Tigercat 1018 FORWARDER SERVICE MANUAL - PDF DOWNLOAD

SERVICE MANUAL Tigercat 1018 FORWARDER Issue 1.1, MARCH 2003

TABLE OF CONTENTS SECTION INTRODUCTION .............................................................................................................. iii SAFETY ............................................................................................................................ 1 CONTROLS AND OPERATION .......................................... SEE OPERATOR'S MANUAL LUBRICATION AND MAINTENANCE ............................................................................... 3 ELECTRICAL AND COMPUTERS .................................................................................... 6 ENGINE START & STOP .................................................................................................. 7 DRIVE ............................................................................................................................... 8 BRAKES ............................................................................................................................ 9 OIL COOLER/RADIATOR, FAN AND HYDRAULIC RESERVOIR .................................. 10 CENTER JOINT, STEERING, CAB ROTATE, AND SNOW BLADE ............................... 11 CRANE, GRAPPLE AND LOAD GATE ........................................................................... 12 HOOD & CAB TILT .......................................................................................................... 13

1018-SM00

1018 Available Literature Operator's Manual ............................... Part No. 15913A Service Manual (This Manual) ............ Part No. 15914A Parts Catalog ....................................... Part No. 15912A Hydraulic Adapters Book ....................... Part No. 1472A Hose Assemblies Book ......................... Part No. 3707A

Tigercat

®

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

Fax: (519) 442-1855

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Tigercat 1018 Forwarder

Introduction

Tigercat 1018 FORWARDER

INTRODUCTION An Operator's manual, Service manual and a Parts catalog are provided by Tigercat to assist the dealer, customer and operator in becoming familiar with the features of the 1018 Forwarder.

The operator's manual will assist the operator with the techniques of proper and safe operation of the Forwarder. The service manual contains safety guidelines, a preventive maintenance schedule and servicing procedures 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 Company reserves the right to change information contained herein at any time without prior notice.

Tigercat Industries Inc.

1018

iii

Tigercat 1018 Forwarder

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 safety 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 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 creating 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 suit 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 1018 Forwarder SECTION 1 - SAFETY MARCH 2003

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

Read and understand all manuals for any attachments or accessories.

CONTENTS - SECTION 1 ARTICULATION LOCK ................................................................................ 1.11 BATTERY DISCONNECT SWITCH ............................................................... 1.7 COOLING SYSTEM ....................................................................................... 1.9 EXHAUST FUMES ....................................................................................... 1.11 FIRE PREVENTION FIRE PREVENTION GUIDELINES ........................................................... 1.12 WHAT ELSE TO DO BEFORE YOU EXPERIENCE A FIRE .................... 1.13 WHAT TO DO AFTER A FIRE ................................................................. 1.14 WHAT TO DO IN CASE OF A MACHINE FIRE ........................................ 1.13 FIRST AID ...................................................................................................... 1.4 FLUID LEAKS ................................................................................................ 1.9 HYDRAULIC PRESSURE HAZARD ............................................................... 1.9 LOOSE CLOTHING HAZARD ...................................................................... 1.10 PARKING THE MACHINE .............................................................................. 1.7 PROTECTIVE CLOTHING ............................................................................. 1.3 SAFETY INTERLOCK SWITCHES ON DOORS ............................................ 1.8 SAFETY PRECAUTIONS, GENERAL ............................................ 1.3, 1.4, 1.5 SAFETY PRECAUTIONS, OPERATING ........................................ 1.6, 1.7, 1.8 SAFETY PRECAUTIONS, SERVICING ..................................... 1.9, 1.10, 1.11 SAFETY SYMBOLS ....................................................................................... 1.2 SIGNAL WORDS ........................................................................................... 1.2

Tigercat 1018 Forwarder

Safety

SAFETY SYMBOLS

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

Follow the instructions in the safety message.

Understanding Signal Words

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

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

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

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

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Tigercat 1018 Forwarder

Safety their respective message. Keep safety labels in good condition. Repair or replace damaged labels.

GENERAL SAFETY PRECAUTIONS 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.

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

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

Prolonged exposure to loud noise can cause permanent hearing loss.

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.

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

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

Do not let an untrained person operate the machine.

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

Do not use the joysticks as a handle when entering or leaving the cab.

Do not use machine foot controls as a step.

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

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 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

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

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Tigercat 1018 Forwarder

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

GENERAL SAFETY PRECAUTIONS continued 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.

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

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

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

Machine should be washed completely at every major service.

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).

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

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

Check all fluid levels.

NOTE:

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

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

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

The machine should be inspected daily for signs of fluid leaks, damage, unusual wear, or faulty operation. Repair or replace malfunctioning parts and systems immediately.

Check window and door guards for damage.

Check protective windows for cracks, a damaged window has reduced strength to stop flying objects.

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

Do not operate the machine with the cab retaining pins removed. Always install retaining pins after lowering the cab.

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

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Tigercat 1018 Forwarder

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.

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 seating accommodation is for one operator only.

WARNING

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.

Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

When operating the machine, ensure there is adequate clearance on both sides and above the machine or any of its attachments. Additional clearance may be necessary where the ground is uneven.

Extreme caution should be exercised when approaching any area where overhanging electrical powerlines 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.

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

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

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

Even though the brakes are fully engaged, block the wheels to prevent movement during transport.

Install articulation lock whenever the machine is to be transported.

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

Read, understand and follow all general safety precautions specified by crane, rotator and grapple manufacturer.

Access to a cell phone or radio to call for assistance in an emergency is advised. Be aware that signal strength for cell phones and radios changes with terrain and location.

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Tigercat 1018 Forwarder

Safety Secure loose items in the cab.

OPERATING SAFETY PRECAUTIONS

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

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

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

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

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

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

Sound the machine horn before starting the machine.

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

EMERGENCY BRAKE KNOB

•

•

The operator's seat is equipped with a lap belt.

Use this restraint system at all times when operating the machine.

Never use the emergency brake to slow down or stop the machine except in an emergency.

Keep the brakes properly adjusted at all times.

Always place the crane in the park position, or rest it on the ground when operation is stopped, regardless if the engine is running or shut off.

Start the engine by following the instructions in this manual. Refer to OPERATING MACHINE in SECTION 2 of the OPERATOR'S MANUAL.

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

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

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

Forwarder operations should only be performed from the operator s seat.

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

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Tigercat 1018 Forwarder

Safety

OPERATING SAFETY PRECAUTIONS continued Before leaving operator's cab, place the crane in the park position or on the ground and lower the snow blade (if equipped) to the ground.

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

Maintain a safe operating distance between the machine and workers and all other personnel. It is the duty of the operator to ensure that no person approach the machine while in use, the risk zone is 60 m (200 feet).

When parking the machine:

Park on level ground ONLY.

Do not park on a hillside or incline.

Place the crane in the park position or on the ground and lower the snow blade (if equipped) to the ground.

Stop the engine and release pilot system pressure by performing the following steps:

Use only prearranged and approved signalling practices.

1. Close both doors. Turn key switch to the ON position. Do not start the engine.

Press pilot reset switch.

Obey flagger's signal and signs

2. Fully apply brake foot pedal 50 times or more.

Do not carry passengers either in the cab or anywhere else on the machine.

3. Pressure may remain in the system after completing all of the above steps.

Use caution when loosening hydraulic connections.

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

Never operate the crane or grapple over the heads of bystanders.

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

Do not work below or behind a forwarder parked on a grade.

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

NEVER travel across a STEEP slope or side hill:

•

If you travel across a MODERATE slope, NEVER make an uphill turn as this could cause a tip-over situation.

When loading, keep load in grapple low and close to the forwarder for best stability.

A load of logs will change the handling and stability of the forwarder.

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

Never approach an unstable log from the downhill side.

Do not overload your forwarder as this can create an unstable condition and cause a roll-over.

MASTER DISCONNECT SWITCH

•

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

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

1.7

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.

Tigercat 1018 Forwarder

Safety

OPERATING SAFETY PRECAUTIONS continued Before moving the machine, place the crane in the park position, and lift the snow blade off the ground high enough to clear obstacles such as stumps.

• SWITCH

Check for correct tire air pressure. If the pressure is too low it will result in swaying. If the pressure is too high it will result in bouncing.

•

ACTUATOR

407-1

If the machine is to travel on public roads, use accessory lights (when installed) and other caution devices to alert operators of other vehicles of your presence. Ensure your machine meets all regulatory requirements.

INTERLOCK SWITCH (L.H. DOOR SHOWN)

SAFETY INTERLOCK SWITCHES ON DOORS: Both doors are equipped with safety interlock switches to prevent the machine from being operated while either of the doors are open (pilot system is shut off).

When transporting the machine, ensure 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.

CAUTION DO NOT use the joystick, steering control lever or armrest to assist entering or leaving the cab.

Before transporting the machine check to ensure that all doors, panels and access covers are installed properly and secured.

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

Read, understand and follow all general safety precautions specified by the crane, rotator, and grapple manufacturer.

To operate: Close both doors and press the PILOT RESET switch.

CAUTION All functions on the machine can now be operated, either as intended or by accidentally touching them.

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.

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

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Tigercat 1018 Forwarder

Safety through bearings, especially the center joint bearings. Also, turn off the master disconnect switch and disconnect the positive (+) battery cable from both batteries.

SERVICING SAFETY PRECAUTIONS

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.

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, and disconnect the positive (+) battery cable from both batteries.

Never use bare hand to check for fluid leaks.

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

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.

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

Pressure can be maintained in a hydraulic system long after the power source and pump have been shut down. Lower grapple and snow blade (if equipped) to the ground and relieve trapped pressure from brake accumulator before performing work on components, or disconnecting any hoses. For the procedure on how to RELIEVE PRESSURE, refer to PARKING THE MACHINE in THIS SECTION.

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

This machine is equipped with a reversible cooling fan to facilitate cleaning of the radiator/oil cooler assembly and engine compartment doors.

Exercise care when working in this area with the engine running. If the FAN SPEED SWITCH is in the VARIABLE position, the fan could turn ON and/or go into REVERSE mode.

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 1.9

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

Tigercat 1018 Forwarder

Safety

SERVICING SAFETY PRECAUTIONS continued 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.

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

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

1018-D088

CAB TILT CYLINDERS FULLY EXTENDED

CAB SUPPORT BRACE MUST USE CAB AND CHASSIS LUGS SHOWN.

PARTIAL CAB TILT WITH CAB SUPPORT BRACE

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

1018-D084

• • CAB LOCKING PINS

•

Before working under cab, machine must be parked on level ground. Cab must be fully tilted with tilt cylinders fully extended, or cab support brace must be installed between chassis and cab to prevent injury.

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

SAFETY7

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.

Always wear your safety gloves when handling cables, chains or logs.

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Tigercat 1018 Forwarder

Safety

SERVICING SAFETY PRECAUTIONS continued RETAINING PIN

ARTICULATION LOCK BAR

1018-D137

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.

ARTICULATION LOCK BAR IN LOCKED POSITION

ARTICULATION LOCK BAR

1018-D090

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.

ARTICULATION LOCK BAR IN STORAGE POSITION

Before working in the center joint area, install the chassis articulation lock bar between the chassis and center joint to prevent accidental articulation and injury. Always replace the lock bar in its storage position after use.

Dispose of fluids properly.

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

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

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

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

CAUTION Do not open cab doors or window screens when machine cab is tilted . The doors and screens are heavy and will swing out with considerable force.

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

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Tigercat 1018 Forwarder

Safety dislodged by vibration this smoldering debris can fall into other areas of the machine and thereby spread a fire.

FIRE PREVENTION

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

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

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

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

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.

8. 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.

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.

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

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.

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

3. 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.

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

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

13. 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.

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

Visual inspection after blow off to ensure thorough cleanliness is vital. Engine exhaust systems provide numerous small pockets where saw dust, small wood chips and other flammable forest debris can gather. Even small accumulations close to hot exhaust components can ignite and smolder. If

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

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

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

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Tigercat 1018 Forwarder

Safety WHAT TO DO IN CASE OF A MACHINE FIRE

FIRE PREVENTION continued

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

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.

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

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

Shut the engine off.

Activate the fire suppression system*

Radio or call for help (as appropriate).

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

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

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

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.

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

Use the PASS method with most extinguishers.

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

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

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

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

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

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

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

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

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

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

Continued on page 14

*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.

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Tigercat 1018 Forwarder

Safety WHAT TO DO AFTER A FIRE

FIRE PREVENTION continued Continued from page 13

TYPICAL FIRE EXTINGUISHER ACCESS HOLE If you are unable to open the access door(s), but can safely reach the fire extinguisher access hole, place the nozzle of the fire extinguisher into the appropriate fire extinguisher access hole and discharge the extinguisher.

20229A

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

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

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

1.14

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

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

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

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

Tigercat 1018 Forwarder SECTION 3 - LUBRICATION & MAINTENANCE CONTENTS - SECTION 3 AIR CLEANER MAINTENANCE ......................................................................... 3.16 AIR CONDITIONING SYSTEM, CHECKING ...................................................... 3.18 APPROVED HYDRAULIC OILS ........................................................................... 3.7 AXLES DRAINING AND REFILLING THE BOGIE HOUSINGS .................................. 3.25 DRAINING AND REFILLING THE DIFFERENTIAL ........................................ 3.24 OIL CAPACITIES ............................................................................................ 3.25 CENTER JOINT .................................................................................................. 3.15 LUBRICATION ................................................................................................ 3.15 MAINTENANCE OF ARTICULATION JOINT .................................................. 3.15 MAINTENANCE OF OSCILLATION JOINT .................................................... 3.15 CRANE MAINTENANCE ..................................................................................... 3.26 CRANE LUBRICATION PROCEDURE ........................................................... 3.26 ENGINE HOOD UP/DOWN CONTROLS ........................................................... 3.21 FILTERS - REMOVE AND REPLACE A/C FRESH AIR FILTER ................................................................................. 3.19 A/C UNIT RECIRCULATING AIR FILTER ...................................................... 3.19 CHARGE PRESSURE FILTER - DRIVE PUMP .............................................. 3.13 CHARGE PRESSURE FILTER - FAN DRIVE PUMP ..................................... 3.13 ENGINE AIR INTAKE ...................................................................................... 3.16 FUEL FILTER/WATER SEPARATOR ............................................................. 3.10 FUEL TANK STRAINER .................................................................................. 3.11 HYDRAULIC OIL DOUBLE FILTERS ............................................................. 3.12 PILOT SYSTEM FILTER ................................................................................. 3.14 GENERAL MAINTENANCE .................................................................................. 3.3 GRAPPLE MAINTENANCE ................................................................................ 3.26 HOOD UP/DOWN CONTROLS .......................................................................... 3.21 HOUR METER ~ MAINTENANCE ........................................................................ 3.2 LINK SNUBBER MAINTENANCE ....................................................................... 3.26 LUBRICATION AND SERVICE POINTS .............................................................. 3.9 NEW MACHINE MAINTENANCE ......................................................................... 3.2 FIRST 50-100 HOUR INSPECTION AND SERVICE REPORT ........................ 3.2 INITIAL PRE-DELIVERY INSPECTION ............................................................ 3.2 OIL LOST FROM LEAKAGE ................................................................................. 3.2 REPLACING THE ENGINE SERPENTINE BELT ............................................... 3.25 SCHEDULED MAINTENANCE ............................................................. 3.4, 3.5, 3.6 FREQUENTLY .................................................................................................. 3.4 8 HOURS .......................................................................................................... 3.4 24 HOURS ........................................................................................................ 3.4 125 HOURS ...................................................................................................... 3.4 250 HOURS ...................................................................................................... 3.5 500 HOURS ...................................................................................................... 3.5 1000 HOURS .................................................................................................... 3.5 SEASONAL ....................................................................................................... 3.6 SERVICE AND LUBRICATION POINTS .............................................................. 3.9 STARTUP PROCEDURE AFTER MAJOR MAINTENANCE .............................. 3.22 TILTING THE CAB .............................................................................................. 3.20 TORQUE CHART ................................................................................................ 3.27 TORQUE CHART, GENERAL ............................................................................ 3.28 WHEELS, INSTALLING ........................................................................................ 3.2

JUNE 2002

Tigercat 1018 Forwarder

Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE FOR 1018 FORWARDER

_______________________________________________________________________________________

NEW MACHINE MAINTENANCE *INITIAL PRE-DELIVERY INSPECTION:PERFORM THE INITIAL PRE-DELIVERY INSPECTION USING Tigercat FORM NUMBER 5296; 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 NUMBER 5296; 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.

IMPORTANT!

TIGHTENING POINTS FOR:-

__________________________________________

THE FIRST 50-100 HOUR INSPECTION REPORT:~

WHEELS:

All hydraulic connections

When installing wheels, ensure that all paint has been removed from the mating surfaces of both the wheel disc and the flange of the axle to ensure metal to metal contact.

For more complete instructions also refer to section 8 of the service manual. __________________________________________

Hose clamps Center joint pin securing bolts Transmission securing bolts Engine mounting bolts Pump securing bolts

HOUR METER ~ MAINTENANCE:

Axle mounting bolts

Check the hour meter (on the T220 Display terminal) on a regular basis to determine your scheduled maintenance times.

The intervals and times on the scheduled maintenance chart in this manual are for normal operating conditions.

If your machine is being operated in difficult or severe conditions, you should service your machine at shorter intervals.

Wheel retaining bolts Cab securing bolts Pin retainers Any other loose nut, bolt or fitting NOTE: Use of filters other than the Tigercat brand could lead to severe wear and rapid failure of system components.

*OIL LOST FROM LEAKAGE

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

LOST OIL (GALLONS) PER PER DAY MONTH LEAKAGE RATE ONE DROP IN 10 SECONDS 0.112 3.36 ONE DROP IN 5 SECONDS 0.225 6.75 ONE DROP PER SECOND 1.125 33.75 THREE DROP PER SECOND 3.75 112.5 DROPS BREAK INTO STREAM 24.00 720.0

_______________________________________________________________________________________

3.2

PER YEAR 40.0 81.0 405.0 1,350.0 8,640.0

Tigercat 1018 Forwarder

Lubrication and Maintenance

GENERAL CAUTION All handles, steps and platforms must be kept free of grease, oil, fuel, mud, snow and ice Clean around filler caps before checking or adding fluids Release hydraulic pressures and clean around hydraulic fittings before breaking connection.

Plug or cap immediately Clean up spills as soon as possible Always use clean oil and containers Drain dirty oil while still warm Do not exceed recommended fluid levels Service all hydraulic filters, and return strainer 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 end of each shift to reduce contamination by condensation Clean up oil spills on walking surfaces and top of engine enclosure immediately Before welding on machine be sure master switch is disconnected 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 Always have a fire extinguisher at hand For safety; when leaving the cab or leaving machine unattended or during service, always place the crane in the park position or other SECURE position, and lower the snow blade (if equipped). Turn the ignition switch off. Turn the battery disconnect switch off.

For safety, always block or support the crane and snow blade (if equipped) when working under them. _______________________________________________________________________________________

3.3

Tigercat 1018 Forwarder

Lubrication and Maintenance

SCHEDULED MAINTENANCE FREQUENTLY:~

A/C condenser, oil cooler, radiator and charge air cooler - refer to CLEANING A/C CONDENSER, OIL COOLER, RADIATOR AND CHARGE AIR COOLER in SECTION 2 of the OPERATOR S MANUAL.

Although the fan control system is programmed to automatically reverse at set intervals, and when temperatures become high, the operator may need to clear debris from the engine cooling air intake door screens using the FAN CONTROL switch. It may also be necessary to manually check for possible restriction depending upon operating conditions in your area. ______________________________________________

Check:~ For leakage around hydraulic components and flexible hoses. * See Oil lost from leakage chart.

For loose nuts, bolts and fittings Condition and tension of engine belts.

EVERY 8 HOURS (EVERY SHIFT):~

Conduct an overall visual inspection.

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

Perform "frequently" maintenance check, And in addition:~ Check engine coolant level

______________________________________________

Check engine oil level Drain fuel/water separator

EVERY 24 HOURS:~

Check air intake precleaner, clean as required

Perform frequently maintenance

Check air cleaner unloader valve

Perform 8 hour maintenance

Check engine air filter restriction indicator

And in addition:~

Check hydraulic oil level in hydraulic tank

Lubricate cab swing bearing, 2-fittings, 10 shots

Check transmission oil level with dipstick

Check hydraulic oil level in cab tilt reservoir

Lubricate mid drive shaft 1-fitting, purge

______________________________________________

Note: Lubrication of mid drive shaft slip joint should be done with machine fully articulated.

EVERY 125 HOURS:~

Lubricate fixed center joint drive shaft, 2-fittings, purge

Perform frequently maintenance

Lubricate rear drive shaft bearing, 1-fitting, purge

Perform 24 hour maintenance

Perform 8 hour maintenance And in addition:~

Lubricate center joint articulation bearings, 2-fittings, purge

Lubricate axles slew bearings*, 1-fitting; 4-places, purge

Lubricate center joint oscillation bearings, 2-fittings, purge

* Remove plugs on slew bearings prior to lubrication, then lubricate, and replace plugs.

Lubricate steering cylinder ends, 4-fittings, purge

Lubricate axles shaft bearings, 1-fitting; 8places, purge

Lubricate cab swing pinion, 1-fitting, 10 shots

Lubricate front drive shaft, 1-fitting, purge

Lubricate load gate cylinder ends, 2-fittings, purge

Lubricate rear drive shaft, 1-fitting, purge Check:~ Check fuel tank filler screen

Lubricate snow blade cylinders and pivots (if equipped), 6-fittings, purge

Fluid level in batteries unless maintenance free

Lubricate link snubber, 8-fittings, purge Clean:~

Engine rpm

Potentially damaging limbs or sticks from machine

All hydraulic pressures 3.4

Tigercat 1018 Forwarder

Lubrication and Maintenance

SCHEDULED MAINTENANCE Hydraulic pump and motor securing bolts

______________________________________________

Torque tightening points as per new machine maintenance

EVERY 500 HOURS:~ Perform frequently maintenance

Visually check for damage to:~ Bunks and load gate

Perform 8 hour maintenance Perform 24 hour maintenance

Front and rear frame

Perform 125 hour maintenance

Center joint area Crane, link, rotator, and grapple Make repairs immediately

Perform 250 hour maintenance And in addition:~ Replace air intake safety element

Visually inspect for:~ Frayed electrical wiring and hydraulic hose

Replace all hydraulic oil double element filters (4 elements) †

Wear in any other components

3 white, high performance element.

Clean/replace:~ Air conditioner re-circulation filter

1 blue, water absorbing element.

Replace charge pressure filter, drive pump †

Cab fresh air filter

Replace charge pressure filter, cooling fan pump †

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

Replace pilot system filter † Refer to diesel engine service manual and attachment manual for additional required maintenance at this scheduled time period.

