..144
START-UP PROCEDURE …………………………….147
DRIVE MOTOR AND GEARBOX ASSEMBLY ……………………143
GEARBOX AND DRIVE MOTOR ASSEMBLY ……………………143
HYDROSTATIC DRIVE SYSTEM …………………………..143
IMPORTANT TRACK DRIVE NOTES…………………………141
NEW MACHINE …………………………………..142
STRAIGHT TRAVEL ……………………………….142
TRACK SAG …………………………………….142
LEFT TRACK SPEED ADJUSTMENT ………………………..152
PRESSURE SETTINGS, DRIVE SYSTEM……………………..141
BEGIN OF REGULATION, SET, FOR DRIVE MOTOR ………..150
BRAKE RELEASE PRESSURE ADJUSTMENT ON DRIVE MOT ……150
CROSSOVER RELIEF VALVES, FOR DRIVE MOTOR …………149
RIGHT TRACK SPEED ADJUSTMENt ……………………….155
SCHEMATIC DIAGRAMS…………………………………141
DRIVE CIRCUIT …………………………………148
DRIVE MOTOR …………………………………..143
SET BRAKE RELEASE PRESSURE ON DRIVE MOT ……………..150
SET STRAIGHT TRAVEL ……………………………….155
TRACK COMPONENTS…………………………………..141
BOTTOM ROLLER RETAINING BOLTS …………………..158
MEASURING TRACK SAG ……………………………156
TRACK SAG ADJUSTMENT ……………………….157
OPERATING THE MACHINE ………………………….156
TORQUING UNDERCARRIAGE BOLTS ……………………157
TRACK SHOE RETAINING BOLTS ……………………..157
WEAR LIMITS……………………………………141
BOTTOM ROLLER WEAR …………………………159
BUSHING WEAR, OUTSIDE DIAMETER ………………159
IDLER WEAR ………………………………..160
PIN AND BUSHING WEAR ……………………….159
TRACK LINK WEAR ……………………………158
TRACK SHOE GROUSER HEIGHT WEAR ………………158
Track slide wear …………………………..160
TRACK DRIVE ASSEMBLY ………………………………142
TRACK SPEED SET-UP PROCEDURE………………………..141
HIGH FORWARD (MOTOR MINIMUM DISPLACEMENT …………154
HIGH REVERSE (VALVE FLOW SETTING) ……………….155
LOW FORWARD (VALVE FLOW SETTING) ………………..153
SET MOTOR MAXIMUM DISPLACEMENT ………………….152
SET STRAIGHT TRAVEL ……………………………155
SUMMERY OF PROCEDURE …………………………..155
SECTION 12 – BOOM FUNCTIONS…………………………….161
ADJUST OIL FLOW TO CYLINDERS (CYLINDER CYCLE TIMES ……168
BOOM CONTROL VALVE ………………………………..163
BOOM SYSTEM DESCRIPTION…………………………….161
‘ER’ BOOM SYSTEM ………………………………162
STANDARD BOOM …………………………………162
CIRCUIT DIAGRAM……………………………………161
‘ER’ BOOM SYSTEM ………………………………165
‘STANDARD’ BOOM SYSTEM …………………………164
CYLINDER CYCLE TIMES, TYPICAL ………………………169
ENGINE ANTI-STALL …………………………………163
Load sensing ……………………………………..163
SET MAIN BOOM, STICK AND TILT PORT RELIEF VALVES ……..166
TILT CYLINDER FLOW ADJUSTMENT ………………………163
SECTION 15 – SWING…………………………………….171
ADJUST OIL FLOW TO SWING MOTOR(SWING MOTOR SPEED) …….175
CIRCUIT SCHEMATIC …………………………………173
LUBRICATE GEARBOX LOWER BEARINGS ……………………174
SET SWING MOTOR SPEED ……………………………..175
SWING BEARING WEAR LIMITS ………………………….178
SWING DRIVE……………………………………….171
SWING HYDRAULICS ………………………………172
SET CROSSLINE RELIEF VALVES …………………174
SWING DRIVE GEARBOX………………………………..171
LUBRICATION OF LOWER BEARING ……………………174
sun gear installation ………………………….177
SWING MOTOR REMOVAL from GEARBOX ……………………176
SECTION 17 – SAW DRIVE…………………………………179
CIRCUIT DESCRIPTION ……………………………….184
CIRCUIT DIAGRAM …………………………………..185
CONTROL VALVES…………………………………….179
saw pilot valve ……………………………….182
FELLING HEAD See ORIGINAL MANUFACTURERS MANUAL………..179
PRESSURE SETTINGS …………………………………186
SAW CONTROL VALVES…………………………………179
main SAW CONTROL VALVE …………………………182
main saw CONTROL valve OPERATING DESCRIPTION ……..182
saw pilot valve ……………………………….182
SAW PUMP …………………………………………180
SECTION 18 – CLAMPS……………………………………189
CIRCUIT DESCRIPTION ……………………………….194
CIRCUIT DIAGRAM …………………………………..195
control valve …………………………………….192
Pressure settings …………………………………196
Air in pilot end caps ………………………….196
PUMP CLAMPS/FAN …………………………………..191
SECTION 19 – WRIST…………………………………….199
ADJUST OIL FLOW TO WRIST (CYCLE TIME) ……………….202
CIRCUIT DIAGRAM …………………………………..201
CYCLE TIMES……………………………………….199
340° WRIST ADDITIONAL NOTES …………………….203
TYPICAL ………………………………………202
ENGINE ANTI-STALL …………………………………202
LOAD SENSING ……………………………………..202
MAIN CONTROL VALVE ………………………………..202
SET WRIST PORT RELIEF VALVES ……………………….202
WRIST DESCRIPTION …………………………………200
TIGERCAT OPTIONAL 110° WRIST ……………………200
TIGERCAT OPTIONAL 340° WRIST ……………………200
TIGERCAT STANDARD 30° WRIST …………………….200

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TIGERCAT 822 FELLER BUNCHER SERVICE MANUAL – PDF DOWNLOAD:

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