______________________________________________

EVERY 250 HOURS:~ Perform frequently maintenance Perform 8 hour maintenance Perform 24 hour maintenance

† Use of hydraulic oil filters other than the Tigercat brand could lead to severe wear and rapid failure of hydraulic system components.

______________________________________________

EVERY 1000 HOURS:~

Perform 125 hour maintenance And in addition:~

Perform frequently maintenance

Replace engine oil and change oil filter

Perform 8 hour maintenance

Replace engine fuel filter

Perform 24 hour maintenance

Replace fuel/water separator

Perform 125 hour maintenance

Replace air intake primary element

Perform 250 hour maintenance

Replace oil in transmission

Perform 500 hour maintenance

Check oil level in bogie axle differentials, 4-places

And in addition:~

Check oil level in bogie axle housings, 2-places

Replace air cleaner unloader valve

Check the center joint for looseness. Refer to CENTER JOINT MAINTENANCE in THIS SECTION for instructions. If a problem is found corrective action should be taken immediately. Refer also to CENTER JOINT in SECTION 11 of the SERVICE MANUAL for more detailed checking and adjustment procedures.

Drain and refill front and rear axle differentials and bogie housings with SAE 90/GL 5 gear oil.

Refer to AXLE LUBRICATION in THIS SECTION and SECTION 8 of the SERVICE MANUAL for axle draining procedure.

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

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

3.5

Tigercat 1018 Forwarder

Lubrication and Maintenance

SCHEDULED MAINTENANCE SEASONAL:~ Drain and refill hydraulic oil reservoir with recommended hydraulic oil. Refer to APPROVED HYDRAULIC OILS in THIS SECTION. Drain and refill cab tilt reservoir with recommended hydraulic oil. Refer to APPROVED HYDRAULIC OILS in THIS SECTION. ______________________________________________

3.6

Tigercat 1018 Forwarder

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 cab tilt pump reservoir, apply brakes and operate differential locks.

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

HYDRAULIC OIL OPERATING RANGE (Not suitable for axle applications)

Tigercat

OPERATING TEMP. RANGE LOWEST START-UP TEMP.

HYDRAULIC OIL TEMPERATURE OIL TYPE SHELL TELLUS T22 TELLUS T68 TELLUS 100 ESSO UNIVIS N22 UNIVIS N68 PETRO CANADA HV22 HV60 HV80 TEXACO RANDO HD68 SUPERFLOW 22 SUPERFLOW AZ

CAUTION

OPERATING MACHINE OUTSIDE LIMITS SHOWN WILL RESULT IN FAILURE OF HYDRAULIC COMPONENTS 19713A R0

3.7

Tigercat 1018 Forwarder AXLE SLEW BEARINGS 17 4 FTG/125

REAR DRIVE SHAFT 19 1 FTG/125

Lubrication and Maintenance CENTER JOINT DRIVE SHAFT 19 1 FTG/8

5

16

FRONT DRIVE SHAFT 19 1 FTG/125

HOOD HINGES 3

11 12

2 FTG/500

4

10 13 14

15

27 MID DRIVE SHAFT 19

DOOR HINGES

1 FTG/8

2 FTG/500

8 FTG/125

18

DOOR HINGES

STEER CYLINDERS

SHAFT BEARINGS

4 FTG/8

25

21

2

4 FTG/500 REAR WINDOW HINGES

LINK, SNUBBER 26

8 FTG/8

2 FTG/500

DOOR HINGES

4 FTG/500

SCREEN HINGES

4 FTG/500 6

9

7 8

1

SNOW BLADE 24

6 FTG/8 DRIVE SHAFT REAR BEARING

1 FTG/8 LOAD GATE CYLINDER 23 2 FTG/8

19

CENTER JOINT OSCILLATION

2 FTG/8

CENTER JOINT ARTICULATION 20

2 FTG/8 ON OPPOSITE SIDE

CAB SWING PINION

1 FTG/8

20

22

ON OPPOSITE SIDE

CAB SWING BEARING 22 2 FTG/24 INSIDE CAB

LEGEND *

ANTIFREEZE SOLUTION MUST MEET GM 6038M SPECIFICATIONS - SEE MANUFACTURERS MAINTENANCE MANUAL

**

LUBRICATE UNTIL GREASE FLOWS OUT PAST OUTER SEALS. DO NOT USE POWER GREASERS AS IT WILL DAMAGE THE SEALS.

***

2 FTG/125

+

STEER MACHINE FULLY BEFORE GREASING MID DRIVE SHAFT SLIP YOKE. LUBRICATION POINT WITH A DESIGNATED NUMBER OF FITTINGS (2 FTG) AND HOURS BETWEEN SERVICING (125 ). JOINT TO BE PURGED. USE LITHIUM BASED GREASE CONTAINING MOLYBDENUM DISULFIDE. Use of hydraulic oil filters other than the Tigercat brand could lead to severe wear and rapid failure of hydraulic system components.

3.8

CHK REP DRN D/R LUB

HOURS CHECK REPLACE DRAIN DRAIN AND REFILL LUBRICATE

Tigercat 1018 Forwarder

Lubrication and Maintenance Tigercat® Model 1018

1

3 4 5 6 7 8 9

10

11 12 13

14

15 16 17 18

19

20 21 22 23 24 25 26 27

COOLING SYSTEM

CHK

ENGINE OIL/FILTER

CHK

CHANGE COOLANT EVERY 2 YEARS REP

DRN

REP REP

FUEL FILTER (ENGINE) FUEL/WATER SEPARATOR FUEL TANK FILLER SCREEN AIR INTAKE PRECLEANER AIR INTAKE PRIMARY ELEMENT AIR INTAKE SAFETY ELEMENT AIR CLEANER UNLOADER VALVE HYDRAULIC OIL RESERVOIR (LEVEL INDICATOR ON TANK) HYDRAULIC FILTER, FULL FLOW, INCLUDES:1 BLUE WATER ABSORBING ELEMENT* 3 WHITE HIGH PERFORMANCE ELEMENTS CHARGE PRESSURE FILTER (DRIVE PUMP) CHARGE PRESSURE FILTER (FAN DRIVE PUMP) PILOT SYSTEM FILTER TRANSMISSION (2 SPEED) TRANSMISSION (SINGLE SPEED)

AXLES-DIFFERENTIAL AXLES-BOGIE HOUSINGS AXLES-SLEW BEARINGS AXLES-SHAFT BEARINGS DRIVE SHAFT, MID SHAFT DRIVE SHAFT, CENTER JOINT DRIVE SHAFT, FRONT SHAFT DRIVE SHAFT, REAR SHAFT DRIVE SHAFT, REAR BEARING CENTER JOINT ARTICULATION CENTER JOINT OSCILLATION CENTER JOINT BEARING PRELOAD STEERING CYLINDERS CAB SWING BEARING CAB SWING PINION LOAD GATE CYLINDER SNOW BLADE CYLINDER & PIVOTS (IF EQUIPPED) CRANE/ROTATOR/GRAPPLE LINK SNUBBER CAB TILT RESERVOIR

USG

50

13.2

18.9

5

CHK CHK REP REP CHK CHK

REP 210

CHK CHK

LUB LUB LUB *** LUB LUB LUB LUB LUB LUB CHK LUB LUB LUB LUB LUB LUB CHK

1018LUBE.XLS

3.9

60/40 ANTIFREEZE* SEE ENGINE MANUFACTURERS MAINTENANCE MANUAL 1 1 1 1 1 1 1 1

REP +

4

REP + REP + REP + D/R

1

CLEAN AS REQUIRED CHECK FILTER RESTRICTION INDICATOR WITH ENGINE RUNNING REFER TO SECTION 3 OF MANUAL DRAIN AND REFILL AS REQUIRED BY SEASONAL OIL CHANGE (SEE HYDRAULIC OIL CHART) CHECK FILTER RESTRICTION INDICATOR ON FILTER WITH ENGINE RUNNING AT FULL AND WITH OIL FLOW

1

D/R

CHK CHK

55.5

DESCRIPTION Qty

Liters

1000 $

500 $

250 $

24 $

8$

ITEM

125 $

SERVICE POINT NO.

SERVICE AND LUBRICATION POINTS REFER TO Tigercat OPERATOR'S MANUAL FOR FURTHER INFORMATION SERVICE EVERY CAPACITY

D/R D/R

5.5

1.5

1 1

6

1.6

1

22 5.8 50 13.2 PURGE PURGE PURGE

2 4 4 8 1

PURGE PURGE PURGE PURGE PURGE PURGE

1 1 1 1 2 2

FILL WITH MIL-L-2105 OR API-GL-4 USE SAE 80 FILL WITH MIL-L-2105C OR API-GL-5 LUBRICANT GRADE/WEATHER TEMPERATURE: BELOW -10F(-23C) USE 75W-90 UP TO 100F(38C) USE 80W-90 ABOVE 100F(38C) USE 85W-140 FILL WITH SAE 90/GL 5 GEAR OIL LITHIUM BASE EP2 GREASE K LITHIUM BASE EP2 GREASE K

LITHIUM BASE EP2 GREASE K

LITHIUM BASE EP2 GREASE K

REFER TO SECTION 3 OF THE MANUAL PURGE 4 LITHIUM BASE EP2 GREASE K PURGE 2 LITHIUM BASE EP2 GREASE K 1 PURGE PURGE 2 LITHIUM BASE EP2 GREASE K PURGE 6 LITHIUM BASE EP2 GREASE K SEE MANUFACTURER'S MAINTENANCE SCHEDULE PURGE 8 3.7 1 REFER TO HYDRAULIC RESERVOIR ABOVE

Tigercat 1018 Forwarder

Lubrication and Maintenance

FILTERS - REMOVE AND REPLACE

Changing the filter: 1. Park machine on level ground, install articulation lock bar, lower the snow blade (if equipped) and place the crane in the park position, stop engine, remove key, open hood, then switch battery disconnect off, and block wheels.

IMPORTANT Failure to service and replace filters at the proper intervals specified in the manufacturer s manuals, could cause damage to the machine and result in the product warranty becoming NULL and VOID. Check Tigercat parts catalog for replacement filters.

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

3. Place rags below to catch the spillage of fuel.

4. Wearing face protection (in case of a fuel spray,) unscrew the old filter.

FUEL FILTER/WATER SEPARATOR This 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 refer to SERVICE AND LUBRICATION POINTS in THIS SECTION.

8. Check the seating area for the gaskets on the filter head and the water sediment bowl and wipe clean.

WATER SEPARATOR BOWL

1018-D056

9. 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.

6. Remove the water sediment bowl from the bottom of the old filter. Discard this gasket also. Dispose of old filter and any fuel properly.

7. Clean the water sediment bowl.

PRIMER PUMP

FUEL WATER SEPARATOR

5. Remove and discard the small 1 I.D. gasket from the threaded extension on the filter head.

FUEL/WATER SEPARATOR

DRAIN CAP

10. Lubricate the new 1 I.D. gasket with clean engine oil and install onto the threaded extension on the filter head.

11. Lubricate the gasket on top of the new filter with clean engine oil and prefill the filter with clean fuel.

12. 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.

13. Start the engine and check for leaks.

3.10

Tigercat 1018 Forwarder

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.

Changing or cleaning the strainer: 1. Park machine on level ground, install articulation lock bar, lower the snow blade (if equipped) and place the crane in the park position, stop engine, remove key, then switch battery disconnect off, and block wheels.

2. Drain the fuel tanks. (plugs in bottom) 3. Remove the oval cover from the right hand fuel tank and O ring from the access hole.

4. Before removing the strainer, clean any debris from the bottom of the tank and wipe it clean.

5. Remove the fuel strainer using the hex on the end of strainer. Carefully clean the strainer (it may be damaged by rough handling).

6. Check for a buildup of foreign materials where the strainer threads on to the pipe and elbow.

7. Reinstall the strainer using the hex on end.

8. Reinstall fuel tank cover plate with O ring.

9. Refuel and check for leaks. Start the engine and check for leaks again.

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.

3.11

Tigercat 1018 Forwarder

Lubrication and Maintenance

HYDRAULIC OIL DOUBLE ELEMENT FILTERS

Changing the filters: 1. Park machine on level ground, install articulation lock bar, lower the snow blade (if equipped) and place the crane in the park position, stop engine, remove key, then switch battery disconnect off, and block wheels.

BLUE ELEMENT

PILOT SYSTEM FILTER

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

3. Place rags below to catch the spillage of oil.

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

HYDRAULIC RESERVOIR 1018-D049

5. Check the seating area for the gasket on the filter heat and wipe it clean.

HYDRAULIC RESERVOIR

6. The Tigercat spin-on filter element is supplied with two gaskets. The 1018 uses the round ('O' ring style) section gasket for all four return filters. Discard the square section gasket.

FILTER HEAD

• DOUBLE ELEMENT FILTERS

1018-D050

• •

DOUBLE ELEMENT FILTERS

The hydraulic return line contains a double filter head with a built in restriction indicator and a 1.7 bar (25 psi) bypass valve. The oil cooling circuit contains another double filter head with the same restriction indicator and bypass valve. In the event of a clogged filter element or thicker oil on cold starts, this bypass filter will open and redirect oil around the filter element. When the filter elements become restricted, the Red pop-up indicator will show RED, indicating that the elements must be changed. It is recommended that all machines use the following different filter elements: 3 white, Tigercat high performance, full flow hydraulic oil filter elements

GASKET FILTER ELEMENT

FILTR_SEALS

ROUND SECTION GASKET INSTALLATION

7. Remove used gasket and clean gasket seat in head.

8. Apply clean oil to new gasket surfaces.

9. Install new gasket on inside lip of filter.

10. Screw on new filter until gasket makes contact.

11. Tighten filter until top edge makes metal to metal contact with filter head. (approximately 1 1/2 additional turns after gasket contact) 12. Start the engine and check for leaks.

1 blue, Tigercat water absorbing, full flow hydraulic oil filter element (installed in first location on return filter head).

Refer to SCHEDULED MAINTENANCE and SERVICE AND LUBRICATION POINTS in THIS SECTION.

3.12

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 OF THIS MANUAL. Use of hydraulic oil filters other than the Tigercat brand could lead to severe wear and rapid failure of hydraulic system components.

Tigercat 1018 Forwarder

Lubrication and Maintenance

CHARGE PRESSURE FILTERSDRIVE PUMP AND FAN DRIVE PUMP

7. Screw on the new filter until the gasket makes contact with the seat in the filter head.

8. Hand tighten filter an additional 1/2 turn only.

9. Start the engine and check for leaks.

DRIVE PUMP CHARGE PRESSURE FILTER

FAN DRIVE PUMP CHARGE PRESSURE FILTER

ENGINE COMPARTMENT 1018-D054 The drive pump charge circuit contains a single element, full flow Tigercat hydraulic filter with a restriction indicator sending unit and a 3.4 bar (50 psi) third port bypass valve. The restriction indicator sending unit turns on the filter bypass warning light in the cab when an oil flow restriction in excess of 3.4 bar (50 psi) is encountered at the filter head. When a restriction is encountered, the bypass valve diverts oil back to tank via the third port to prevent unfiltered oil from entering the drive circuit.

The fan drive circuit contains a single element, full flow Tigercat hydraulic filter with a restriction indicator sending unit and a 3.4 bar (50 psi) third port bypass valve. The restriction indicator sending unit for this filter is not connected to a warning light. When a restriction is encountered, the bypass valve diverts oil back to tank via the third port to prevent unfiltered oil from entering the fan drive circuit.

Changing a pressure filter:

IMPORTANT HYDRAULIC FILTER SERVICING GUIDELINES NEVER PRE-FILL ANY HYDRAULIC FILTERS ON 200, 700, 800 AND 1000 SERIES MACHINES NEVER PRE-FILL CHARGE PRESSURE FILTERS ON 600 SERIES SKIDDERS Tigercat generally does not recommend the pre-filling 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.

ALWAYS PRE-FILL DUAL HEAD HYDRAULIC FILTERS ON 600 SERIES SKIDDERS Dual head hydraulic filters on 600 series skidders must always be pre-filled with clean oil as noted specifically in the manuals for each of these machines.

All 600 series hydraulic circuits direct oil from the dual head filters to the main and drive pump inlets. Air must not be allowed to enter the inlets of these pumps. Entry of air directly into pump inlets can cause significant and costly damage to pumps. In this particular case the risk of damage to pumps caused by entry of air into the circuit is considered to be greater than the risk of damage caused by unfiltered oil.

Prefiltering of any hydraulic oil used to pre-fill these filters is strongly recommended to eliminate the risk of damage caused by unfiltered oil.

1. Park machine on level ground, install articulation lock bar, lower the snow blade (if equipped) and place the crane in the park position, stop engine, remove key, then switch battery disconnect off, and block wheels.

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

3. Place rags below to catch the spillage of oil.

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

5. Check the seating area for the gasket on the filter head and wipe it clean.

6. The new filter has an attached gasket. Apply hydraulic oil to the gasket surface.

3.13

Tigercat 1018 Forwarder

Lubrication and Maintenance

PILOT SYSTEM FILTER The pilot system for the proportional control valves contains a single element, full flow Tigercat hydraulic filter with a restriction indicator sending unit and a 3.4 bar (50 psi) third port bypass valve.

The restriction indicator sending unit for this filter is not connected to a warning light. When a restriction is encountered, the bypass valve diverts oil back to tank via the third port to prevent unfiltered oil from entering the pilot system circuit.

BLUE ELEMENT

PILOT SYSTEM FILTER

IMPORTANT HYDRAULIC FILTER SERVICING GUIDELINES NEVER PRE-FILL ANY HYDRAULIC FILTERS ON 200, 700, 800 AND 1000 SERIES MACHINES NEVER PRE-FILL CHARGE PRESSURE FILTERS ON 600 SERIES SKIDDERS Tigercat generally does not recommend the pre-filling 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.

ALWAYS PRE-FILL DUAL HEAD HYDRAULIC FILTERS ON 600 SERIES SKIDDERS Dual head hydraulic filters on 600 series skidders must always be pre-filled with clean oil as noted specifically in the manuals for each of these machines.

All 600 series hydraulic circuits direct oil from the dual head filters to the main and drive pump inlets. Air must not be allowed to enter the inlets of these pumps. Entry of air directly into pump inlets can cause significant and costly damage to pumps. In this particular case the risk of damage to pumps caused by entry of air into the circuit is considered to be greater than the risk of damage caused by unfiltered oil.

Prefiltering of any hydraulic oil used to pre-fill these filters is strongly recommended to eliminate the risk of damage caused by unfiltered oil.

HYDRAULIC RESERVOIR

HYDRAULIC RESERVOIR 1018-D049 Changing the filter: 1. Park machine on level ground, install articulation lock bar, lower the snow blade (if equipped) and place the crane in the park position, stop engine, remove key, then switch battery disconnect off, and block wheels.

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

3. Place rags below to catch the spillage of oil.

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

5. Check the seating area for the gasket on the filter head and wipe it clean.

6. The new filter has an attached gasket. Apply hydraulic oil to the gasket surface.

IMPORTANT

7. Screw on the new filter until the gasket makes contact with the seat in the filter head.

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 OF THIS MANUAL. Use of hydraulic oil filters other than the Tigercat brand could lead to severe wear and rapid failure of hydraulic system components.

8. Hand tighten filter an additional 1/2 turn only.

9. Start the engine and check for leaks.

3.14

Tigercat 1018 Forwarder

Lubrication and Maintenance

CENTER JOINT

OSCILLATION JOINT CHECK FOR MOVEMENT IN THIS JOINT AREA

REAR CHASSIS

MAINTENANCE OF ARTICULATION JOINT

B

Maintenance in this area is usually limited to: a) Regular lubrication of the two center joint articulation grease fittings to purge the articulation pivot bearings of debris and water.

Refer to SERVICE AND LUBRICATION POINTS in SECTION 3 for lubrication intervals. Use only high quality, lithium based EP2 grease containing molybdenum disulphide. b) Visually checking the center joint articulation for looseness every 250 hours. With an observer on the ground, keeping well clear of the center joint area, perform the following test to check for looseness of center joint articulation.

1. Have operator lift the crane out of the park position, and maneuver it 90 degrees to one side of the machine. Fold the stick boom down, and rapidly raise and lower the main boom several times to bounce machine (it may be necessary to adjust the boom up and boom down parameters using the T220 Display Terminal).

2. As the machine bounces, check for motion between the front chassis and center joint lugs. Also check for a clunking sound at the center joint area.

CENTER JOINT

ARTICULATION JOINT CHECK FOR MOVEMENT IN THIS JOINT AREA

1018-D089

A FRONT CHASSIS

250 HOUR CHECK

MAINTENANCE OF OSCILLATION JOINT Maintenance in this area is usually limited to: a) Regular lubrication of the two center joint oscillation grease fittings to purge the oscillation pivot bearings of debris and water.

Refer to SERVICE AND LUBRICATION POINTS in SECTION 3 for lubrication intervals. Use only high quality, lithium based EP2 grease containing molybdenum disulphide. b) Visually checking the center joint oscillation for looseness every 250 hours. With an observer on the ground, keeping well clear of the center joint area, perform the following test to check for looseness of center joint.

1. Have operator place the crane into the park position. Drive the machine in forward and reverse rapidly several times.

3. Have operator place the crane back into the park position and switch the CRANE/ OFF/SNOW BLADE switch to OFF.

2. Check for motion between the center joint and rear chassis. Also check for a clunking sound at the center joint area.

4. Movement between front chassis and center joint lugs or clunking of the pivot indicates a loose articulation joint and articulation joint preload must be checked.

Refer to CHECKING ARTICULATION PRELOAD in SECTION 11 of the SERVICE MANUAL.

3. Movement between center joint and rear chassis or clunking indicates a loose oscillation joint and oscillation joint preload must be checked. Refer to CHECKING/ ADJUSTING OSCILLATION PRELOAD in SECTION 11 of the SERVICE MANUAL.

3.15

Tigercat 1018 Forwarder

Lubrication and Maintenance

AIR CLEANER MAINTENANCE

ENGINE AIR CLEANER

AIR CLEANER

EXHAUST PORT AREA

1018-D047

1018-D046

ENGINE AIR CLEANER

ENGINE AIR CLEANER

AIR CLEANER

ENGINE AIR PRECLEANER 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 exhaust port area. For servicing procedures, refer to SECTION 7 of the SERVICE MANUAL. AS THE AIR SPINS, CENTRIFUGAL FORCE SEPARATES FOREIGN MATERIALS FROM THE CLEAN AIR

SENDING UNIT FOR WARNING LIGHT IN CAB

ENGINE AIR PRECLEANER

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

The air cleaner on this machine uses two filter elements, a primary element and a safety element accessible from the left side of the engine compartment.

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

A warning light on the cab instrument panel will come ON when the elements in the engine air cleaner become excessively clogged with dust causing air intake restriction.

In addition, a filter restriction indicator is mounted to the output side of the filter, this should show green when the engine is running at high RPM. Service is required if the indicator shows red.

UNLOADER VALVE

THE TURBO II PRECLEANER HAS SPECIALLY DESIGNED BLADES THAT CAUSE THE INCOMING AIR TO SPIN TURBO 2

FILTER RESTRICTION INDICATOR

ONLY THE PURIFIED AIR GOES TO THE AIR FILTER

TURBO II PRECLEANER OPERATION

1018-D048

AIR CLEANER UNLOADER VALVE

AIR CLEANER UNLOADER VALVE This rubber valve on the tube of the air cleaner housing should be checked at the beginning of every shift. (8 hours) If this valve is missing, damaged or has become hard, it will cause the air cleaner to become ineffective. The valve should suck closed at 1/3 throttle.

3.16

Tigercat 1018 Forwarder

Lubrication and Maintenance

This valve should be replaced every 1000 hours. Remove the unloader valve from the tube of the air cleaner housing. Check and clean the valve. A good valve should be soft and flexible.

If it is plugged, be sure to check the filter elements as they may need replacing as well.

Reattach the valve to the tube.

When operating in high dust conditions, the unloader valve should be checked and squeezed every 2 hours to release dust buildup.

In addition to the SCHEDULED MAINTENANCE, the following instructions should also be noted.

The most common and damaging servicing problems are:

•

SAFETY ELEMENT

ENGINE AIR PRECLEANER

Engine exposure to dust during servicing is the largest single reason for engine damage due to dust.

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.

2. Avoid dislodging dust from filter element(s) by gently pulling the element off the outlet tube.

3. Always clean the sealing surface of the outlet tube before inserting a new filter element.

PRIMARY ELEMENT

•

IMPROPER SERVICING

•

4. Always clean the inside of the outlet tube and filter housing.

5. Check your old filter, It can help you detect foreign material on the sealing surface that is causing leakage.

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.

OUTLET TUBE 1018-D068

AIR FILTER ELEMENTS

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.

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 centre.

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 here send dust directly to the engine.

NOTE: This does not apply to oil filters.

3.17

Tigercat 1018 Forwarder

Lubrication and Maintenance

CHECKING THE AIR CONDITIONING SYSTEM

IMPORTANT

Any service work must be performed by authorized A/C technicians. The system should be charged with R134a refrigerant only. PAG (polyalkeylene glycol) oil should be present in the system and must be used on O ring fittings during assembly.

A/C SYSTEM TOTAL CAPACITIES PAG OIL R134a REFRIGERANT (polyalkylene glycol) 3 LBS. 12 OZ.

It is recommended that during cold weather when the A/C system is not in use, that it be run for a period of 5 minutes every 2 weeks.

This will circulate oil to all components of the A/C system.

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

2 OZ.

Always use personal protective equipment to guard against flying debris.

The compressor and charge valves are accessible from the left side engine compartment. The receiver drier is accessible from the front of the engine compartment, on the front of the charge air cooler. The evaporator core is accessible from behind the operator s seat inside the cab.

Use this checklist to maintain system between service intervals.

a. Check and adjust compressor drive belt tension.

Check the condenser core for dirt and debris.

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

d. Check the evaporator core and the inside of the A/C housing for dirt and debris. Clean as required. e. Run air conditioning system for 3 - 5 minutes. f.

A/C CONDENSER

b. Check air intake filters and clean as required. c.

COOLER PACKAGE

WINGNUT

Check to see that compressor clutch will engage.

3.18

1018-D061

A/C CONDENSER AND COOLER PACKAGE

Tigercat 1018 Forwarder

Lubrication and Maintenance FRESH AIR FILTER

HOSE TO A/C HEATER UNIT

SHUT-OFF VALVE

ENGINE

1018-D039 1018-D042

HOT WATER SHUT-OFF VALVE

FRESH AIR FILTER

FILTER - FRESH AIR

HOT WATER SHUT OFF VALVE During times when cab heating is not required the HOT WATER SHUT OFF VALVE, on the heater hose from the engine, can be closed to prevent hot water from seeping through the A/C unit, thereby reducing the cooling system effect.

Additional Note: For machines equipped with the optional ESPAR HEATER option it is recommended that the inline fuse be removed from the ESPAR circuit when the HOT WATER SHUT OFF VALVE is closed. This eliminates the risk of damage to the heater caused by accidental programming of the ESPAR HEATER to operate when the coolant supply is shut off.

When the control switch is in the FRESH AIR position , outside air is drawn into the cab air conditioning unit through this filter and mixed with interior air from the cab. To reduce dust in the cab area, use the FRESH AIR option with the A/C on.

This pressurizes the cab, forcing dust out and reducing dust coming in. The FRESH AIR filter is accessible from outside of the cab, at the back between the lights. It should be cleaned or replaced every 125 hours. This is done by removing 6 bolts (M10) and removing the air inlet cover. Next remove two nuts (M10) and remove the filter box cover. This will allow access to the filter.

WARNING These filters may require cleaning or replacement more frequently under extreme operating conditions.

TEMPERATURE CONTROL

RECIRCULATING AIR FILTER

1018-D067

BEHIND SEAT

••

FILTER, RECIRCULATING AIR - A/C UNIT Air in the cab is drawn into the A/C-HEATER unit via this filter and recirculated. The filter is located on the front face of the A/C unit towards the left hand side. It should be cleaned or replaced every 125 hours. This is done by removing two thumb screws in the filter box cover.

1018-D031

A/C AND FAN CONTROLS

HEAT - VARIABLE/TEMPERATURE CONTROL This is a variable, rotary dial to adjust the amount of heated air for the cab. Make sure this control is off or at the coolest setting (full counterclockwise), when using the air conditioning. Refer also to HOT WATER SHUT OFF VALVE. 3.19

Tigercat 1018 Forwarder

Lubrication and Maintenance

TILTING THE CAB

CAUTION

WARNING

Keep hands away from the locking pin area.

Before tilting the cab, ensure that the machine is parked on level ground with the cab facing forward. Lower the snow blade (if equipped) and place the crane in the park position. Turn the ignition switch off.

CAB SUPPORT BRACE STORED UNDER HOOD

RAISING THE CAB 1. Position the forwarder on level ground.

2. Lower the snow blade (if equipped) and place the crane in the park position.

3. Turn ignition off 4. Check to be sure that the area above the tires on the right hand side of the cab is clear of all personnel and obstacles.

CAB LOCKING PINS

1018-D074

CAB SUPPORT BRACE

7. Press and hold the CAB UP button.

8. Insert CAB SUPPORT BRACE for partial tilt.

This brace is stored under the hood, on the left hand side of the engine. Secure brace at each end with the cab locking pins. Full tilt is limited by the cylinder stroke and is beyond centre of gravity. The cab will stay at this limit provided forwarder is on level ground.

WARNING

Before working under cab; 1018-D075

Machine must be parked on level ground.

Cab must be fully tilted with tilt cylinders fully extended, or cab support brace must be installed.

LEFT SIDE BELOW CAB

5. Remove the left side Cab Locking Pins. (2 pins) This is done by first removing the locking bolts. (2 bolts) LEFT SIDE HYDRAULIC TANK ACCESS DOOR

WARNING

If cab support brace is damaged or lost, it must be replaced immediately with Tigercat brace PART NO. 15314B. DO NOT attempt to work under a partially raised cab supported only by the hydraulic cylinders or a substitute device.

CAB TILT CONTROL

CAB TILT CONTROL 6. Locate the cab tilt control stored inside the left side hydraulic tank access door.

1018-D083

3.20

Tigercat 1018 Forwarder

Lubrication and Maintenance HOOD UP/DOWN CONTROLS

LOWERING THE CAB 1. Clear the area under the cab of obstructions and secure all lines and wires.

ENGINE HOOD

2. If the Cab Support Brace was used, you may have to take the weight off of it by slightly raising the cab before removing it. Be sure to place the brace back in the storage location for future use.

3. Press and hold the CAB DOWN button.

CAUTION Keep hands away from the locking pin area as the cab is being lowered.

ENGINE HOOD OPEN

1018-D041

TO OPEN: Check to be sure that the area in front of the hood is clear of all personnel and obstacles.

4. Watch closely for pinching of hydraulic lines and wires.

5. When fully lowered, insert Cab Locking Pins and tighten locking bolts (2 pins) (2 bolts)

HOOD CONTROL

6. Place the cab tilt control back into the storage location inside the left side hydraulic tank access door.

CAB TILT CONTROL

7. Close the left side hydraulic tank access door.

1018-D040

LEFT SIDE HYDRAULIC TANK ACCESS DOOR

Ensure that the battery disconnect switch is ON. Press and hold the HOOD UP button on the HOOD CONTROL stored inside the left side hydraulic tank access door.

1018-D088

When maintenance is complete, make certain that all personnel, tools and other obstacles are clear. Then press and hold the HOOD DOWN button until the hood is firmly seated on its stops.

CAB TILT CYLINDERS FULLY EXTENDED

Return the control pendent to its storage location, and close hydraulic tank access door.

CAB SUPPORT BRACE MUST USE CAB AND CHASSIS LUGS SHOWN.

PARTIAL CAB TILT WITH CAB SUPPORT BRACE 1018-D084

• ••

CAB LOCKING PINS

•• 3.21

Tigercat 1018 Forwarder

Lubrication and Maintenance

STARTUP PROCEDURE AFTER MAJOR MACHINE MAINTENANCE

LOOSEN HOSE ON TOP OF DRIVE MOTOR

This procedure should be followed:

after major service or a rebuild.

whenever the machine has been drained of hydraulic oil.

when any major component has been removed, repaired or replaced.

PRE-STARTUP AND FILLING 1. Ensure all filters are in place. Do not pre-fill the charge pressure filters, or the pilot system filter.

1018-D085

2. Check oil levels in the engine, the transmission, and both front and rear axles.

3. Check coolant level in the radiator.

DRIVE MOTOR

Loosen hose on top of drive motor(s).

LOOSEN HOSE ON LEFT HAND SIDE OF FAN DRIVE PUMP

4. Do a final inspection of all fittings and clamps to make sure they are tight and will not leak.

5. Install the articulation lock (pinned at both ends) and switch the FWD.|PARK|REV. to PARK

7. Do not start engine. Purge air from hydraulic system by adding oil as follows;

Prepare the hydraulic oil fill pump on the machine to add hydraulic oil. Clean and install the fill line, remove cap on end of pipe and insert pipe into oil supply drum.

Pre-fill the cases of the hydrostatic pump and any other components that have been drained of oil.

LOOSEN PLUG ON TOP OF MAIN PUMP

LOOSEN HOSE ON TOP OF HYDROSTATIC DRIVE PUMP

1018-D087

Loosen hose on left hand side of fan pump.

Loosen the bypass valve in the manifold on the hydraulic oil cooler.

Operate the hydraulic oil fill pump by turning the switch on the pump ON.

Watch for oil leaking from each plug previously loosened and tighten each plug when oil leaks out.

Continue running the hydraulic oil fill pump and watch the oil sight gauge on the reservoir.

Allow the hydraulic oil fill pump to run until the hydraulic tank is full. The hydraulic oil sight gauge will indicate FULL.

1018-D086

MAIN AND DRIVE PUMPS

Loosen hose on the top of hydrostatic drive pump controller

Loosen plug on the top of the main pump.

FAN DRIVE PUMP

NOTE: If the axles were drained of oil, refer to FILLING THE AXLES in SECTION 8 of THE SERVICE MANUAL

3.22

Tigercat 1018 Forwarder

Lubrication and Maintenance

MACHINE STARTUP M2 DRIVE PUMP PRESSURE

M3 DRIVE MOTOR DISPLACEMENT

Before beginning this procedure, perform the PRESTARTUP AND FILLING steps.

1. Ensure the articulation lock is installed and pinned at each end.

M LOAD SENSE PRESSURE (COPIED)

CAUTION

Machine operator must ONLY take directions from the person doing the set-up.

CHARGE PRESSURE (DRIVE)

2. Disconnect the round 24 pole Deutsch connector from the left side of the engine (prevents engine starting).

1018-D134

M7 DRIVE MOTOR CONTROL SIGNAL

M1 DRIVE PUMP PRESSURE

'PL' LOAD SENSE PRESSURE

TEST PORTS

PX MAIN PUMP PRESSURE

NOTE: If the machine was on wheels, the steer and drive functions were not properly purged or flushed. Remove the articulation lock pin and at LOW IDLE, slowly operate the steer function right and left a few times. With the emergency brake released, slowly operate the drive function forward and reverse a few times.

3. Crank engine for 10 seconds, wait for 10 seconds. Repeat 6 times to pump oil into pumps.

4. Reconnect the round 24 pole Deutsch connector. Do not start engine.

5. Install a 0-1000 psi. gauge on the 'CHARGE' test port to check charge pressure. Watch gauge closely during startup.

NOTE: If possible, allow the machine to stand for 4 to 6 hours before setting any of the operating pressures. This will allow any air bubbles in the oil to escape and is a good time to check for leaks.

6. Start engine. If charge pressure does not rise within 5 to 10 seconds, TURN ENGINE OFF. If charge pressure is between 18-31 bar (260-450 psi), run engine at IDLE for 20 minutes. Check engine oil pressure in cab.

Do not operate any functions. Remove gauge from 'CHARGE' test port.

7. With engine at IDLE, emergency brake ON, hold foot brake down, bleed service brake and parking brake release line in the front and rear axles.

8. Set engine speed at IDLE and run each function for 2 minutes to purge air from circuit.

9. Set engine speed to 1400 rpm and run each function again for 2 minutes to flush circuit.

10. Top up the radiator with clean coolant. With cylinders fully retracted, top up the hydraulic oil reservoir with clean hydraulic oil.

3.23

Tigercat 1018 Forwarder

Lubrication and Maintenance

AXLE LUBRICATION Each bogie axle has three separate oil reservoirs that require individual draining/filling. The axle must be level when draining/filling lubricant. The scheduled time to perform an oil change in the axles is when doing the seasonal hydraulic oil change. Refill the axle differentials and bogie housings with SAE 90/GL 5 gear oil.

BOGIE HOUSING BREATHER

DIFFERENTIAL FILL/LEVEL PLUG

BOGIE HOUSING FILL PLUGS (2 PLACES)

3

5

1 DIFFERENTIAL DRAIN PLUG

2

4

BOGIE HOUSING DRAIN PLUG (4 PLACES)

BOGIE HOUSING LEVEL PLUG (2 PLACES)

1018-i05

AXLE DRAINING AND REFILLING 6. Clean any filings from the magnetic drain plug (1).

DRAINING AND REFILLING DIFFERENTIAL: (1 PER AXLE) 1. Park machine on level ground, install articulation lock bar, lower the snow blade (if equipped) and place the crane in the park position, stop engine, remove key, then switch battery disconnect off, and block wheels.

7. Replace the differential housing drain plug (1).

8. Refill the differential by pumping oil into the fill/ level plug (3) on the differential. Stop adding oil when the oil level reaches the bottom of the differential level fill/level plug (3).

9. Replace the differential fill/level plug (3).

2. The axle must be level in order to drain and refill it properly.

3. Clean around all fill, level and drain plugs before removing them.

4. Remove the differential fill/level plug (3) located opposite the input yoke on the differential housing.

5. Remove the differential housing drain plug (1) located on the bottom of the differential, and drain the oil into a suitable container for disposal.

3.24

Tigercat 1018 Forwarder

Lubrication and Maintenance REPLACING THE ENGINE SERPENTINE BELT

DRAINING AND REFILLING BOGIE HOUSING: (2 PER AXLE) 10. Remove the bogie housing fill plugs (5) located on the top of the bogie housing.

Note, there are two bogie housing fill plugs to be removed per axle.

In order to replace the engine serpentine belt it is necessary to disassemble the fan drive pump coupling.

COUPLER 1/4" BOLTS

11. Remove the bogie housing level plugs (4) located on the outside of the housing below the bearing cap. Note, there are two bogie housing level plugs to be removed per axle.

FAN DRIVE PUMP BOLTS

12. Remove the bogie housing drain plugs (2) on the inside of the bogie housings, towards the bottom. Note, there are four plugs in total to be removed per axle to drain the bogie housings. Drain the oil into a suitable container for disposal.

13. Clean any filings from the magnetic drain plugs (2).

1018-D076

COUPLER

FAN DRIVE PUMP BOLT LOCATION

1. Park the machine on level ground. Place the crane in the park position, and lower the snow blade (if equipped) and turn engine off.

14. Replace the bogie housing drain plugs (2) in all locations.

15. Refill the bogie housings by pumping oil into the fill plug (5) on the bogie housings. Stop adding oil when the oil level reaches the bottom of the bogie housing level plug (4).

Note, each of the bogie housings must be filled separately.

2. Remove the A/C compressor belt (if equipped).

3. Remove the fasteners that hold the pump drive coupler together (8 bolts - 1/4"). Note the engine will have to be jogged to access all of the bolts.

16. Replace the bogie housing level plugs (4).

4. Carefully slide the black rubber section of the coupler towards the fan pump. This will provide enough clearance to replace the serpentine belt.

17. Replace the bogie housing fill plugs (5).

CAPACITIES For front and rear axle oil fill capacities, refer to the table: SERVICE AND LUBRICATION in SECTION 3 of THIS MANUAL.

5. Replace the serpentine belt. Ensure that all of the ribs on the serpentine belt align with the grooves on the engine pulleys.

6. Reassemble the pump drive coupler, using the original bolts. Use loctite 242 (temporary) or equivalent. Torque all bolts to 8-10 lbf-ft using an opposing torque pattern.

7. Reinstall, align and tension the A/C compressor belt (if equipped).

3.25

Tigercat 1018 Forwarder

Lubrication and Maintenance LINK SNUBBER MAINTENANCE

CRANE, ROTATOR AND GRAPPLE MAINTENANCE

IMPORTANT

Refer to the manufacturer s maintenance and service manual for information on your crane, rotator and grapple.

All service points on snubber must be greased every shift (8 hours) to ensure a long service life.

CRANE LUBRICATION PROCEDURE

EARLIER MACHINES This model of link provides a snubbing action in one direction (side to side movement of the grapple). There are 6 grease fittings on the link, for daily lubrication of the sleeves, bushings and housings.

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

LATER MACHINES This model of link provides snubbing action in both directions. There are 8 grease fittings on the link, for daily lubrication of the sleeves, bushings and housings.

1. Fully extend booms and place opened grapple on the ground.

2. Slightly force grapple into ground but do not lift machine.

3. While in this position, lubricate all cylinder retaining pins and joints daily.

LINK SNUBBER MAINTENANCE (EARLIER MODEL SHOWN) ADJUSTING SNUBBER TENSION 1018-D079

Tension is adjusted by turning the adjusting bolts.

Turn the adjusting bolts only 1/2 turn at a time until the desired tension is achieved. Over-tightening may result in grapple stiffness and reduced friction sleeve life.

3.26

Tigercat 1018 Forwarder

Lubrication and Maintenance

TORQUE CHART LOCATION

THREAD

TORQUE (LUBRICATED) Nm

lbf-ft

Steer Cylinders Pin keeper plate bolts Piston nut Gland

M20 x 2.5 1 3/4" UNF -

530 2370 745

400 1750 550

Snow Blade Cylinders (if equipped) Pin keeper plate bolts Piston nut, arc/boom cylinder Gland keeper plate bolts

M20 x 2.5 2" UNF M16 x 2.0

530 3050 275

400 2250 200

Cab pin keeper plate bolts

M20 x 2.5

530

400

Center joint bearing Articulation bearing retaining bolts Articulation pin retaining bolts Oscillation end cap bolts

M16 x 2.0 M20 x 2.5 M20 x 2.5

275 530 530

200 400 400

Engine mounting Rear Bolts Front Bolt

M22 x 2.5 M24 x 3.0

725 925

540 675

Main/Drive Pump mounting Cummins drive plate to flywheel Cummins bell housing Cummins engine mounting brackets Scania drive plate to flywheel Scania bell housing Scania rear engine mounting brackets Scania front engine mounting brackets

3/8" UNC M10 x 1.5 M12 x 1.75 M12 x 1.75 3/8 UNC M14 x 2.0 M12 x 1.75

45-49 43 110 110 45-49 175 110

33-36 32 80 80 33-36 130 80

1 1/4" x 18 UNEF M12 x 1.75 M20 x 2.5 1/2" UNF

640-711 110 530 163-179

475-525 80 400 120-132

Axle mounting bolts Front/Rear Bridge mounting bolts front/rear

M30 x 3.5 M24 x 3.0

1850 925

1350 675

Wheel nuts

M22 x 1.5

540

400

Transmission Housing to Mounting Bracket Mounting Bracket to Frame

M16 x 2.0 M20 x 2.5

275 530

200 400

Drive shafts Yoke retaining nut, rear shaft Hanger bearing retaining bolts Hanger bearing mount bolts Universal joint bolts

REV 1 05/2000

Torque values pertaining to the engine and attachments are provided in the appropriate manuals.

3.27

Tigercat 1018 Forwarder

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 COARSE THREADS 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 THREADS 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 LUBRICATED lbf-ft Nm lbf-ft Nm 11 - 12 15 - 16 8 - 10 11 - 13 20 - 28 27 - 38 26 - 30 35 - 40 44 -48 60 - 65 33 - 36 45 - 49 70 - 77 95 - 104 52 - 57 71 - 77 106 - 117 144 - 158 80 - 88 109 - 119 153 - 168 208 - 228 115 - 127 156 - 172 212 - 233 288 - 316 159 - 175 216 - 237 376 - 414 510 - 561 282 - 310 393 - 420 606 - 667 822 - 904 455 - 501 617 - 679 909 - 1000 1233 - 1355 682 - 750 925 - 1016 1288 - 1417 1746 - 1921 966 - 1062 1310 - 1441 1817 - 1999 2464 - 2710 1360 - 1496 1844 - 2027 DRY LUBRICATED lbf-ft Nm lbf-ft Nm 13 - 14 18 - 19 10 - 13 14 - 17 23 - 28 31 - 38 18 - 25 25 - 33 49 - 54 67 - 73 37 - 41 50 - 55 78 - 86 106 - 116 58 - 64 79 - 86 120 - 132 163 - 179 90 - 99 122 - 134 171 - 188 232 - 255 128 - 141 174 - 191 240 - 264 326 - 358 180 - 198 244 - 268 420 - 462 570 - 626 315 - 347 427 - 470 668 - 735 906 - 996 501 - 550 679 - 745 995 - 1096 1359 - 1486 746 - 821 1012 - 1113 1445 - 1590 1960 - 2155 1083 - 1191 1469 - 1613 2012 - 2213 2728 - 2997 1509 - 1660 2046 - 2250

COARSE DRY THREADS lbf-ft Nm 1/4" - 20 7- 8 10 - 11 5/16" - 18 14 - 18 19 - 24 3/8" - 16 31 - 34 42 - 46 7/16" - 14 49 - 54 66 - 73 1/2" - 13 75 - 83 102 - 112 9/16" - 12 109 - 120 148 - 162 5/8" - 11 150 - 165 204 - 223 3/4" - 10 266 - 293 360 - 397 7/8" - 9 394 - 433 535 - 586 1" - 8 591 - 649 802 - 879 1 1/8" - 7 794 - 873 1077 - 1183 1 1/4" - 7 1120 - 1232 1519 - 1670 FINE DRY THREADS lbf-ft Nm 1/4" - 28 9 - 10 12 - 13 5/16" - 24 17 - 22 23 - 29 3/8" - 24 35 - 39 48 - 53 7/16" - 20 55 - 61 75 - 83 1/2" - 20 85 - 94 116 - 127 9/16" - 18 121 - 133 164 - 180 5/8" - 18 170 - 187 231 - 253 3/4" - 16 297 - 327 403 - 443 7/8" - 14 434 - 477 589 - 646 1" - 12 646 - 711 876 - 965 1 1/8" - 12 891 - 980 1208 - 1328 1 1/4" - 12 1240 - 1364 1682 - 1849

LUBRICATED lbf-ft Nm 8 - 10 11 - 13 10 - 15 13 - 20 23 - 25 31 - 34 37 - 41 50 - 55 57 - 63 77 - 85 82 - 90 111 - 122 113 - 124 152 - 168 200 - 220 271 - 298 296 - 326 402 - 441 443 - 489 601 - 663 596 - 656 808 - 889 840 - 924 1139 - 1252 LUBRICATED lbf-ft Nm 9 - 10 12 - 13 16 - 20 21 - 27 26 - 29 35 - 39 41 - 45 56 - 61 64 - 70 87 - 95 91 - 100 124 - 135 128 - 141 174 - 191 223 - 245 303 - 332 326 - 359 442 - 486 484 - 534 657 - 724 668 - 735 906 - 996 931 - 1024 1262 - 1387

METRIC

SIZE

CLASS 4.8 LUBRICATED DRY Nm lbf-ft Nm lbf-ft

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

M6 M8 M10

4.8 12 23

3.5 8.5 17

6 15 29

4.5 11 21

9 22 43

6.5 16 32

11 28 55

8.5 20 40

13 32 63

9.5 24 47

17 40 80

12 30 60

15 37 75

11.5 28 55

19 47 95

14.5 35 70

M12 M14 M16

40 63 100

29 47 73

50 80 125

37 60 92

75 120 190

55 88 140

95 150 240

70 110 175

110 175 275

80 130 200

140 225 350

105 165 225

130 205 320

95 150 240

165 260 400

120 190 300

M18 M20 M22

135 190 260

100 140 190

175 240 330

125 180 250

260 375 510

195 275 375

330 475 650

250 350 475

375 530 725

275 400 540

475 675 925

350 500 675

440 625 850

325 460 625

560 800 1075

410 580 800

M24 M27 M30

330 490 675

250 360 490

425 625 850

310 450 625

650 950 1300

475 700 950

825 1200 1650

600 875 1200

925 1350 1850

675 100 1350

1150 1700 2300

850 1250 1700

1075 1600 2150

800 1150 1600

1350 2000 2700

1000 1500 2000

M33 M36

900 1150

675 850

1150 1450

850 1075

1750 2250

1300 1650

2200 2850

1650 2100

2500 3200

1850 2350

3150 4050

2350 3000

2900 3750

2150 2750

3700 4750

2750 3500

3.28

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

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

Tigercat 1018 Forwarder

SECTION 6 - ELECTRICAL & COMPUTERS CONTENTS - SECTION 6 ELECTRICAL HARNESS INSTALLATION CUMMINS ENGINE ....................................................................................................... 8 SCANIA ENGINE ........................................................................................................... 9 FUSE AND RELAY PANELS ........................................................................................ 6, 7 HTC (HYDROSTATIC TRANSMISSION CONTROLLER) INPUTS ......................................................................................................................... 2 OUTPUTS ..................................................................................................................... 3 PVC (PROPORTIONAL VALVE CONTROLLER) INPUTS ......................................................................................................................... 4 OUTPUTS ..................................................................................................................... 5 SCHEMATIC DIAGRAM CUMMINS (10180102 TO 10180104) ................................. 12, 14, 16, 18, 20, 22, 24 CUMMINS ENGINE (10180101, 1018105 & UP) ................ 40, 42, 44, 46, 48, 50, 52 SCANIA ENGINE ................................................................ 26, 28, 30, 32, 34, 36, 38 WIRE COLOUR CODE CHART ...................................................................................... 10

SEPTEMBER 2002

Tigercat 1018 Forwarder

Electrical & Computers

The Tigercat 1018 Forwarder is controlled electronically by two solid-state computers.

HTC (HYDROSTATIC TRANSMISSION CONTROLLER)

1. HTC (Hydrostatic Transmission Controller) The HTC provides fully integrated control of the entire transmission chain.

The HTC computer monitors and analyzes inputs and produces outputs (as defined in its program) to control the machine. The HTC controls all of the drive functions on the machine.

2. PVC (Proportional Valve Controller) The PVC is a logic device that controls all of the proportional valve functions.

Inputs: The HTC computer monitors analogue, digital, and frequency inputs. The following chart lists the function for each of the HTC input connections.

Both the HTC and PVC computers are connected to the T220 Display Terminal, located on the instrument panel. The operator can view output information and enter parameter information for both the HTC and PVC computers using the T220 Display Terminal. Refer to T220 DISPLAY TERMINAL in SECTION 2 of the OPERATOR S MANUAL for more information.

1018 Tigercat Forwarder HTC Inputs Pin No. A10 A11 A12 A13 A17 A18 A29 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 B17 B18 B19 B20 B21 B22 B23 B24 B25 B26 B27 B28 B29 B30 B31 B32 B33 B34 B35

W ire No.

Signal Na m e

PUR 254 W HT 237 BLK H23 RED 150C RED 150B RED 217

Hydrostatic Drive Motor RPM Sensor Diesel Engine RPM Sensor HTC Ground HTC Power HTC Power W orking RPM Rotary Dial

PUR 295

Diesel Engine Torque Signal

RED 53A

Hydraulic Oil Level Sensor

PUR 224 YEL 225 PUR 163 YEL 45

Engine Oil Pressure Sensor Coolant Temperature Sensor Transmission High/Low Switch Hydraulic Oil Temperature Sensor

YEL 27 RED 221 RED 219 TAN 161 TAN 226 TAN 227 PUR 140 PUR 141 TAN 160 TAN 159 GRN 39 GRN 40 TAN 228 TAN 229 TAN 230 RED 231 RED 232 ORG 46A RED 233 RED 201A RED 235

Fuel Level Sensor Drive Pedal Travel Speed Rotary Dial All W heel Drive Switch Direction Selection - Forward Direction Selection - Reverse Low Gear Feedback Sensor High Hear Feedback Sensor Drive Pedal Safety Switch Park Brake Sensor Differential Lock Switch - Front Differential Lock Switch - Rear W orking RPM Switch Drive Mode Selector - Economy Low Brake Pressure Sensor Fan - Clean Off Fan - Clean On Fan - A/C turned on Fan Speed Max. Pilot Reset Brake Pedal

HTC.XLS

6.2

Signal Type Frequency Frequency Frequency Frequency Ground Supply Supply Analog Analog Analog Analog Analog Analog Analog Analog Analog Analog Analog Analog Analog Analog Analog Analog Analog Analog Digital Digital Digital Digital Digital Digital Digital Digital Digital Digital Digital Digital Digital Digital Digital Digital Analog

Input Signal Ra nge 0-8000 Hz 0-8000 Hz 0-8000 Hz 0-8000 Hz Ground 20-28 Volts 20-28 Volts 0-10 Volts 0-10 Volts 0-10 Volts 4-20 mA 4-20 mA 0-185 Ohms 0-185 Ohms 0-185 Ohms 0-185 Ohms 0-4000 Ohms 0-4000 Ohms 0-4000 Ohms 0-4000 Ohms 0-4000 Ohms 0-90 Ohms 0-10 Volts 0-10 Volts 0-10 Volts <2 Volts=On, >8 Volts=Off <2 Volts=On, >8 Volts=Off <2 Volts=On, >8 Volts=Off <2 Volts=On, >8 Volts=Off <2 Volts=On, >8 Volts=Off <2 Volts=On, >8 Volts=Off <2 Volts=On, >8 Volts=Off <2 Volts=On, >8 Volts=Off <2 Volts=On, >8 Volts=Off <2 Volts=On, >8 Volts=Off <2 Volts=On, >8 Volts=Off <2 Volts=On, >8 Volts=Off <2 Volts=On, >8 Volts=Off <2 Volts=On, >8 Volts=Off <2 Volts=On, >8 Volts=Off <2 Volts=On, >8 Volts=Off 0-10 Volts

Tigercat 1018 Forwarder

Electrical & Computers

Outputs: The HTC computer directs an output (24 Volt electrical current) to the solenoids on the drive pump, the fan pump, the brake valve, and auxiliary functions valve. It also controls engine RPM by sending appropriate signals to the engine s control computer. The following chart lists the function for each of the HTC output connections.

1018 Tigercat Forwarder HTC Outputs Pin No. W ire No. A1 A2 TAN 222 A3 A4 A5 A6 TAN220 A7 TAN 236 A8 TAN 218 A9 RED 162 A14 A15 A16 A19 TAN 165 A20 TAN 166 A21 GRN 114 A22 GRN 240 A23 YEL 241 A24 GRN 296 A25 GRN 244 A26 GRN 52 A27 YEL 245 A28 GRN 243A A30 GRN 11 A31 RED 70 A32 YEL 246 A33 YEL 247 A34 YEL 248 A35 BLK H22

Signa l Na m e

Signa l Type

Drive Pedal Reference Voltage

Ref. Voltage

Travel Speed Rotary Dial Reference Voltage Brake Pedal Refence Voltage W orking RPM Rotary Dial Reference Voltage All W heel Drive Switch Reference Voltage Scania Engine Startup Delay

Ref. Voltage Ref. Voltage Ref. Voltage Ref. Voltage Digital PW M Ref. Voltage Communication Receive From PC Communication Communication Transmission To PC Communication Transmission High Gear Solenoid Digital All W heel Drive Disengage Solenoid Digital W arning Lights Digital Cooling Fan Reverse Relay Digital Differential Lock Solenoid - Front Digital Differential Lock Solenoid - Rear Digital Alarm Digital Park Brake Release Solenoid Digital Proportional Front and Rear Brake Solenoids Analog Proportional Cooling Fan Drive Analog Proportional Forward Drive Solenoid Analog Proportional Reverse Drive Solenoid Analog Engine Throttle Output Analog Communication Ground Communication

HTC.XLS

6.3

Output Signa l Ra nge 10 Volts

10 10 10 10 24

Volts Volts Volts Volts Volts

10 Volts

24 24 24 24 24 24 24 24 24 24 24 24 24

Volts Volts Volts Volts Volts Volts Volts Volts Volts Volts Volts Volts Volts

Tigercat 1018 Forwarder

Electrical & Computers

PVC (PROPORTIONAL VALVE CONTROLLER)

Inputs:

The PVC computer monitors and analyzes inputs and produces outputs (as defined in its program) to control the machine. The PVC controls all of the proportional valve functions on the machine.

Proportional valve functions are:

The PVC computer monitors analogue, digital, and PVC-Net inputs. PVC-Net is a data bus system that allows several input signals to be sent to the PVC through a reduced number of wires. The following chart lists the function for each of the PVC input connections.

Cab Rotate Steering Snow Blade (if equipped) Crane Rotate Main Boom Stick Boom Telescope Boom Grapple Rotate Grapple Open/Close.

Refer to SECTION 11 and SECTION 12 in THIS MANUAL for more information about proportional valve functions.

1018 Tigercat Forwarder PVC Inputs Pin No.

Wire No.

Signal Name

Signal Type

A17

BLK H28

PVC Ground

Ground

Ground

A18

RED 173

PVC Power

Supply

20-28 Volts

B1

GRN 286

Steer/Drive Normal|Reverse Switch

Digital

<2 Volts=On, >8 Volts=Off

B2

RED 201B

Pilot Reset Relay

Digital

<2 Volts=On, >8 Volts=Off

B3

GRN 287

Cab Rotate Clockwise Switch

Digital

<2 Volts=On, >8 Volts=Off

B4

GRN 288

Cab Rotate Counterclockwise Switch

Digital

<2 Volts=On, >8 Volts=Off

B5

TAN 175

Communication Transmission To HTC

Communication

B6

TAN 176

Communication Receive From HTC

Communication

B7

YEL 177

Communication Transmission To T220 Display

Communication

B8

YEL 178

Communication Receive From T220 Display

Communication

B9

TAN 167

Communication Transmission To PC

Communication

B10

TAN 168

Communication Receiver From PC

Communication

B11

GRN 179

Right Joystick A5

PVC Net

B12

GRN 180

Right Joystick A4

PVC Net

B13

GRN 181

Right Joystick A7

PVC Net

B14

GRN 182

Right Joystick A6

PVC Net

Input Signal Range

B15 B16 B17

BLK H26

PVC Ground

Ground

Ground

B18

RED 174

PVC Power

Supply

20-28 Volts

GRN 184

Steering Joystick (X)

Analog

0-10 Volts

GRN 185 GRN 186

Steering Joysick Reference Voltage Steer Joystick Ground

B27 B28 B29 B30 B31 B32 B33 B34 B35

6.4

Ref. Voltage Ground

10 Volts Ground

Tigercat 1018 Forwarder

Electrical & Computers

Outputs: The PVC computer directs a proportional output (24 Volt electrical current) to the solenoids on the steer valve, boom valve, and auxiliary functions valve. The PVC also communicates with the HTC, and forwards the required signals from the PVC-Net to it. The following chart lists the function for each of the PVC output connections.

1018 Tigercat Forwarder PVC Outputs Pin No.

Wire No.

Signal Nam e

Signal Type

Output Signal Range

A1

GRN 157

Proportional Steer Solenoid

Analog

0-1.5 Amps

A2

GRN 158

Proportional Steer Solenoid

Analog

0-1.5 Amps

A3

GRN 134A

PVC Crane/Snow Blade Relay (16)

Analog

0-1.5 Amps

A4

GRN 135A

PVC Crane/Snow Blade Relay (17)

Analog

0-1.5 Amps

A5

GRN 136

Proportional Stick Out Solenoid

Analog

0-1.5 Amps

A6

GRN 137

Proportional Stick In Solenoid

Analog

0-1.5 Amps

A7

GRN 24

Proportional Grapple Rotate Solenoid

Analog

0-1.5 Amps

A8

GRN 26

Proportional Grapple Rotate Solenoid

Analog

0-1.5 Amps

A9

GRN 138

Proportional Telescope In Solenoid

Analog

0-1.5 Amps

A10

GRN 139

Proportional Telescope Out Solenoid

Analog

0-1.5 Amps

A11

GRN 116

Proportional Crane Rotate Solenoid

Analog

0-1.5 Amps

A12

GRN 117

Proportional Crane Rotate Solenoid

Analog

0-1.5 Amps

A13

GRN 18

Proportional Grapple Open Solenoid

Analog

0-1.5 Amps

A14

GRN 19

Proportional Grapple Close Solenoid

Analog

0-1.5 Amps

A15

GRN 171

Proportional Cab Rotate Solenoid

Analog

0-1.5 Amps

A16

GRN 172

Proportional Cab Rotate Solenoid

Analog

A19

GRN 280

Steer Solenoid

Ref. Voltage

24 Volts

PVC Crane/Snow Blade Relay (18)

Ref. Voltage

24 Volts

GRN 265

Stick Solenoid

Ref. Voltage

24 Volts

GRN 266

Rotator Solenoid

Ref. Voltage

24 Volts

GRN 267

Telescope Solenoid

Ref. Voltage

24 Volts

GRN 268

Crane Rotate Solenoid

Ref. Voltage

24 Volts

GRN 269

Grapple Open/Close Solenoid

Ref. Voltage

24 Volts

GRN 281

Cab Rotate Solenoid

Ref. Voltage

24 Volts

0-1.5 Amps

A20 A21

GRN 284A

A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 A33 A34 A35 B19

TAN 226

Direction Selection - Forw ard

Digital

24 Volts=On, 0 Volts=Off

B20

TAN 227

Direction Selection - Reverse

Digital

24 Volts=On, 0 Volts=Off

B21

GRN 261

Cab Rotate Brake Release Solenoid

Digital

24 Volts=On, 0 Volts=Off

B23

GRN 285

PVC Crane/Snow Blade Relays (16,17&18)

Digital

24 Volts=On, 0 Volts=Off

B24

TAN 228A

Working RPM Sw itch

Digital

24 Volts=On, 0 Volts=Off

B25

GRN 39

Dif ferential Lock Sw itch - Front

Digital

24 Volts=On, 0 Volts=Off

B26

GRN 40

Dif ferential Lock Sw itch - Rear

Digital

24 Volts=On, 0 Volts=Off

B22

6.5

FUSE BAY NUMBER 4

FUSE BAY NUMBER 5

LIGHTS FRONT CHASSIS

FUSE BAY NUMBER 3

LIGHTS CAB FRONT

FUSE BAY NUMBER 6

16726B R0 25 AMP

LIGHTS, EXTERIOR, SIDE

15 AMP

WIPER MOTOR

20 AMP

LIGHTS, EXTERIOR, CAB ROOF

20 AMP

LIGHTS, EXTERIOR, CAB ROOF

20 AMP

LIGHTS, EXTERIOR, CAB FRONT

10 AMP

LIGHTS, EXTERIOR, FRAME, FRONT

20 AMP

LIGHTS, EXTERIOR, FRAME, REAR

5 AMP

T220 DISPLAY

10 AMP

PVC, B18 CONNECTION

10 AMP

FAN MOTOR, HEATER A/C UNIT

30 AMP

COMPRESSOR, HEATER A/C UNIT

2 AMP

AUXILIARY POWER OUTLET, 12V.

2 AMP

AIR SCOURCE CONTROL, HEATER A/C UNIT

5 AMP

HTC, A29 CONNECTION

10 AMP

HTC, A18 CONNECTION

10 AMP

PVC, A18 CONNECTION

FUSE PANEL (10180102-10180104)

6.6

A/C & HEATER

COMPUTER START

RELAY 4

ENGINE DROOP

RELAY 2

RELAY 6

RELAY 5

RELAY 3

RELAY 1

RELAY 8

LIGHTS CAB 2

RELAY 7

RELAY 10 RELAY 12

LIGHTS REAR CHASSIS

COMPRESSOR, AIRRIDE SEAT

LIGHTS CAB SIDE

HORN

10 AMP

RELAY 11

LOAD GATE

RELAY 9

5 AMP

10 AMP

RELAY 14

CRANE / BLADE INTERLOCK

RELAY 13

RELAY 16

CRANE / BLADE INTERLOCK

RELAY 15

(SCANIA)

RELAY 20

(OPTIONAL)

(SCANIA) RELAY 18

FUEL HEATER

RELAY 19

ENGINE STOP

RELAY 17

RELAY 22

SPARE

RELAY 21

2 A/C RECIRC. DOOR 2 RADIO

10 INTERIOR LIGHT 10 A/C WIPER RELAYS

2 12V AUX. OUTLET

SPARE (ACCESSORY)

SPARE (BATTERY)

10 BULB TEST

10 DIMMER

10 SWITCHES

15 SENSORS

10 WARNING LIGHTS

RELAY COIL, PILOT RESET

SPARE

5 AMP

ENGINE TORQUE

WARNING LIGHTS, ENGINE DIAGNOSTICS

COOLING FAN REVERSAL

ACC. (ACCESSORIES)

5 AMP

CRANE/ BLADE INTERLOCK

15 AMP

WIPER / WASHER

ACC. (ACCESSORIES)

LIGHTS CAB 1

15 AMP

A/C COMPRESSOR

VOLTAGE CONVERTER

10 PVC B18

PVC A18

10

10 HTC A29

5 HTC A18

30 A/C FAN HIGH SPEED

10 A/C COMPRESSOR

SPARE

SPARE

10 ROAD LIGHTS

7.5 ROAD LIGHT RELAY

7.5 HAZARD

7.5 TURN SIGNAL

15 WIPER/ WASHER

SEAT COMPRESSOR

10

10 HORN

10 24V AUX. OUTLET

10 24V AUX. OUTLET

10 FUEL HEATER (OPTIONAL)

FUSE AND RELAY PANEL (10180101 & 10180105 & UP)

16480B R0

20 LIGHTS REAR CHASSIS

LIGHTS FRONT CHASSIS

20

25 LIGHTS CAB SIDE

20 LIGHTS CAB FRONT

20 LIGHTS CAB 2

20 LIGHTS CAB 1

5 LOAD GATE

SWITCH, DIMMER

10 AMP

SPARE (BATTERY)

BULB TEST

15 AMP

5 COMPUTER DISPLAY

LIGHTS, INTERIOR

10 AMP

15 START CIRCUIT

SWITCHES, EXTERIOR LIGHTS

10 AMP

10 VOLTAGE CONVERTOR

RELAY COIL, HEATER A/C UNIT

10 AMP

COMPUTER LATCHING

FUSE BAY NUMBER 2

RELAY COIL, WIPER MOTOR

PILOT RESET

FUSE BAY NUMBER 1 5 AMP

10 AMP

5 PILOT RESET

Tigercat 1018 Forwarder Electrical & Computers

Tigercat 1018 Forwarder

CAB TILT PUMP/MOTOR

Electrical & Computers

ENGINE GRID HEATER

80 AMP 125 AMP

125 AMP 80 AMP

CAB TILT PUMP/MOTOR

ENGINE GRID HEATER 7.5 AMP

ENGINE 24 POLE - B

7.5 AMP

ENGINE 24 POLE - B

7.5 AMP

ENGINE 24 POLE - C

7.5 AMP

ENGINE 24 POLE - C

10 AMP

ENGINE 24 POLE - D

10 AMP

ENGINE 24 POLE - D

10 AMP

ENGINE 24 POLE - M

10 AMP

ENGINE 24 POLE - M

10 AMP

ENGINE 24 POLE - S

10 AMP

ENGINE 24 POLE - S

20 AMP

HTC/PVC +

20 AMP

HTC/PVC +

30 AMP

A/C

30 AMP

A/C

150 AMP

150 AMP

MAIN POWER SUPPLY

MAIN POWER SUPPLY

19807A R0

19806A R0

ENGINE COMPARTMENT (CUMMINS) FUSE AND RELAY PANEL (10180102-10180104)

ENGINE COMPARTMENT (CUMMINS) FUSE AND RELAY PANEL (10180101, 10180105 & UP)

IN 80 AMP

FUSE PANEL

IN

IN

CAB TILT PUMP/MOTOR

IN

1018-D143

ENGINE COMPARTMENT FUSE PANEL

10 AMP

AUXILIARY POWER OUTLET 24V.

20 AMP

HTC/PVC +

30 AMP

A/C

IN

IN 150 AMP

MAIN POWER SUPPLY 19805A R0

ENGINE COMPARTMENT (SCANIA) FUSE AND RELAY PANEL

6.7

Tigercat 1018 Forwarder

Electrical & Computers

NOTE: CAB ELECTRICAL HARNESSES NOT SHOWN ON THIS DIAGRAM

ELECTRICAL HARNESS INSTALLATION - CUMMINS ENGINE 15605BIL

6.8

Tigercat 1018 Forwarder

Electrical & Computers

NOTE: CAB ELECTRICAL HARNESSES NOT SHOWN ON THIS DIAGRAM

ELECTRICAL HARNESS INSTALLATION - SCANIA ENGINE 13162BIL

6.9

Tigercat 1018 Forwarder

Electrical & Computers

6.10

Tigercat 1018 Forwarder

Electrical & Computers

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

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

6.11

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 15483B REV 2 (SHEET 1 OF 7) CUMMINS ENGINE OPTION (MACHINES 10180102,10180103 & 10180104 ONLY) 1018-36-1

6.12

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 15483B REV 2 (SHEET 1 OF 7) CUMMINS ENGINE OPTION (MACHINES 10180102,10180103 & 10180104 ONLY)

6.13

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 15483B REV 2 (SHEET 2 OF 7) CUMMINS ENGINE OPTION (MACHINES 10180102,10180103 & 10180104 ONLY) 1018-36-2

6.14

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 15483B REV 2 (SHEET 2 OF 7) CUMMINS ENGINE OPTION (MACHINES 10180102,10180103 & 10180104 ONLY)

6.15

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 15483B REV 2 (SHEET 3 OF 7) CUMMINS ENGINE OPTION (MACHINES 10180102,10180103 & 10180104 ONLY) 1018-36-3

6.16

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 15483B REV 2 (SHEET 3 OF 7) CUMMINS ENGINE OPTION (MACHINES 10180102,10180103 & 10180104 ONLY)

6.17

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 15483B REV 2 (SHEET 4 OF 7) CUMMINS ENGINE OPTION (MACHINES 10180102,10180103 & 10180104 ONLY) 1018-36-4

6.18

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 15483B REV 2 (SHEET 4 OF 7) CUMMINS ENGINE OPTION (MACHINES 10180102,10180103 & 10180104 ONLY)

6.19

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 15483B REV 2 (SHEET 5 OF 7) CUMMINS ENGINE OPTION (MACHINES 10180102,10180103 & 10180104 ONLY) 1018-36-5

6.20

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 15483B REV 2 (SHEET 5 OF 7) CUMMINS ENGINE OPTION (MACHINES 10180102,10180103 & 10180104 ONLY)

6.21

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 15483B REV 2 (SHEET 6 OF 7) CUMMINS ENGINE OPTION (MACHINES 10180102,10180103 & 10180104 ONLY) 1018-36-6

6.22

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 15483B REV 2 (SHEET 6 OF 7) CUMMINS ENGINE OPTION (MACHINES 10180102,10180103 & 10180104 ONLY)

6.23

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 15483B REV 2 (SHEET 7 OF 7) CUMMINS ENGINE OPTION (MACHINES 10180102,10180103 & 10180104 ONLY) 1018-36-7

6.24

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 15483B REV 2 (SHEET 7 OF 7) CUMMINS ENGINE OPTION (MACHINES 10180102,10180103 & 10180104 ONLY)

6.25

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 16467B REV 2 (SHEET 1 OF 7) SCANIA ENGINE OPTION ONLY 1018-40-1

6.26

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 16467B REV 2 (SHEET 1 OF 7) SCANIA ENGINE OPTION ONLY

6.27

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 16467B REV 2 (SHEET 2 OF 7) SCANIA ENGINE OPTION ONLY 1018-40-2

6.28

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 16467B REV 2 (SHEET 2 OF 7) SCANIA ENGINE OPTION ONLY

6.29

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 16467B REV 2 (SHEET 3 OF 7) SCANIA ENGINE OPTION ONLY 1018-40-3

6.30

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 16467B REV 2 (SHEET 3 OF 7) SCANIA ENGINE OPTION ONLY

6.31

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 16467B REV 2 (SHEET 4 OF 7) SCANIA ENGINE OPTION ONLY 1018-40-4

6.32

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 16467B REV 2 (SHEET 4 OF 7) SCANIA ENGINE OPTION ONLY

6.33

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 16467B REV 2 (SHEET 5 OF 7) SCANIA ENGINE OPTION ONLY 1018-40-5

6.34

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 16467B REV 2 (SHEET 5 OF 7) SCANIA ENGINE OPTION ONLY

6.35

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 16467B REV 2 (SHEET 6 OF 7) SCANIA ENGINE OPTION ONLY 1018-40-6

6.36

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 16467B REV 2 (SHEET 6 OF 7) SCANIA ENGINE OPTION ONLY

6.37

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 16467B REV 2 (SHEET 7 OF 7) SCANIA ENGINE OPTION ONLY 1018-40-7

6.38

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 16467B REV 2 (SHEET 7 OF 7) SCANIA ENGINE OPTION ONLY

6.39

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 16468B REV 2 (SHEET 1 OF 7) CUMMINS ENGINE OPTION (MACHINES 10180101, 10180105 & UP ONLY) 1018-41-1

6.40

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 16468B REV 2 (SHEET 1 OF 7) CUMMINS ENGINE OPTION (MACHINES 10180101, 10180105 & UP ONLY)

6.41

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 16468B REV 2 (SHEET 2 OF 7) CUMMINS ENGINE OPTION (MACHINES 10180101, 10180105 & UP ONLY) 1018-41-2

6.42

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 16468B REV 2 (SHEET 2 OF 7) CUMMINS ENGINE OPTION (MACHINES 10180101, 10180105 & UP ONLY)

6.43

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 16468B REV 2 (SHEET 2 OF 7) CUMMINS ENGINE OPTION (MACHINES 10180101, 10180105 & UP ONLY) 1018-41-3

6.44

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 16468B REV 2 (SHEET 2 OF 7) CUMMINS ENGINE OPTION (MACHINES 10180101, 10180105 & UP ONLY)

6.45

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 16468B REV 2 (SHEET 4 OF 7) CUMMINS ENGINE OPTION (MACHINES 10180101, 10180105 & UP ONLY) 1018-41-4

6.46

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 16468B REV 2 (SHEET 4 OF 7) CUMMINS ENGINE OPTION (MACHINES 10180101, 10180105 & UP ONLY)

6.47

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 16468B REV 2 (SHEET 5 OF 7) CUMMINS ENGINE OPTION (MACHINES 10180101, 10180105 & UP ONLY) 1018-41-5

6.48

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 16468B REV 2 (SHEET 5 OF 7) CUMMINS ENGINE OPTION (MACHINES 10180101, 10180105 & UP ONLY)

6.49

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 16468B REV 2 (SHEET 6 OF 7) CUMMINS ENGINE OPTION (MACHINES 10180101, 10180105 & UP ONLY) 1018-41-6

6.50

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 16468B REV 2 (SHEET 6 OF 7) CUMMINS ENGINE OPTION (MACHINES 10180101, 10180105 & UP ONLY)

6.51

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 16468B REV 2 (SHEET 7 OF 7) CUMMINS ENGINE OPTION (MACHINES 10180101, 10180105 & UP ONLY) 1018-41-7

6.52

Tigercat 1018 Forwarder

Electrical & Computers

MACHINE SCHEMATIC DIAGRAM 16468B REV 2 (SHEET 7 OF 7) CUMMINS ENGINE OPTION (MACHINES 10180101, 10180105 & UP ONLY)

6.53

Tigercat 1018 Forwarder

Electrical & Computers

6.54

Tigercat 1018 Forwarder SECTION 7 - ENGINE START & STOP SEPTEMBER, 2002

CONTENTS - SECTION 7 CUMMINS ENGINE (10180101, 10180105 & UP) CIRCUIT DIAGRAM AT REST ..................................................................................... 9 PILOT SYSTEM ON .................................................................. 13 RUN .......................................................................................... 11 START....................................................................................... 10 ENGINE START CIRCUIT DESCRIPTION .................................... 8 PILOT RESET CIRCUIT DESCRIPTION ...................................... 12 CUMMINS ENGINE (10180102 TO 10180104 ONLY) CIRCUIT DIAGRAM AT REST ..................................................................................... 3 PILOT SYSTEM ON .................................................................... 7 RUN ............................................................................................ 5 START......................................................................................... 4 ENGINE START CIRCUIT DESCRIPTION .................................... 2 PILOT RESET CIRCUIT DESCRIPTION ........................................ 6 SCANIA ENGINE CIRCUIT DIAGRAM AT REST ................................................................................... 15 PILOT SYSTEM ON .................................................................. 19 RUN .......................................................................................... 17 START....................................................................................... 16 ENGINE START CIRCUIT DESCRIPTION .................................. 14 PILOT RESET CIRCUIT DESCRIPTION ...................................... 18

Tigercat 1018 Forwarder

Engine Start & Stop

CUMMINS ENGINE (10180102 TO 10180104 ONLY)

When the ignition switch is turned to the START position, voltage is supplied to the start circuit through wire 23 to the emergency shut-down switch and continues through wire 151 to the coil of the start relay.

ENGINE START CIRCUIT For detailed engine information refer to the engine manufacturer s manual.

The start relay closes when the ignition switch is turned and supplies voltage through wire 12 to close the start solenoid contacts and supply battery power to the starter to turn the engine.

For engine starting and stopping procedures refer to OPERATING MACHINE: STARTING ENGINE and STOPPING ENGINE in SECTION 2 of the OPERATOR S MANUAL. The engine is started by turning the ignition switch to the START position and then releasing it to the RUN position after the engine starts. After the engine has started no functions will operate until both cab doors are closed and the PILOT RESET SWITCH switch is pressed. Refer to PILOT RESET SWITCH, PILOT SYSTEM OFF LIGHT and PILOT SYSTEM SHUT OFF in SECTION 2 of the OPERATOR S MANUAL for more information.

PILOT RESET SWITCH EMERGENCY SHUT DOWN SWITCH

The Cummins engine is equipped with a grid heater to aid in starting. This circuit receives power from terminal B41 on the 50 pin connector at the engine. The voltage flows through wire 314 to close the contacts on the grid heater relay, which allows power from wire 01B to flow to the heater element.

When the grid heater is active terminal B11 on the 50 pin connector is grounded, this completes the circuit for the WAIT TO START LIGHT on the instrument panel through wire 292. Accessory power flows to the light through wire 316.

START RELAY

GRID HEATER RELAY

IGNITION SWITCH ON

1018-D144

1018-D141

STARTING ENGINE

RELAYS

If the engine stalls during operation of the vehicle, the ignition must be turned to the OFF position to reset before the engine can be restarted.

START SOLENOID STARTER

CIRCUIT DESCRIPTION

Refer to schematic diagrams showing the ENGINE START CIRCUIT in THIS SECTION.

With the battery disconnect switch ON, power is able to flow to all constant power circuits.

1018-D142

1018-D145

BATTERY DISCONNECT SWITCH ON 7.2

START MOTOR AND SOLENOID

1018-32-REST

START CIRCUIT - AT REST

CUMMINS ENGINE START CIRCUIT (10180102 TO 10180104 ONLY)

Tigercat 1018 Forwarder Engine Start & Stop

7.3

1018-32-START

BATTERY DISCONNECT ON IGNITION SWITCH - START POSITION

START CIRCUIT

CUMMINS ENGINE START CIRCUIT (10180102 TO 10180104 ONLY)

Tigercat 1018 Forwarder Engine Start & Stop

7.4

1018-32-RUN

BATTERY DISCONNECT ON IGNITION SWITCH - RUN POSITION

START CIRCUIT

CUMMINS ENGINE START CIRCUIT (10180102 TO 10180104 ONLY)

Tigercat 1018 Forwarder Engine Start & Stop

7.5

Tigercat 1018 Forwarder

Engine Start & Stop

CUMMINS ENGINE (10180102 TO 10180104 ONLY)

PILOT RESET SWITCH

PILOT RESET

EMERGENCY SHUT DOWN SWITCH

The HTC & PVC computer systems are not powered during engine start-up. The computers will be turned on when the pilot reset switch is depressed. When the pilot reset switch is depressed, voltage flows through wires 152 and 152B through a diode to wire 152C which will power relay 1. The closed contacts on relay 1 allow accessory power to flow from wire 20B through wire 20C to close the contacts of relay 3.

This relay is latched closed by wires 20D, a diode, and wire 20E, the only way to break this latch is to turn off accessory power (either by turning the ignition switch off, or using the emergency shut-down switch). The closed contacts on relay 3 allow constant power from wire 197 to flow through wire 150 to the HTC and PVC.

IGNITION SWITCH ON

1018-D144

Pressing the pilot reset switch allows accessory power from wire 153 to flow through wire 152.

This energizes relay 5 and closes a latching circuit (through wires 201 and 152A) provided the cab door switches are closed. The HTC and PVC are sent an input signal via wires 201A and 201B. Once the pilot reset switch has been depressed, all functions will be live . If either of the cab doors are opened, the latching circuit is broken, and all functions will be locked out until the door is closed and the pilot reset switch is depressed again. This prevents accidental movement of the machine when the cab doors are open.

STARTING ENGINE

PILOT SYSTEM SHUT OFF

• •

ACTUATOR

407-1

7.6

PILOT SYSTEM SHUT OFF

1018-32-PILOT

BATTERY DISCONNECT ON IGNITION SWITCH - START POSITION PILOT SYSTEM ON

START CIRCUIT

CUMMINS ENGINE START CIRCUIT (10180102 TO 10180104 ONLY)

Tigercat 1018 Forwarder Engine Start & Stop

7.7

Tigercat 1018 Forwarder

Engine Start & Stop

CUMMINS ENGINE (10180101, 10180105 & UP)

When the ignition switch is turned to the START position, voltage is supplied to the start circuit through wire 23 to the emergency shut-down switch and continues through wire 151 to the coil of the start relay.

ENGINE START CIRCUIT For detailed engine information refer to the engine manufacturer s manual.

The start relay closes when the ignition switch is turned and supplies voltage through wire 12 to close the start solenoid contacts and supply battery power to the starter to turn the engine.

For engine starting and stopping procedures refer to OPERATING MACHINE: STARTING ENGINE and STOPPING ENGINE in SECTION 2 of the OPERATOR S MANUAL. PILOT RESET SWITCH EMERGENCY SHUT DOWN SWITCH

1018-D144

The Cummins engine is equipped with a grid heater to aid is starting. This circuit receives power from terminal B41 on the 50 pin connector at the engine. The voltage flows through wire 314 to close the contacts on the grid heater relay, which allows power from wire 01B to flow to the heater element.

IGNITION SWITCH ON

STARTING ENGINE

The engine is started by turning the ignition switch to the START position and then releasing it to the RUN position after the engine starts. After the engine has started no functions will operate until both cab doors are closed and the PILOT RESET SWITCH switch is pressed. Refer to PILOT RESET SWITCH, PILOT SYSTEM OFF LIGHT and PILOT SYSTEM SHUT OFF in SECTION 2 of the OPERATOR S MANUAL for more information.

When the grid heater is active terminal B11 on the 50 pin connector is grounded, this completes the circuit for the WAIT TO START LIGHT on the instrument panel through wire 292. Accessory power flows to the light through wire 316.

START RELAY

GRID HEATER RELAY

If the engine stalls during operation of the vehicle, the ignition must be turned to the OFF position to reset before the engine can be restarted.

CIRCUIT DESCRIPTION Refer to schematic diagrams showing the ENGINE START CIRCUIT in THIS SECTION.

1018-D141

RELAYS

With the battery disconnect switch ON, power is able to flow to all constant power circuits.

START SOLENOID STARTER

1018-D142

1018-D145

BATTERY DISCONNECT SWITCH ON 7.8

START MOTOR AND SOLENOID

1018-35-REST

START CIRCUIT - AT REST

CUMMINS ENGINE START CIRCUIT (10180101, 10180105 & UP)

Tigercat 1018 Forwarder Engine Start & Stop

7.9

1018-35-START

BATTERY DISCONNECT ON IGNITION SWITCH - START POSITION

START CIRCUIT

CUMMINS ENGINE START CIRCUIT (10180101, 10180105 & UP)

Tigercat 1018 Forwarder Engine Start & Stop

7.10

1018-35-RUN

BATTERY DISCONNECT ON IGNITION SWITCH - RUN POSITION

START CIRCUIT

CUMMINS ENGINE START CIRCUIT (10180101, 10180105 & UP)

Tigercat 1018 Forwarder Engine Start & Stop

7.11

Tigercat 1018 Forwarder

Engine Start & Stop

CUMMINS ENGINE (10180101, 10180105 & UP)

PILOT RESET SWITCH

PILOT RESET The HTC & PVC computer systems are not powered during engine start-up. The computers are powered when the PILOT RESET SWITCH is pressed. Refer to PILOT RESET SWITCH, PILOT SYSTEM OFF LIGHT and PILOT SYSTEM SHUT OFF in SECTION 2 of the OPERATOR S MANUAL for more information.

When the PILOT RESET SWITCH is pressed, voltage flows through wires 152 and 152B through a diode to wire 152C which powers relay 3. The closed contacts on relay 3 in turn allow accessory power to flow from wire 20B through wire 20C to close the contacts of relay 4. Relay 3 is latched closed by wires 20D, a diode, and wire 20E, the only way to break this latch is to turn off accessory power (either by turning the ignition switch off, or using the emergency shut-down switch). The closed contacts on relay 4 allow constant power from wire 197 to flow through wire 150 to the HTC and PVC. Pressing the PILOT RESET SWITCH allows accessory power from wire 153 to flow through wire 152. This energizes relay 1 and closes a latching circuit (through wires 201 and 152A) provided the cab door switches are closed. The HTC and PVC are sent an input signal via wires 201A and 201B. Once the pilot reset switch has been pressed, all functions are live . If either of the cab doors are opened, the latching circuit is broken, and all functions will be locked out until the door is closed and the pilot reset switch is pressed again. This prevents accidental movement of the machine when the cab doors are open.

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

7.12

EMERGENCY SHUT DOWN SWITCH

1018-D144

IGNITION SWITCH ON

STARTING ENGINE

PILOT SYSTEM SHUT OFF

•• ••

ACTUATOR

407-1

PILOT SYSTEM SHUT OFF

1018-35-PILOT

BATTERY DISCONNECT ON IGNITION SWITCH - START POSITION PILOT SYSTEM ON

START CIRCUIT

CUMMINS ENGINE START CIRCUIT (10180101, 10180105 & UP)

Tigercat 1018 Forwarder Engine Start & Stop

7.13

Tigercat 1018 Forwarder

Engine Start & Stop

SCANIA ENGINE

CIRCUIT DESCRIPTION

ENGINE START CIRCUIT

Refer to schematic diagrams showing the ENGINE START CIRCUIT in THIS SECTION.

For detailed engine information refer to the engine manufacturer s manual.

With the battery disconnect switch ON, power is able to flow to all constant power circuits.

For engine starting and stopping procedures refer to OPERATING MACHINE: STARTING ENGINE and STOPPING ENGINE in SECTION 2 of the OPERATOR S MANUAL. The engine is started by turning the ignition switch to the START position and then releasing it to the RUN position after the engine starts. After the engine has started no functions will operate until both cab doors are closed and the PILOT RESET SWITCH switch is pressed. Refer to PILOT RESET SWITCH, PILOT SYSTEM OFF LIGHT and PILOT SYSTEM SHUT OFF in SECTION 2 of the OPERATOR S MANUAL for more information.

PILOT RESET SWITCH EMERGENCY SHUT DOWN SWITCH

BATTERY DISCONNECT SWITCH ON When the ignition switch is turned to the START position, voltage is supplied to the start circuit through wire 23 to the emergency shut-down switch and continues through wire 151 to pin D on connector C69 of the engine s main supply box.

Pin D on connector C69 is connected to the starter relay through the engine s wiring harness (consult engine manufacturer s manual). The start relay closes and supplies battery power to the starter to turn the engine.

1018-D145

IGNITION SWITCH ON

1018-D144

STARTING ENGINE

If the engine stalls during operation of the vehicle, the key must be turned to the OFF position to reset before the engine can be restarted.

START SOLENOID

STARTER

1018-D150

7.14

START MOTOR AND SOLENOID

1018-33-REST

START CIRCUIT - AT REST

SCANIA ENGINE START CIRCUIT

Tigercat 1018 Forwarder Engine Start & Stop

7.15

1018-33-START

BATTERY DISCONNECT ON IGNITION SWITCH - START POSITION

START CIRCUIT

SCANIA ENGINE START CIRCUIT

Tigercat 1018 Forwarder Engine Start & Stop

7.16

1018-33-RUN

BATTERY DISCONNECT ON IGNITION SWITCH - RUN POSITION

START CIRCUIT

SCANIA ENGINE START CIRCUIT

Tigercat 1018 Forwarder Engine Start & Stop

7.17

Tigercat 1018 Forwarder

Engine Start & Stop

SCANIA ENGINE

PILOT RESET SWITCH

PILOT RESET The HTC & PVC computer systems are not powered during engine start-up. The computers are powered when the PILOT RESET SWITCH is pressed. Refer to PILOT RESET SWITCH, PILOT SYSTEM OFF LIGHT and PILOT SYSTEM SHUT OFF in SECTION 2 of the OPERATOR S MANUAL for more information.

When the PILOT RESET SWITCH is pressed, voltage flows through wires 152 and 152B through a diode to wire 152C which powers relay 3. The closed contacts on relay 3 in turn allow accessory power to flow from wire 20B through wire 20C to close the contacts of relay 4. Relay 3 is latched closed by wires 20D, a diode, and wire 20E, the only way to break this latch is to turn off accessory power (either by turning the ignition switch off, or using the emergency shut-down switch). The closed contacts on relay 4 allow constant power from wire 197 to flow through wire 150 to the HTC and PVC. Pressing the PILOT RESET SWITCH allows accessory power from wire 153 to flow through wire 152. This energizes relay 1 and closes a latching circuit (through wires 201 and 152A) provided the cab door switches are closed. The HTC and PVC are sent an input signal via wires 201A and 201B. Once the pilot reset switch has been pressed, all functions are live . If either of the cab doors are opened, the latching circuit is broken, and all functions will be locked out until the door is closed and the pilot reset switch is pressed again. This prevents accidental movement of the machine when the cab doors are open.

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

7.18

EMERGENCY SHUT DOWN SWITCH

1018-D144

IGNITION SWITCH ON

STARTING ENGINE

PILOT SYSTEM SHUT OFF

•• ••

ACTUATOR

407-1

PILOT SYSTEM SHUT OFF

1018-33-PILOT

BATTERY DISCONNECT ON IGNITION SWITCH - START POSITION PILOT SYSTEM ON

START CIRCUIT

SCANIA ENGINE START CIRCUIT

Tigercat 1018 Forwarder Engine Start & Stop

7.19

Tigercat 1018 Forwarder

Engine Start & Stop

7.20

Tigercat 1018 Forwarder

SECTION 8 - DRIVE SEPTEMBER, 2002

CONTENTS - SECTION 8 AUXILIARY FUNCTION VALVE ..................................................................... 8.8 PRESSURE SETTINGS AND ADJUSTMENTS ....................................... 8.22 AXLES .......................................................................................................... 8.24 AXLE LUBRICATION ................................................................................ 8.26 CAPACITIES ............................................................................................ 8.27 DIFFERENTIAL AND DIFFERENTIAL LOCKS ........................................ 8.24 DRAINING AND REFILLING BOGIE HOUSING:(2 PER AXLE) ............... 8.26 DRAINING AND REFILLING DIFFERENTIAL:(1 PER AXLE) .................. 8.26 SERVICE/PARKING BRAKES .................................................................. 8.25 WHEEL INSTALLATION .......................................................................... 8.27 CHARGE PUMP ............................................................................................. 8.6 CIRCUIT DESCRIPTION ............................................................................... 8.3 CIRCUIT DIAGRAM ..................................................................................... 8.11 DRIVE MOTOR DESCRIPTION ..................................................................... 8.7 DRIVE MOTOR PRESSURE SETTINGS AND ADJUSTMENTS ................ 8.19 MOTOR BEGIN OF DISPLACEMENT CONTROL ................................... 8.20 MOTOR MINIMUM DISPLACEMENT ....................................................... 8.19 DRIVE PUMP DESCRIPTION ........................................................................ 8.4 DRIVE PUMP PRESSURE SETTINGS AND ADJUSTMENTS .................... 8.13 MAIN RELIEF VALVE SETTINGS AND OVERLOAD PROTECTION ...... 8.17 PUMP BEGIN OF REGULATION CONTROL ........................................... 8.14 SUMMARY ............................................................................................... 8.18 HTC (HYDROSTATIC TRANSMISSION CONTROLLER) ........................... 8.10 HYDRAULIC OIL HEATING PROCEDURE ................................................. 8.12 TEST DRIVE ................................................................................................ 8.12 DIFFERENTIAL LOCKS ........................................................................... 8.13 MOTOR BEGIN OF DISPLACEMENT CONTROL PRESSURE ............... 8.13 PUMP BEGIN OF REGULATION CONTROL PRESSURE ...................... 8.12 SERVICE BRAKE OPERATION ............................................................... 8.13 STEERING OPERATION ......................................................................... 8.13 TRANSMISSION .......................................................................................... 8.24

Tigercat 1018 Forwarder

Drive

8.2

Tigercat 1018 Forwarder

Drive

HYDROSTATIC DRIVE SYSTEM The primary components of the 1018 hydrostatic drive system are a hydraulic pump and a hydraulic motor connected together by two hydrostatic hoses. The pump converts the mechanical power of the diesel engine into hydraulic power. This high pressure flow of hydraulic oil is then transmitted to the hydraulic motor through the first connecting hose. The motor then reconverts the hydraulic power back into the mechanical power used to propel the machine. Low pressure hydraulic oil flow then returns from the motor to the pump through the other connecting hose thereby completing a continuous closed loop hydraulic circuit.

A hydraulic system is termed closed loop when the hydraulic oil returning from the motor is fed straight back to the pump without first returning to tank.

When the machine is travelling forward, one side of the closed loop is a high pressure supply while the other side is a low pressure return. The supply and return will alternate from side to side of the closed loop as the direction of travel of the vehicle goes from forward to reverse.

Hydrostatic drives are used because they offer enhanced operator control of vehicle speed and tractive effort. As well hydrostatic drive systems give flexibility in the positioning of components within the machine when compared to mechanical drive systems.

HIGH PRESSURE SUPPLY

SWASHPLATE AXIAL PISTON PUMP

BENT AXIS PISTON MOTOR

TO VEHICLE DRIVE

FROM DIESEL ENGINE

LOW PRESSURE RETURN 1018-10

CONTINUOUS CLOSED LOOP HYDRAULIC CIRCUIT

8.3

Tigercat 1018 Forwarder

Drive

DRIVE PUMP The hydrostatic drive pump is mounted in tandem with main pump (which is mounted on the engine flywheel housing). The main pump is driven directly by the diesel engine through a flexible plate coupling. A splined through shaft in the main pump connects the input driveshaft of the drive pump directly to the output of the engine.

displacement angle, the piston pump will produce maximum flow in one direction in the closed loop.

As the swashplate is de-stroked the flow smoothly decreases until there is no flow at an angle of zero (0°). Continuing to angle the swashplate past this neutral position steplessly reverses the direction of flow from the piston pump.

SWASHPLATE CONTROL VALVE SOLENOID

DRIVESHAFT DRIVE PUMP

MAIN PUMP

ßFRONT

1018-D086

PUMPS

The drive pump is a variable displacement, swashplate, axial piston type. This pump is made variable by slipping the pump pistons against a tiltable swashplate cradle. The volume and direction of oil flow from the piston pump is determined by the angle of this swashplate. When the swashplate is stroked to a maximum

1018-11

SHOWN WITH BLANKING PLATE REMOVED

SWASHPLATE AP131-DRIVE

DRIVE PUMP SCHEMATIC 8.4

PISTON

DRIVE PUMP

Tigercat 1018 Forwarder

Drive

The HTC (Hydrostatic Transmission Controller) sends an electrical current output to the proportional solenoids installed on the drive pump controller. To propel the machine forward, a proportional current is sent from terminal A32 on the HTC, through wire 246 to the forward solenoid on the pump. To propel the machine reverse, a proportional current is sent from terminal A33 on the HTC, through wire 247 to the reverse solenoid on the pump. The proportional solenoids shift the actuation piston. The actuation piston in turn shifts the swashplate control valve spool. This changes the position of the control cylinder, which is directly connected to the swashplate of the piston pump. The angle and direction that the swashplate moves determines the speed and direction of travel of the vehicle. The angle and direction that the swashplate moves is directly

proportional to the current being sent from the HTC. When no current is supplied from the HTC, pilot oil is not supplied to the swashplate. The swashplate therefore remains in the neutral position and no oil is pumped by the piston pump.

There are two high pressure relief valves at the P and S ports on the pump. These are intended only to act as pressure limiting safety devices in the event that the system does not respond quickly enough to high pressure surges. The high pressure relief valves always dump oil from the high pressure to the low pressure side of the closed loop thereby keeping the hydraulic oil within the closed loop.

For pressure setting procedures refer to DRIVE PUMP PRESSURE SETTINGS AND ADJUSTMENTS in THIS SECTION.

MAIN PUMP

NOTE SPRING ORIENTATION WHEN SERVICING MAIN PUMP AND/OR DRIVE PUMP DRIVE PUMP

1018-39

DRIVE PUMP AND MAIN PUMP CONNECTION CROSS SECTION (NOTE SPRING ORIENTATION AT THE CONNECTION BETWEEN PUMPS)

8.5

Tigercat 1018 Forwarder

Drive

CHARGE PUMP The charge pump is a gear pump mounted in tandem with the cooling circulation pump. This tandem gear pump is located on the left side power take off toward the front of the engine.

CHARGE PRESSURE FILTER

COOLING PUMP

1018-D115

CHARGE PUMP

CHARGE PUMP

The charge pump is a fixed displacement internal gear pump that is fed from the hydraulic oil reservoir. The charge pump continuously introduces oil from the hydraulic tank back into the hydrostatic drive system. The charge pump relief valve maintains a constant pilot pressure for use by the swashplate control system. In addition, the charge pump oil is used as make up oil to the low pressure side of the closed loop to replenish losses due to internal leakage in the hydrostatic pump and motor. This same flow acts as a cooling fluid for the drive pump and drive motor to ensure peak hydrostatic drive performance and long service life.

Excess charge pump oil is relieved by the charge pressure relief valve into the case of the drive pump. The charge pressure filter ensures that only clean charge pump oil is introduced into the closed loop hydrostatic circuit and the swashplate control system. Should this pressure filter become clogged with debris, charge pump flow is diverted to tank thus preventing the entry of unfiltered charge pump oil into the closed loop.

8.6

Tigercat 1018 Forwarder

Drive

HYDROSTATIC DRIVE MOTOR

A minimum displacement adjusting screw on the outside of the motor housing limits the maximum speed of the motor.

One motor is used to drive the forwarder. It is mounted to the input side of the transmission. A splined connection transmits the torque from the motor shaft to the transmission input.

WARNING Improper adjustment of Minimum Displacement Adjusting Screw can result in motor and transmission failure due to overspeeding. When installing a new motor always ensure minimum displacement adjusting screw is set correctly. Refer to SET MOTOR MINIMUM DISPLACEMENT, in THIS SECTION.

The drive motor is an axial piston, variable displacement type. It forms a closed loop circuit with the pump.

DRIVE MOTOR

MINIMUM DISPLACEMENT ADJUSTING SCREW

BEGIN OF DISPLACEMENT CONTROL PRESSURE ADJUSTMENT 1018-D103

A flushing valve is incorporated into the motor.

This valve provides a regulated flow of oil from the low pressure side of the loop into the motor case.

This action reduces the possibility of particle build up in the loop by providing a continuous change of oil, it also assists with cooling. This valve is factory set and requires no adjustment.

DRIVE MOTOR

High pressure oil from the drive pump enters the drive motor via port A or port B , depending on the direction of travel. The oil is directed to the back of a set of pistons in the motor s rotary group.

The pistons push against the back of the output shaft at an angle causing it to rotate.

The angle of the pistons relative to the drive shaft determine the speed and available torque .

Reducing the piston angle provides increased speed with less torque. Increasing the piston angle provides reduce speed with more torque.

The displacement control spool is operated by pilot pressure from the drive pump. When sufficient pressure from the pump is directed to the spool, it shifts against a spring and directs oil to the displacement control cylinder thus decreasing the displacement of the motor. Removal of the pressure signal from the drive motor causes the displacement control spool to return to the neutral position, shutting off the pressure to the displacement control cylinder thus increasing displacement to maximum. The point at which the displacement control spool begins to move is known as begin of regulation set point or control start setting .

1018-12

CONTROL PRESSURE PORT

MINIMUM DISPLACEMENT ADJUSTING SCREW

VALVE SEGMENT

BEGIN OF DISPLACEMENT CONTROL ADJUSTMENT AQ065

8.7

DRIVE MOTOR SCHEMATIC

PISTON DISPLACEMENT CONTROL CYLINDER

CROSS SECTION OF DRIVE MOTOR

Tigercat 1018 Forwarder

Drive

AUXILIARY FUNCTION VALVE

THE AUXILIARY FUNCTION VALVE CONTAINS THE FOLLOWING: 1. Pressure reducing valve for auxiliary function.

GEAR SHIFT SOLENOID

2. Sequence valve & three way pilot operated directional control valve for auxiliary function.

RP1 TEST PORT

AUXILIARY FUNCTION VALVE

BRAKE VALVE

3. Solenoid valves for the gear shift, cab rotate brake release, rear drive disconnect, spare, front and rear differential locks.

1018-D095

Note: The pressure reducing valve and sequence valve on the auxiliary function valve are set by loosening the locknut and turning the adjusting screw OUT (counter-clockwise) to reduce the pressure setting or IN (clockwise) to increase the pressure setting.

AUXILIARY FUNCTION VALVE

FUNCTION VALVE PRESSURE SETTINGS AND ADJUSTMENTS in THIS SECTION for additional details on setting the valve.

2. SEQUENCE VALVE & PILOT OPERATED THREE WAY DIRECTIONAL CONTROL VALVE The auxiliary function valve manifold receives high pressure oil from the main hydraulic pump. As stated above, oil entering the manifold first passes through the pressure reducing valve. A sequence valve (set at 21.722.3bar [315-325psi]) and a three way directional control valve are installed down

1. PRESSURE REDUCING VALVE The auxiliary function valve manifold receives high pressure oil from the main hydraulic pump. A pressure reducing valve (set at 19.720.3bar [285-295psi]) is installed in this manifold to divert excess oil back to tank through port T . Refer to AUXILIARY

3 PILOT OPERATED 3-WAY VALVE

1

98689

PRESSURE REDUCING VALVE

1

PRESSURE REDUCING VALVE

2

98690

PRESSURE SEQUENCE VALVE

4 SOLENOID VALVE S

4

3

2

PRESSURE SEQUENCE VALVE

SOLENOID VALVE

PILOT OPERATED 3-WAY VALVE 91982

94024

1018-22A

1018-22

AUXILIARY FUNCTION VALVE 8.8

Tigercat 1018 Forwarder

Drive

stream from the pressure reducing valve. In the event of a pressure reducing valve failure the pressure at the sequence valve rises to 21.7-22.3bar (315-325psi) then the sequence valve sends a pilot signal to the directional control valve, which closes and cuts off the oil supply to the remainder of the manifold. This protects the actuators in the axles, transmission and cab rotate brake from over pressure.

When the ALL WHEEL DRIVE SWITCH is in the OFF position the HTC sends an electrical signal to the all wheel drive declutch solenoid (C5). When the solenoid is energized, it shifts the valve spool and allows oil to flow against the back of a clutch piston in the transmission, disengaging the rear drive shaft.

3. SOLENOID VALVES A. Gear Shift Solenoid (external) The gear shift solenoid is externally mounted on the auxiliary function manifold. The HTC (Hydrostatic Transmission Controller) monitors the input from the TRANSMISSION HIGH/ LOW switch on the instrument panel and sends an electrical signal to the gear shift solenoid as required.

When the solenoid is energized, it shifts the valve spool and allows oil to flow against the back of an actuator in the transmission. The actuator slides towards the center of the transmission, and engages HIGH gear (gear 2). When the signal is removed, the spool in the valve is spring returned to its original position and allows oil to flow against the front of the actuator. This force shifts the actuator back towards the front of the transmission, and engages LOW gear (gear 1). In the event of a loss of electrical power to the gear shift solenoid valve the gear shift will automatically engage low gear.

B. Cab Rotate Brake Release (C4) Refer to SECTION 11 in THIS MANUAL for details about the cab rotate motor.

C. All Wheel Drive Declutch (C5) The all wheel drive function is spring applied and normally on . A set of springs apply force to the back of the clutch piston, which engages the rear drive shaft to the transmission. The HTC (Hydrostatic Transmission Controller) monitors the input from the ALL WHEEL DRIVE OFF/ON switch on the instrument panel.

8.9

When the ALL WHEEL DRIVE SWITCH is in the ON position the signal is removed from the all wheel drive declutch solenoid (C5), the valve spool spring returns to its original position and engages the rear drive shaft. Oil from the clutch piston housing in the transmission drains back through the circuit and returns to tank.

D.

Spare (C6)

This solenoid valve is not used.

E. Front & Rear Differential Lock (C7 & C8) The HTC (Hydrostatic Transmission Controller) monitors the input from the DIFF LOCK ON/OFF and DIFF LOCK SELECTOR switches on the armrest and sends an electrical signal to the front and/or rear differential lock solenoids (C7 and C8 respectively). When a differential lock solenoid is energized, it shifts the valve spool and allows oil to flow against the back of a piston in the axle. The actuator engages the differential lock, and drive torque is provided to all wheels on that axle. When the signal is removed, the valve spool is spring returned to its original position and allows the oil from the piston housing in the axle differential to drain back through the circuit and return to tank, releasing the differential lock.

Tigercat 1018 Forwarder

Drive

HTC (HYROSTATIC TRANSMISSION CONTROLLER) The HTC monitors and analyzes inputs and produces outputs (as defined in its program) to control the machine. The HTC controls all of the drive functions on the machine.

HINGED ACCESS PANEL

HTC

PVC

HTC (HYDROSTATIC TRANSMISSION CONTROL) & PVC (PROPORTIONAL VALVE CONTROL) 1018-D116

Inputs: The computer monitors variable signals from the BRAKE PEDAL, DRIVE PEDAL, ENGINE WORKING RPM ROTARY DIAL and TRAVEL SPEED ROTARY DIAL. The HTC also reacts to digital signals from the DRIVE MODE, WORKING RPM , FWD.|PARK|REV., STEER/DRIVE, and TRANSMISSION switches.

Outputs: The computer directs an output (24 Volt proportional electrical current) to the swashplate control valve solenoids on the drive pump to drive the machine either forward or reverse. It also controls engine RPM by sending appropriate signals to the engine s control computer. Signals are also sent to the brake valve, and auxiliary function valves.

The angle and direction of drive pump swashplate movement is directly proportional to the current being sent fromt the HTC computer. The drive pump in turn operates the drive motor displacement control using pilot pressure.

For more detailed information about the operation of the closed loop hydrostatic drive system refer to HYDROSTATIC DRIVE SYSTEM, DRIVE PUMP, and DRIVE MOTOR in THIS SECTION.

8.10

Tigercat 1018 Forwarder

1018-13

Drive

DRIVE CIRCUIT 8.11

Tigercat 1018 Forwarder

Drive

HYDRAULIC OIL HEATING PROCEDURE

TEST DRIVE The test drive will verify the following:

There is a specific procedure to heat up the hydraulic oil in the machine in preparation for setting up hydraulic pressures.

1. Pump begin of regulation control pressure: FORWARD 1.7-2.3 bar (24-34 psi) REVERSE 1.7-2.3 bar (24-34 psi)

1. Park machine on level ground, start the engine, depress the PILOT RESET switch, place the WORKING RPM switch in the ON position, and set engine to full throttle using the ENGINE WORKING RPM rotary dial.

Place a sheet of cardboard in front of the oil cooler portion of the heat exchanger. The radiator must remain uncovered to prevent engine overheating.

2. Motor begin of displacement control pressure: 5.7-6.3 bar (82-92 psi) 3. Steering check; slow and fast.

4. Front and rear differential lock functions.

5. Service braking check; slow and fast.

M2 DRIVE PUMP PRESSURE

M3 DRIVE MOTOR DISPLACEMENT

WARNING

M LOAD SENSE PRESSURE (COPIED)

DO NOT leave the machine while heating the oil, as overheating of engine or hydraulic oil can cause serious damage.

2. Operate the TELESCOPE OUT function, while at the same time operating the GRAPPLE CLOSE function. Hold both joystick thumb switches to their maximum position. Release after 5 seconds, wait 5 seconds, then repeat.

This will cause oil to pass over the telescope out port relief, which will generate heat.

Monitor ENGINE COOLANT TEMPERATURE and HYDRAULIC OIL TEMPERATURE on the T220 display.

CHARGE PRESSURE (DRIVE) 1018-D134

M7 DRIVE MOTOR CONTROL SIGNAL

M1 DRIVE PUMP PRESSURE

'PL' LOAD SENSE PRESSURE

TEST PORTS

PX MAIN PUMP PRESSURE

Install three 0-5,000 psi gauges on M1 , M2 and M3 test ports in the TEST PORT COMPARTMENT. Install a 0-500 psi gauge on M7 test port in the TEST PORT COMPARTMENT. NOTE: Fasten these four gauges so they can be easily viewed from the operator s seat in the cab. Make certain that the gauges (and hoses) will not be damaged if the cab rotate function is operated.

WARNING Hydraulic oil temperature rises quickly when passing over relief valves. Remove the cardboard blocking the oil cooler if necessary to maintain the proper temperature. Do not pass oil over the relief valves for longer than 5 seconds at a time.

Damage to valves can occur from excessive heat.

Fasten your seat belt and move the machine to a suitable test area, where it can be safely driven at full speed for approximately 150 feet.

Place the crane in the park position, and raise the snow blade (if equipped).

3. Ensure that the hydraulic oil temperature is between 48C and 60C (120F and 140F).

1. PUMP BEGIN OF REGULATION CONTROL PRESSURE

4. Once the hydraulic oil is up to operating temperature, proceed to required hydraulic set-up procedure.

A. Drive the machine FORWARD, using the DRIVE PEDAL. Increase the speed slowly using the TRAVEL SPEED rotary dial.

B. Note the pressure at the M7 test port, when pressure is first seen at the M2 test port. M2 should begin to register when M7 is at 1.7-2.3 bar (24-34 psi). This is the FORWARD regulation control pressure for the drive pump.

8.12

Tigercat 1018 Forwarder

Drive

C. Drive the machine in REVERSE, using the DRIVE PEDAL. Increase the speed slowly using the TRAVEL SPEED rotary dial.

brake (note that the machine may creep slightly). Steer the machine.

D. Note the pressure at the M7 test port, when pressure is first seen at the M1 test port. M1 should begin to register when M7 is at 1.7-2.3 bar (24-34 psi). This is the REVERSE regulation control pressure for the drive pump.

Note: This test may have to be done a few times to get a proper reading.

2. MOTOR BEGIN OF DISPLACEMENT CONTROL PRESSURE A. Drive the machine in either direction, using the DRIVE PEDAL. Increase the speed slowly using the TRAVEL SPEED rotary dial.

B. Note the pressure at the M7 test port, when pressure is first seen at the M3 test port. M3 should begin to register when M7 is at 5.7-6.3 bar (82-92 psi). This is the proper motor begin of displacement control setpoint.

All wheels should rotate as machine is being steered. Steer several times, check all wheels.

B. Release the drive pedal C. Set the DIFF. LOCK SELECTOR switch to FRONT , then press and hold the DIFF. LOCK switch ON. Press the drive pedal slightly to disengage the parking brake. While steering the machine, all front wheels should slide instead of rotating. Rear wheels should still rotate.

D. Release the differential lock switch.

E. Release the drive pedal.

F.

Note: This test may have to be done a few times to get a proper reading.

Set the DIFF. LOCK SELECTOR switch to REAR, then press and hold the DIFF.LOCK switch ON. Press the drive pedal slightly to disengage the parking brake. While steering the machine, all rear wheels should slide instead of rotating. Front wheels should still rotate.

3. STEERING OPERATION

G. Release the differential lock switch.

A. Set the FWD.|PARK|REV. switch to either the FWD. or REV. position. Press the DRIVE PEDAL slightly to disengage the parking brake (note that the machine may creep slightly).

Operate the STEERING CONTROL slightly in one direction until it hits the stop.

H. Release the drive pedal.

B. Operate the STEERING CONTROL slightly in the opposite direction, as SLOWLY as possible, until it hits the end stop. This should result in slow, gentle articulation of the machine.

C. Operate the STEERING CONTROL back to the other end stop, as FAST as possible (control moved to its extent). This should result in quick, severe articulation of the machine.

I.

Set the DIFF. LOCK SELECTOR switch to BOTH, then depress and hold the DIFF. LOCK switch ON. Press the drive pedal slightly to disengage the parking brake. While steering the machine, all wheels should slide instead of rotating.

5. SERVICE BRAKE OPERATION A. Set the FWD.|PARK|REV. switch to either the FWD. or REV. position. Drive the machine and allow it to accelerate fully.

B. Press the service BRAKE PEDAL approximately half way down. This should result in slow, gentle stop of the machine.

D. If this condition is not obtained, check the PVC parameters.

C. Set the FWD.|PARK|REV. switch to either the FWD. or REV. position. Drive the machine and allow it to accelerate fully.

D. Press the service BRAKE PEDAL down fully to the floor. This should result in quick, severe stop of the machine.

For additional information on the steering system refer to SECTION 11 of THIS MANUAL. 4. DIFFERENTIAL LOCKS A. Bring the machine to a full stop, ensure that both front and rear differential locks are turned OFF. Set the FWD.|PARK|REV. switch to either the FWD. or REV. position. Press the drive pedal slightly to disengage the parking

8.13

For additional information on the braking system refer to SECTION 9 of THIS MANUAL.

Tigercat 1018 Forwarder

Drive

DRIVE PUMP PRESSURE SETTINGS AND ADJUSTMENTS

43

IMPORTANT

The adjustment or set-up procedure is a series of steps that must be done in a proper sequence to achieve optimum performance from the machine. Any deviation from the procedures could present a safety hazard, damage components and/or affect the operation of the machine.

1018-D015

NOTE: Ensure hydraulic oil is at operating temperature. Refer to HYDRAULIC OIL HEATING PROCEDURE in THIS SECTION.

A. SET THE PUMP BEGIN OF REGULATION CONTROL PRESSURE Perform this procedure on the DRIVE PUMP. 1. Park machine on level ground, place the crane in the park position, lower the snow blade (if equipped). Install the articulation lock and stop engine.

WARNING

BRAKE RET MIN PEDAL 102 % BRAKE RET MAX PEDAL 104 %

CAUTION

2. Connect a 0-500 psi gauge to the M7 test port, and a 0-5,000 psi gauge to the M1 test port.

M LOAD SENSE PRESSURE (COPIED)

CHARGE PRESSURE (DRIVE) 1018-D134

M1 DRIVE PUMP PRESSURE

'PL' LOAD SENSE PRESSURE

TEST PORTS

PX MAIN PUMP PRESSURE

Avoid the risk of unintentionally driving the machine with brake parameters adjusted.

Brake parameters affect brake performance and machine stopping distance.

4. Start the engine, press the PILOT RESET switch, and place the TRANSMISSION switch to HIGH (gear 2). Set the FWD.|PARK|REV. switch to the REV. position.

M7 DRIVE MOTOR CONTROL SIGNAL

To temporarily adjust HTC parameters requires use of the HTC LINK program. The HTC LINK program operates on a laptop or other computer connected to the machine s HTC computer via the 9 PIN COMPUTER PORT (with the SELECTOR SWITCH in the HTC position). The HTC LINK program should only be operated by trained and authorized Tigerat Service personnel.

Temporarily reset brake parameters to the following values:

To prevent injury caused by accidental steering of the machine when setting pressures, make sure the articulation lock pin is installed between the center joint and front chassis and held securely in place by the lynch pins provided.

M2 DRIVE PUMP PRESSURE

COMPUTER PORT AND SELECTOR SWITCH

3. A temporary adjustment of the HTC computer s brake parameters is required to perform this procedure. This procedure requires that an assistant hold down the brake pedal while partially depressing the drive pedal. Normal HTC brake parameter settings cause the drive pedal function to stop operating immediately when the brake pedal is pressed.

NOTE: Relief valves in the drive pump are not adjustable, and are factory set to 420 bar (6090 PSI).

M3 DRIVE MOTOR DISPLACEMENT

8.14

Tigercat 1018 Forwarder

Drive

CAUTION The machine should not be able to move with the transmission in HIGH gear (gear 2) while brake pedal is depressed.

5. With the aid of an assistant, hold down the BRAKE PEDAL and while partially depressing the DRIVE PEDAL, increase the setting of the TRAVEL SPEED rotary dial and monitor the gauges. Note the pressure at the M7 test port, when pressure is first seen at the M1 test port. M1 should begin to register when M7 is at 1.7-2.3 bar (24-34 psi). This is the REVERSE regulation control pressure for the drive pump. (NOTE: The assistant operating the controls in the cab will be required to repeat the pedal functions as directed by the mechanic making the adjustments.)

LOCKING NUT ( Z SIDE)

1018-14

7. Disconnect the 0-5,000 psi gauge from the M1 test port, and connect it to the M2 test port.

My

DRIVE PUMP CONTROLLER

Y SIDE OF CONTROLLER

Z SIDE OF CONTROLLER

Z SIDE REGULATION BEGIN CUP 1018-D106

REGULATION BEGIN CUP ( Y SIDE)

Y

ENGINE

Z SIDE SPANNER NUT

PUMP BEGIN OF REGULATION ENGINE

If the REVERSE reading is higher than 1.7-2.3 bar (24-34 psi), then turn the regulation begin cup on the Z side of the pump OUT (counterclockwise) until the correct reading is obtained with the spanner nut tightened.

6. Check the pressures to verify that this setting has not changed as the spanner nut was tightened.

Z

Mz

To adjust the REVERSE regulation control pressure, loosen the spanner nut and adjust the regulation begin cup with a 13mm offset closed-end wrench.

If the REVERSE reading is lower than 1.7-2.3 bar (24-34 psi), then turn the regulation begin cup on the Z side of the pump IN (clockwise) until the correct reading is obtained with the spanner nut tightened.

REGULATION BEGIN CUP ( Z SIDE)

WARNING Before working under cab; Machine must be parked on level ground.

Cab must be fully tilted with tilt cylinders fully extended, or cab support brace must be installed.

Refer to TILTING THE CAB in SECTION 3 of THIS MANUAL for more information.

SPANNER NUT ( Y SIDE)

SPANNER NUT ( Z SIDE) (LOCKING MECHANISM FOR REGULATION BEGIN CUP)

Y SIDE SPANNER NUT

Y SIDE REGULATION BEGIN CUP

1018-D105

PUMP BEGIN OF REGULATION

CAUTION The machine should not be able to move with the transmission in HIGH gear (gear 2) while brake pedal is depressed.

9. With the aid of an assistant, hold down the BRAKE PEDAL and while partially depressing the DRIVE PEDAL, increase the setting of the 8. Set the FWD.|PARK|REV. switch to the FWD. TRAVEL SPEED rotary dial and monitor the position. gauges. Note the pressure at the M7 test port, when pressure is first seen at the M2 test port. M2 should begin to register when M7 is at 1.7-2.3 bar (24-34 psi). This is the 8.15

Tigercat 1018 Forwarder

Drive

FORWARD regulation control pressure for the drive pump. (NOTE: The assistant operating the controls in the cab will be required to repeat the pedal functions as directed by the mechanic making the adjustments.)

To adjust the FORWARD regulation control pressure, loosen the spanner nut and adjust the regulation begin cup with a 13mm offset closed-end wrench.

If the FORWARD reading is higher than 1.72.3 bar (24-34 psi), then turn the regulation begin cup on the Y side of the pump OUT (counter-clockwise) until the correct reading is obtained with the spanner nut tightened.

If the FORWARD reading is lower than 1.7-2.3 bar (24-34 psi), then turn the regulation begin cup on the Y side of the pump IN (clockwise) until the correct reading is obtained with the spanner nut tightened.

10. Check the pressures to verify that this setting has not changed as the spanner nut was tightened.

11. Shut off the engine.

12. Remove all pressure gauges and reinstall all plugs and caps.

13. Reset brake parameters to normal settings: BRAKE RET MIN PEDAL 5 % BRAKE RET MAX PEDAL 90 %

8.16

Tigercat 1018 Forwarder

Drive

B. VERIFY THE MAIN RELIEF VALVE SETTINGS AND OVERLOAD PROTECTION. NOTE: Relief valves in the drive pump are not adjustable, and are factory set to 420bar(6090 PSI)

4. Start the engine, press the PILOT RESET switch, and place the TRANSMISSION switch in HIGH gear (gear 2). Set the FWD.|PARK|REV. switch to the FWD. position.

CAUTION

Perform this procedure on the DRIVE PUMP.

The machine should not be able to move with the transmission in HIGH gear (gear 2) while brake pedal is depressed.

1. Park machine on level ground, place the crane in the park position, lower the snow blade (if equipped). Install the articulation lock and stop engine.

M2 DRIVE PUMP PRESSURE

M3 DRIVE MOTOR DISPLACEMENT

M LOAD SENSE PRESSURE (COPIED)

CHARGE PRESSURE (DRIVE) 1018-D134

M7 DRIVE MOTOR CONTROL SIGNAL

'PL' LOAD SENSE PRESSURE

TEST PORTS

PX MAIN PUMP PRESSURE

5. With the aid of an assistant, hold down the BRAKE PEDAL, set the TRAVEL SPEED rotary dial to MAXIMUM, then depress the DRIVE PEDAL fully and monitor the gauges.

The pressure on the M2 test port should rise to 418.2-421.6 bar (6065-6115 psi) and remain constant. The pressure on the M7 test port should rise to 17.2-17.8 bar (250-260 psi), this indicates that the drive pump is at maximum displacement and the drive motor is at minimum displacement.

M1 DRIVE PUMP PRESSURE

2. Connect a 0-500 psi gauge to the M7 test port.

Connect a 0-10,000 psi gauge to the M2 test port.

3. A temporary adjustment of the HTC computer s brake parameters is required to perform this procedure. This procedure requires that an assistant hold down the brake pedal while partially depressing the drive pedal. Normal HTC brake parameter settings cause the drive pedal function to stop operating immediately when the brake pedal is pressed.

To temporarily adjust HTC parameters requires use of the HTC LINK program. The HTC LINK program operates on a laptop or other computer connected to the machine s HTC computer via the 9 PIN COMPUTER PORT (with the SELECTOR SWITCH in the HTC position). The HTC LINK program should only be operated by trained and authorized Tigerat Service personnel.

If the drive pedal is held for 5 seconds with the service brake applied, then an overload protection system is engaged. The HTC will reduce the current being sent to the solenoids installed on the drive pump controller, which will result in reduced pressure on the M7 test port. This indicates that the drive motor is being stroked to maximum displacement, and the drive pump is being stroked towards its minimum displacement.

FORWARD RELIEF VALVE

1018-D139

RH SIDE VIEW

Temporarily reset brake parameters to the following values: BRAKE RET MIN PEDAL 102 % BRAKE RET MAX PEDAL 104 %

CAUTION Avoid the risk of unintentionally driving the machine with brake parameters adjusted.

Brake parameters affect brake performance and machine stopping distance.

1018-D137

LH SIDE VIEW DRIVE PUMP RELIEF

8.17

REVERSE RELIEF VALVE

Tigercat 1018 Forwarder

Drive

5. Connect a 0-500 psi gauge to the M7 test port. Connect a 0-10,000 psi gauge to the M1 test port.

6. Start the engine, press the PILOT RESET switch, and place the TRANSMISSION switch in HIGH gear (gear 2). Set the FWD.|PARK|REV. switch to the REV. position.

CAUTION

10. Remove all pressure gauges and reinstall all plugs and caps.

11. Reset brake parameters to normal settings:

7. With the aid of an assistant, hold down the BRAKE PEDAL, set the TRAVEL SPEED rotary dial to MAXIMUM, then depress the DRIVE PEDAL fully and monitor the gauges.

The pressure on the M1 test port should rise to 418.2-421.6 bar (6065-6115 psi) and remain constant. The pressure on the M7 test port should rise to 17.2-17.8 bar (250-260 psi), this indicates that the drive pump is at maximum displacement and the drive motor is at minimum displacement.

If the drive pedal is held for 5 seconds with the service brake applied, then an overload protection system is engaged. The HTC will reduce the current being sent to the solenoids installed on the drive pump controller, which will result in reduced pressure on the M7 test

BRAKE RET MIN PEDAL 5 % BRAKE RET MAX PEDAL 90 % SUMMARY: PUMP BEGIN OF REGULATION ADJUSTMENT: 1. Adjust pump REVERSE regulation control pressure. Set adjustment screw such that pump begins to operate (increase in pressure on M1) when the pilot pressure (M7) is at 1.72.3 bar (24-34 psi).

2. Adjust pump FORWARD regulation control pressure. Set adjustment screw such that pump begins to operate (increase in pressure on M2) when the pilot pressure (M7) is at 1.72.3 bar (24-34 psi).

VERIFICATION OF MAIN RELIEF SETTINGS AND OVERLOAD PROTECTION: 3. Verify pump FORWARD relief setting.

Pressure on the M2 test port should rise to 418.2-421.6 bar (6065-6115 psi) and remain constant. The pressure on the M7 test port should drop after 5 seconds when the overload protection is engaged.

4. Verify pump REVERSE relief setting.

Pressure on the M1 test port should rise to 418.2-421.6 bar (6065-6115 psi) and remain constant. The pressure on the M7 test port should drop after 5 seconds when the overload protection is engaged.

1018-D139

RH SIDE VIEW

1018-D137

8. If M1 and M2 gauge readings are incorrect contact Tigercat Customer Service for more information as the relief valves are not adjustable.

9. Shut off the engine.

The machine should not be able to move with the transmission in HIGH gear (gear 2) while brake pedal is depressed.

FORWARD RELIEF VALVE

port. This indicates that the drive motor is being stroked to maximum displacement, and the drive pump is being stroked towards its minimum displacement.

LH SIDE VIEW

REVERSE RELIEF VALVE

DRIVE PUMP RELIEF 8.18

Tigercat 1018 Forwarder

Drive

DRIVE MOTOR PRESSURE SETTINGS AND ADJUSTMENTS

2. Tilt the cab and install the CAB SUPPORT BRACE. Refer to TILTING THE CAB in SECTION 3 of the manual.

IMPORTANT

3. Switch the vacuum pump on to reduce the amount of hydraulic oil lost. Refer to HYDRAULIC OIL VACUUM PUMP in SECTION 2 of the OPERATOR S MANUAL.

The adjustment or set-up procedure is a series of steps that must be done in a proper sequence to achieve optimum performance from the machine. Any deviation from the procedures could present a safety hazard, damage components and/or affect the operation of the machine.

VACUUM PUMP VACUUM GAUGE

IMPORTANT

When installing a new or rebuilt motor, ensure minimum displacement screw is set correctly.

Improper adjustment of min. displacement adjusting screw can result in motor failure due to overspeeding.

It may be necessary to verify the length of adjusting screw used by removing and measuring the screw.

1018-D051

R.H. HYDRAULIC TANK COMPARTMENT MINIMUM DISPLACEMENT ADJUSTMENT

To set the hydrostatic drive motor pressures and speeds, the following procedure must be performed in the order shown.

A. Set the motor minimum displacement.

B. Set the motor begin of displacement control pressure.

A. MOTOR MINIMUM DISPLACEMENT ADJUSTMENT

1018-D102

REVERSE PRESSURE SWITCH

DRIVE MOTOR

4. Loosen the locknut using a 19mm wrench.

Remove the minimum displacement adjusting screw (largest screw) from the top of motor housing using a 5mm Allen key and measure its length.

NOTE: Ensure hydraulic oil is at operating temperature. Refer to HYDRAULIC OIL HEATING PROCEDURE in THIS SECTION of the manual.

Perform this procedure on the DRIVE MOTOR. 1. Park machine on level ground, place the crane in the park position, lower the snow blade (if equipped). Install the articulation lock and stop engine.

'X'

WARNING DIM X

To prevent injury caused by accidental steering of the machine when setting pressures, make sure the articulation lock pin is installed between the center joint and front chassis and held securely in place by the lynch pins provided.

VACUUM PUMP ON/OFF SWITCH

TYPICAL 'X' DIMENSION

5. Reinstall the minimum displacement adjusting screw and locknut into the motor housing. For a 75mm long screw, it should be adjusted such that the dimension from the top of the locknut to the end of the exposed screw is 13.0mm. (For different length screws, 8.19

Tigercat 1018 Forwarder

Drive

measure the length and subtract 62.0mm from this total length. This is the amount of screw that should be exposed above the locknut.)

(For example: 100mm screw, minus 62.0mm will leave 38.0mm above locknut).

B. MOTOR BEGIN OF DISPLACEMENT CONTROL PRESSURE ADJUSTMENT

Perform this procedure on the DRIVE MOTOR. 1. Park machine on level ground, place the crane in the park position, lower the snow blade (if equipped). Install the articulation lock and stop engine.

M2 DRIVE PUMP PRESSURE

M LOAD SENSE PRESSURE (COPIED)

CHARGE PRESSURE (DRIVE) 1018-D134

'PL' LOAD SENSE PRESSURE

TEST PORTS

PX MAIN PUMP PRESSURE

Avoid the risk of unintentionally driving the machine with brake parameters adjusted.

Brake parameters affect brake performance and machine stopping distance.

4. Start the engine, depress the PILOT RESET switch, and place the TRANSMISSION switch in HIGH gear (gear 2). Set the FWD.|PARK|REV. switch to the FWD. position.

CAUTION The machine should not be able to move with the transmission in HIGH gear (gear 2) while brake pedal is depressed.

M1 DRIVE PUMP PRESSURE

M7 DRIVE MOTOR CONTROL SIGNAL

BRAKE RET MIN PEDAL 102 % BRAKE RET MAX PEDAL 104 %

CAUTION

NOTE: Ensure hydraulic oil is at operating temperature. Refer to HYDRAULIC OIL HEATING PROCEDURE in THIS SECTION of the manual.

M3 DRIVE MOTOR DISPLACEMENT

Temporarily reset brake parameters to the following values:

2. Connect a 0-500 psi gauge to the M7 test port, and a 0-5,000 psi gauge to the M3 test port.

3. A temporary adjustment of the HTC computer s brake parameters is required to perform this procedure. This procedure requires that an assistant hold down the brake pedal while partially depressing the drive pedal. Normal HTC brake parameter settings cause the drive pedal function to stop operating immediately when the brake pedal is pressed.

To temporarily adjust HTC parameters requires use of the HTC LINK program. The HTC LINK program operates on a laptop or other computer connected to the machine s HTC computer via the 9 PIN COMPUTER PORT (with the SELECTOR SWITCH in the HTC position). The HTC LINK program should only be operated by trained and authorized Tigerat Service personnel.

8.20

5. With the aid of an assistant, hold down the BRAKE PEDAL and while partially depressing the DRIVE PEDAL, increase the setting of the TRAVEL SPEED rotary dial and monitor the gauges. As the pilot pressure (M7) increases, it will reach the Control Start Pressure .

Control Start Pressure is the pilot pressure at which the motor displacement begins to decrease. The Control Start Pressure is indicated by an increase in pressure at test port (M3). The pressure at test port (M3) should begin to register when the pilot pressure (M7) is at 5.7-6.3 bar (82-92 psi).

(NOTE: The assistant operating the controls in the cab will be required to repeat the pedal functions as directed by the mechanic making the adjustments.)

BEGIN OF DISPLACEMENT CONTROL PRESSURE ADJUSTMENT (BOTTOM)

1018-D104

DRIVE MOTOR

Tigercat 1018 Forwarder

Drive 7. Check the motor to verify that this setting has not changed as the locknut was tightened.

WARNING

Before working under cab;

8. Shut off the engine.

Machine must be parked on level ground.

Cab must be fully tilted with tilt cylinders fully extended, or cab support brace must be installed.

Refer to TILTING THE CAB in SECTION 3 of THIS MANUAL for more information.

10. Reset brake parameters to normal settings:

MINIMUM DISPLACEMENT ADJUSTING SCREW

BRAKE RET MIN PEDAL 5 % BRAKE RET MAX PEDAL 90 % SUMMARY:

To adjust the Control Start Pressure, loosen the lock nut with a 10mm wrench and turn the adjusting screw with a 3mm Allen key.

CONTROL PRESSURE PORT

9. Remove all pressure gauges and reinstall all plugs and caps.

The settings must be made in the order shown.

MOTOR MINIMUM DISPLACEMENT ADJUSTMENT: 1. Check adjusting screw for proper length.

VALVE SEGMENT

Begin of Displacement adjustment: 1. Adjust motor begin of displacement adjustment screw such that motor begins to stroke (increase in pressure on M3) when the pilot pressure (M7) is at 5.7-6.3 bar (82-92 psi).

BEGIN OF DISPLACEMENT CONTROL ADJUSTMENT AQ065

PISTON DISPLACEMENT CONTROL CYLINDER

CROSS SECTION OF DRIVE MOTOR

If the reading is higher than 5.7-6.3 bar (82-92 psi), then turn the adjusting screw OUT (counter-clockwise) until the correct reading is obtained with the locknut tightened.

If the reading is lower than 5.7-6.3 bar (82-92 psi), then turn the adjusting screw IN (clockwise) until the correct reading is obtained with the locknut tightened.

6. If these readings are obtained, then the motor begin of displacement control setpoint is now adjusted correctly. This means that the motor will begin to stroke when the pilot pressure (supplied by the pump) reaches 5.7-6.3 bar (82-92 psi). This is a critical setting for the smooth and efficient drive operation of the machine.

8.21

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Drive

AUXILIARY FUNCTION VALVE PRESSURE SETTINGS AND ADJUSTMENTS

7. The pressure reducing valve setting must be set above its normal setting to properly adjust the sequence valve. Use a 3/4 wrench to loosen the pressure reducing valve locknut.

Turn the pressure reducing valve IN (clockwise) using a 3/16 Allen key, until the gauge on RP1 is reading 21.7-22.3bar (315325psi).

Refer also to AUXILIARY FUNCTION VALVE in THIS SECTION for more information about the auxiliary function valve.

TO ADJUST SEQUENCE VALVE: 1. Park the machine on level ground, place the crane in the park position, and lower the snow blade to the ground (if equipped). Shut off the engine.

2. Locate the auxiliary function valve manifold located inside the left side hydraulic tank access door.

1018-D095

9. Reset the pressure reducing valve to 19.720.3bar (285-295psi). Tighten the locknut.

RP1 TEST PORT

10. Turn off the engine, remove the gauge, close access door.

GEAR SHIFT SOLENOID

AUXILIARY FUNCTION VALVE

BRAKE VALVE

AUXILIARY FUNCTION VALVE

3. Connect a 0-5000 psi gauge to the RP1 test port.

4. Ensure that the hydraulic oil is at operating temperature. Refer to HYDRAULIC OIL HEATING PROCEDURE in SECTION 8 of THIS MANUAL. 5. Start the engine (and run at idle). Press the PILOT RESET switch, and place the ALL WHEEL DRIVE switch to the ON position.

PRESSURE SEQUENCE VALVE (TOP)

1018-D094

PRESSURE REDUCING VALVE (BOTTOM )

AUXILIARY FUNCTION VALVE ADJUSTMENTS

6. Loosen the sequence valve locknut using a 3/4 wrench. Temporarily turn the sequence valve, all the way IN (clockwise), very carefully, until it just touches bottom using a 3/16 Allen key. Do not over tighten.

8. Re-adjust sequence valve OUT, until the pressure (at RP1 gauge) rapidly drops to near ZERO. Turn it back IN until the pressure rises to 21.7-22.3bar (315-325psi) and then VERY SLOWLY turn it back OUT until it drops to near ZERO. Tighten the locknut at this point.

8.22

Tigercat 1018 Forwarder

Drive

TO ADJUST PRESSURE REDUCING VALVE: Note: In order to adjust the sequence valve, the pressure reducing valve setting must be increased. If both settings must be checked, it is more logical to set the sequence valve first.

1. Park the machine on level ground, place the crane in the park position, and lower the snow blade to the ground (if equipped). Shut off the engine.

2. Locate the auxiliary function valve manifold located inside the left side hydraulic tank access door.

GEAR SHIFT SOLENOID

AUXILIARY FUNCTION VALVE

BRAKE VALVE 1018-D095

RP1 TEST PORT

AUXILIARY FUNCTION VALVE

3. Connect a 0-5000 psi gauge to the RP1 test port.

6. Use a 3/4 wrench to loosen the pressure reducing locknut. Adjust the pressure reducing valve to 19.7-20.3bar (285-295 psi) by using a 3/16 Allen key to turn the adjustment screw IN (clockwise) to increase the pressure, and turning it OUT (counterclockwise) to decrease the pressure.

Tighten the locknut.

7. Turn off the engine, remove the gauge, close access door.

SUMMARY: The settings must be made in the order shown.

SEQUENCE VALVE: 1. Turn sequence valve in all the way.

2. Set the pressure reducing valve to 21.722.3bar (315-325psi).

3. Re-adjust sequence valve OUT, until the pressure rapidly drops to near ZERO. Turn it back IN until the pressure rises to 21.7-22.3bar (315-325psi) and then VERY SLOWLY turn it back OUT until it drops to near ZERO. PRESSURE REDUCING VALVE: 1. Adjust the pressure reducing valve to 19.720.3bar (285-295 psi).

4. Ensure that the hydraulic oil is at operating temperature. Refer to HYDRAULIC OIL HEATING PROCEDURE in SECTION 8 of THIS MANUAL. 5. Start the engine (and run at idle). Press the PILOT RESET switch.

PRESSURE SEQUENCE VALVE (TOP)

1018-D094

PRESSURE REDUCING VALVE (BOTTOM )

AUXILIARY FUNCTION VALVE ADJUSTMENTS

8.23

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Drive

TRANSMISSION

AXLES

The transmission transmits power to both the front and rear axles unless pilot pressure is supplied to the port in the transmission housing to de-clutch the all wheel drive function. When the declutch is operated, drive power is directed to the front axle only. Power is supplied to the transmission by the hydraulic motor mounted to the input side of the transmission. The output shafts transmit the power to the front and rear axles through the driveshafts.

Power from the drive motor is transmitted to the front and rear axles via the transmission and the front and rear drive shafts.

Shifting gears in the transmission is accomplished by applying pilot pressure to one of the two gear shift connections. When a gear is engaged, a feed back signal from the shifting sensor is sent back to the HTC. If the HTC sends an electrical signal to the solenoid on the gear change valve and does not receive the proper feedback, a Gearbox alarm will occur to alert the operator of the condition. Refer to AUXILIARY FUNCTION VALVE in THIS SECTION for additional information on the gear shift hydraulic circuit.

The gears and bearings in the transmission are lubricated by splash lubrication inside the case.

The oil level in the transmission must always be kept up to the proper level as indicated on the dipstick. Add oil to the transmission as required using the fill hose stored in the hydraulic tank.

Refer to SERVICE AND LUBRICATION POINTS chart in SECTION 3 of THIS MANUAL for recommended lubricant information.

Both axles are bolted directly to their respective frames. The centre joint is pivot mounted to the rear frame allowing it to oscillate.

Both front and rear axle assemblies are configured in an identical manner, but are installed in opposing directions.

Each axle assembly consists of (1) input yoke, (2) differential with hydraulic differential lock, (3) Inboard multiple wet disk brakes, (4) slew bearings (5) Bogie housings and gear sets, (6) axle housings and shafts.

The gear oil in the differentials and bogie housings is separated within the axle by internal seals. This results in the need to individually drain and fill these components. Refer also to AXLE LUBRICATION in THIS SECTION. DIFFERENTIAL AND DIFFERENTIAL LOCKS The differentials distribute the power to each side of the axle while allowing the wheels on each side of the differential to turn at different speeds. The differential locks, in the front and rear axle assemblies, are hydraulically controlled and can be independently turned ON or OFF by switches in the cab.

CAUTION

DIPSTICK

1018-D058

Use differential locks sparingly and for brief periods of time, only when additional traction is needed or serious damage may occur.

By placing the DIFF. LOCK SELECTOR switch in the desired position, one or both of the axles can have the differential lock activated by pressing the DIFF. LOCK switch ON. This function energizes the differential lock control valve solenoids (C7 & C8, located on the auxiliary function valve) and directs pilot oil to the corresponding differential lock engagement pistons to lock the differential(s).

Refer to AUXILIARY FUNCTION VALVE in THIS SECTION for additional information on the differential lock hydraulic circuit.

TRANSMISSION OIL LEVEL

Differential locks provide positive drive to both sides of the axle (all 4 wheels) when tractive conditions might otherwise allow one side to spin.

8.24

Tigercat 1018 Forwarder

Drive steel and friction disks and apply the brakes. For information on the hydraulic brake circuit refer to SECTION 9 of THIS MANUAL.

SERVICE/PARKING BRAKES The wet disk type brake assembly consists of a housing, an outer cap, a piston, a series of steel and friction disks and an inner cap. One brake assembly is located on each side of the differential case inside the slew bearings.

The axle assemblies are equipped with brake bleed screws. Brakes must be bled whenever there has been potential for air to enter the system, such as removal of hydraulic line. All passages must be bled one at a time. Refer to BRAKE BLEEDING in SECTION 9 of THIS MANUAL for brake bleeding procedure.

The brake housing is bolted to the differential housing and the inner cap is threaded onto the brake housing. A locking dowel is installed into the differential housing to prevent rotation of the inner cap. The steel disks are secured to the brake housing, and the friction disks are splined to the shaft which connects the differential to the centre gear in the bogie housing.

The parking brake is provided by a pair of cup springs applying force to the piston, which in turn applies a clamping force on the steel and friction disks. In order to release the parking brake, hydraulic pressure must be applied through the parking brake release port to the opposing side of the piston to overcome the spring force. This pressure is sent from the solenoid operated brake valve.

CUP SPRINGS (PARKING BRAKE)

When the brake pedal control in the cab is depressed, an electronic signal is sent to the HTC. The HTC then sends the proportional signal to the brake valve solenoids. The brake valve then allows brake pressure oil to flow through the service brake port to move the piston against the

OUTER CAP

HOUSING

PISTON 1018-16

4

3 1

2

1018-15

AXLE ASSEMBLY PARTIAL CROSS SECTION 8.25

INNER CAP

SERVICE BRAKE PORT

BRAKE HOUSING ASSEMBLY

6

5

PARKING BRAKE RELEASE PORT

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Drive

AXLE LUBRICATION

5. Remove the differential housing drain plug (1) located on the bottom of the differential, and drain the oil into a suitable container for disposal.

Each bogie axle has three separate oil reservoirs that require individual draining/filling. The axle must be level when draining/filling lubricant. Refer to SCHEDULED MAINTENANCE in SECTION 3 of THIS MANUAL for recommended lubricants and maintenance schedule.

6. Clean any filings from the magnetic drain plug (1).

7. Replace the differential housing drain plug (1).

DRAINING AND REFILLING DIFFERENTIAL: (1 PER AXLE)

8. Refill the differential by pumping oil into the fill/ level plug (3) on the differential. Stop adding oil when the oil level reaches the bottom of the differential level fill/level plug (3).

1. Park machine on level ground, install articulation lock bar, lower the snow blade (if equipped) and place the crane in the park position, stop engine, remove key, then switch battery disconnect off, and block wheels.

9. Replace the differential fill/level plug (3).

DRAINING AND REFILLING BOGIE HOUSING: (2 PER AXLE)

2. The axle must be level in order to drain and refill it properly.

10. Remove the bogie housing fill plugs (5) located on the top of the bogie housing. Note, there are two bogie housing fill plugs to be removed per axle.

3. Clean around all fill, level and drain plugs before removing them.

4. Remove the differential fill/level plug (3) located opposite the input yoke on the differential housing.

11. Remove the bogie housing level plugs (4) located on the outside of the housing below the bearing cap. Note, there are two bogie housing level plugs to be removed per axle.

BOGIE AHOUSING BREATHER

DIFFERENTIAL LEVEL/FILL PLUG

3

BOGIE HOUSING

5 FILL PLUGS (2 PLACES)

1

DIFFERENTIAL DRAIN PLUG

2

4

BOGIE HOUSING DRAIN PLUG (4 PLACES)

BOGIE HOUSING LEVEL PLUGS (2 PLACES)

1018-18

BOGIE AXLE FILL DRAIN AND LEVEL PLUGS 8.26

Tigercat 1018 Forwarder

Drive WHEEL INSTALLATION

12. Remove the bogie housing drain plugs (2) on the inside of the bogie housings, towards the bottom. Note, there are four plugs in total to be removed per axle to drain the bogie housings. Drain the oil into a suitable container for disposal.

13. Clean any filings from the magnetic drain plugs (2).

NOTE: All wheel installation joints and surfaces should be clean, flat surfaces (free of paint, grease and oil etc.) using grade 10 nuts, hardened washers and standard torque practices.

Thoroughly clean the wheel studs in the axle flange, as well as the nuts and washers.

When cleaning studs in the axle flange, double check and be sure to use the proper size die for the threads (M22x1.5).

Install wheel nuts by hand to insure bolts are not cross threaded.

Torque the M22x1.5 wheel nuts to 545Nm (400 lbf/ft).

14. Replace the bogie housing drain plugs (4) in all locations.

15. Refill the bogie housings by pumping oil into the fill plug (5) on the bogie housings. Stop adding oil when the oil level reaches the bottom of the bogie housing level plug (4).

Note, each of the bogie housings must be filled separately.

WARNING

16. Replace the bogie housing level plugs (4).

17. Replace the bogie housing fill plugs (5).

If a power wrench is used to install wheel nuts, be sure that the nuts are first handengaged to prevent stripping. Operate the wrench slowly to prevent damage to the threads.

IMPORTANT To prevent serious damage, care should be taken to refill the axle(s) before moving the machine after draining.

CAPACITIES For front and rear axle oil fill capacities, refer to the table: SERVICE AND LUBRICATION in SECTION 3 of THIS MANUAL.

8.27

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Drive

8.28

Tigercat 1018 Forwarder SECTION 9 - BRAKES SEPTEMBER, 2002

CONTENTS - SECTION 9 ACCUMULATOR ............................................................................................ 9.4 CHARGING AND TESTING DEVICE ......................................................... 9.4 CHARGING THE ACCUMULATOR ............................................................ 9.4 CHECKING THE GAS PRE-CHARGE PRESSURE ................................... 9.4 ACCUMULATOR CHARGE VALVE ............................................................... 9.2 BRAKE ADJUSTMENT ................................................................................ 9.12 BRAKE BLEEDING ...................................................................................... 9.11 BRAKE PEDAL CONTROL ............................................................................ 9.2 BRAKE VALVE ............................................................................................... 9.6 DESCRIPTION ........................................................................................... 9.6 PARKING BRAKES .................................................................................... 9.8 PRESSURE REDUCING VALVE ................................................................ 9.7 PRESSURE RELIEF ................................................................................... 9.7 SERVICE BRAKES ..................................................................................... 9.8 CIRCUIT DIAGRAM ....................................................................................... 9.9 EMERGENCY BRAKE VALVE ..................................................................... 9.10

Tigercat 1018 Forwarder

Brakes

BRAKE PEDAL CONTROL

ACCUMULATOR CHARGE VALVE

The brake pedal is manually operated and communicates with the HTC (Hydrostatic Transmission Controller) electronically. The pedal has a high-precision potentiometer built into it, and will vary the voltage signal to the HTC proportionally as it is depressed.

The main pump supplies oil directly to the load sensing accumulator charge valve. The accumulator charge valve regulates the pressure in the accumulator and braking systems between 104-129 bar (1500-1870psi). When no flow or pressure is required by the accumulator charge valve, the main pump stands by. In this state, the brake system remains responsive because the reserve has been built in the accumulator. When flow and pressure are required by the accumulator charge valve, a pilot signal is sent to the main pump (via the LS port) which causes the pump to stroke. Refer to LOAD SENSING in SECTION 11 of THIS MANUAL for more information on load sense systems.

DRIVE PEDAL

HIGH PRECISION POTENTIOMETER 1018-D129

BRAKE PEDAL

BRAKE PEDAL CONTROL ACCUMULATOR CHARGING VALVE

ACCUMULATOR

1018-D118

ACCUMULATOR CHARGE VALVE

NOTE: The accumulator will hold sufficient pressure, after the engine is turned off, for up to 5 brake applications, beyond this the pressure drops substantially.

Refer to BRAKE VALVE and ACCUMULATOR in THIS SECTION for further information on the brake valve and the accumulator.

9.2

Tigercat 1018 Forwarder

Brakes

CHECKING ACCUMULATOR CHARGE CYCLE

7. Start and run the engine for a further 20 seconds and shut engine off, to recharge the accumulator. Turn the ignition switch to the ON position, and depress the pilot reset switch. Pump the brakes 5 times, the pressure should remain above 62bar (900 psi). It should take an additional 5 or more brake applications (total of 10 or more) to drain the accumulator from a full charge of 104-129bar (1500-1870psi).

1. Park the machine on level ground, place the crane in the park position, lower the snow blade (if equipped) to the ground and shut off the engine.

2. Place the ignition switch in the ON position, and press the PILOT RESET switch. Press the BRAKE PEDAL 50 or more times to release the pressure stored in the accumulator.

8. Remove the gauge.

3. Connect a 0-5000 psi gauge to the P1 test port on the brake valve manifold.

FRONT BRAKE SOLENOID

PARKING BRAKE RELEASE SOLENOID

'RP1' TEST PORT 1018-D091

REAR BRAKE SOLENOID PRESSURE RELIEF VALVE PRESSURE REDUCING VALVE

'P1' TEST PORT

BRAKE VALVE MANIFOLD

4. Ensure that the hydraulic oil temperature is at operating temperature. Refer to HYDRAULIC OIL HEATING PROCEDURE in SECTION 8 of THIS MANUAL. 5. Start the engine and run for 20 seconds, then shut off engine. The pressure should rise rapidly to 104-129bar (1500-1870 psi) and should not fall below this range until the engine is shut off. The accumulator is now holding pressure for the braking system.

Note: In cold weather, this time may need to be increased to account for thicker oil.

6. There will be a slow drop in pressure as the accumulator drains, through valve leakage in the system. The pressure should not drop below 62bar (900 psi) in the first 5 minutes.

Leakage rate will be rapid at first and will slow down as the pressure drops.

9.3

Tigercat 1018 Forwarder

Brakes

ACCUMULATOR

CHECKING THE GAS PRE-CHARGE PRESSURE

The accumulator is piston type and is installed with a nitrogen pre-charge pressure of approximately 55 bar (800 psi).

Bleed off the system pressure as stated earlier.

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

VALVE GUARD GAS VALVE

Install the charging and testing device onto the gas valve. While depressing the button on the charging device, observe gas pressure reading on gauge.

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

WARNING

The accumulator must not be altered. DO NOT weld or machine the pressure vessel.

PISTON

CHARGING THE ACCUMULATOR

WARNING

USE ONLY NITROGEN for charging accumulators, NEVER USE OXYGEN OR AIR, due to the risk of explosion.

HYDRAULIC CONNECTION AX205

ACCUMULATOR (PISTON TYPE)

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

The gas pressure should be checked if the pilot system exhibits repeated and frequent charging cycles.

NITROGEN BOTTLE

WARNING Hydraulic circuits with accumulators store hydraulic oil under pressure, therefore the system may remain pressurized after the engine is turned off.

HOSE*

ADAPTER*

PRESSURE GAUGE*

ADAPTER*

ACCUMULATOR ASSEMBLY PART NO. 90254 INCLUDES PARTS SHOWN *

Prior to performing any maintenance or system modifications, exercise CAUTION to bleed off any stored system pressure by depressing the brake pedal 50 or more times with the ignition switch ON, and the PILOT RESET depressed. Caution: Serious injury can result if this is not done.

ACCU-2

A low pressure switch is installed in the hydraulic circuit, which will signal the HTC (Hydrostatic Transmission Controller) when the accumulator has less than 62bar (900psi) of pressure. This will trigger an Low Brake Pressure alarm on the T220 display terminal in the cab. This alarm warns the operator that the machine s brake capabilities will NOT be sufficient.

9.4

CHARGING AND TESTING DEVICE

Place the crane in the park position, lower the snow blade to the ground (if equipped) and shut off the engine.

Turn the ignition switch to the ON position, and depress the pilot reset switch. Press the brake pedal 50 or more times to release the pressure stored in the accumulator.

Remove the hydraulic hose installed on the back of the accumulator.

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

Tigercat 1018 Forwarder

Remove the valve guard and cap.

Screw the charging and testing device onto the gas valve.

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

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

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

Brakes

Note: The pre-charge pressure will vary dependant upon the temperature. Once the desired pre-charge is reached, wait two minutes for the gas temperature to equalize.

Re-check pre-charge and adjust if necessary.

Disconnect hose from nitrogen bottle.

Remove charging and testing device from accumulator and install valve cap and guard.

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

NEVER USE AN AUTOMOTIVE TYPE VALVE.

Re-install the hydraulic hose on the back of the accumulator.

Bleed Brake system. Refer to BRAKE BLEEDING in THIS SECTION.

9.5

Tigercat 1018 Forwarder

Brakes

BRAKE VALVE THE BRAKE VALVE CONTAINS THE FOLLOWING:

PARKING BRAKE RELEASE SOLENOID

1. Pressure reducing valve for brake functions.

FRONT BRAKE SOLENOID

REAR BRAKE SOLENOID

PRESSURE RELIEF VALVE

2. Pressure relief for brake functions.

3. The two solenoid proportional pressure regulating valves for front and rear service brake application control.

'RP1' TEST PORT

4. Solenoid valve for the parking brake release control.

1018-D091

Note: The pressure reducing valve and relief valve on the brake valve are set by loosening the locknut and turning the adjusting screw OUT (counter-clockwise) to reduce the pressure setting and IN (clockwise) to increase the pressure setting.

PRESSURE REDUCING VALVE

'P1' TEST PORT

BRAKE VALVE MANIFOLD

1018-20A

SOLENOID VALVE

3

HIGH PRESSURE 2 RELIEF VALVE PRESSURE 1 REDUCING VALVE

1

98689

&

98699

PRESSURE RELIEF VALVE

4

SOLENOID VALVES

1018-20 AW110

2

PRESSURE REDUCING VALVE

3 94024

BRAKE VALVE

9.6

CHECK VALVE

4

SOLENOID VALVE

Tigercat 1018 Forwarder

Brakes

1. PRESSURE REDUCING VALVE

2.

PRESSURE RELIEF The brake valve manifold receives high pressure oil from the main hydraulic pump.

As stated above, oil entering the manifold first passes through the pressure reducing valve.

A pressure relief valve (set at 68.3-71.7bar [990-1040psi]) is installed down stream from the pressure reducing valve. If the pressure reducing valve were to fail, this pressure relief valve will divert excess oil back to tank through port T protecting the remainder of the brake system from the high pressure.

The brake valve manifold receives high pressure oil from the main hydraulic pump.

A pressure reducing valve (set at 63.366.7bar [920-965psi]) is installed in this manifold to divert excess oil back to tank through port T .

TO ADJUST PRESSURE REDUCING VALVE: Note: In order to adjust the pressure relief valve, the pressure reducing valve setting must be increased. If both settings must be checked, it is more logical to set the pressure relief valve first.

TO ADJUST PRESSURE RELIEF VALVE:

1. Park the machine on level ground, place the crane in the park position, and lower the snow blade to the ground (if equipped). Shut off the engine.

1. Park the machine on level ground, place the crane in the park position, and lower the snow blade to the ground (if equipped). Shut off the engine.

2. Locate the brake valve manifold located inside the left side hydraulic tank access door.

2. Locate the brake valve manifold located inside the left side hydraulic tank access door.

3. Connect a 0-5000 psi gauge to the RP1 test port.

3. Connect a 0-5000 psi gauge to the RP1 test port.

PARKING BRAKE RELEASE SOLENOID

'RP1' TEST PORT 1018-D091

4. Ensure that the hydraulic oil is at operating temperature. Refer to HYDRAULIC OIL HEATING PROCEDURE in SECTION 8 of THIS MANUAL.

FRONT BRAKE SOLENOID REAR BRAKE SOLENOID

5. Start the engine (and run at idle).

PRESSURE RELIEF VALVE

6. Loosen the pressure relief valve locknut using a 3/4 wrench. Use a 3/16 Allen key to temporarily turn the pressure relief valve adjusting screw, all the way IN, very carefully, until it just touches bottom. Do not over tighten.

PRESSURE REDUCING VALVE

'P1' TEST PORT

BRAKE VALVE MANIFOLD

7. The pressure reducing valve setting must be set above the pressure relief setting to properly adjust the relief. Loosen the pressure reducing valve locknut using a ¾ wrench. Use a 3/16 Allen key to turn the pressure reducing valve adjusting screw IN (clockwise) until the gauge on RP1 is reading approximately 75bar (1087psi).

4. Ensure that the hydraulic oil is at operating temperature. Refer to HYDRAULIC OIL HEATING PROCEDURE in SECTION 8 of THIS MANUAL. 5. Start the engine (and run at idle).

6. Loosen the pressure reducing valve locknut using a 3/4 wrench. Set the pressure reducing valve to 63.3-66.7bar (920-965psi) by using a 3/16 Allen key to turn the adjustment screw IN (clockwise) to increase the pressure, and turning it OUT (counterclockwise) to decrease the pressure.

Tighten the locknut.

8. Re-adjust pressure relief valve OUT, until the pressure (on RP1 gauge) drops to 68.371.7bar (990-1040psi). Tighten the locknut at this point.

9. Reset the pressure reducing valve to 63.366.7bar (920-965psi). Tighten the locknut.

10. Turn off the engine, remove the gauge, close access door.

7. Turn off the engine, remove the gauge, close access door.

9.7

Tigercat 1018 Forwarder

Brakes 4. PARKING BRAKES FRONT BRAKE SOLENOID

PARKING BRAKE RELEASE SOLENOID

'RP1' TEST PORT 1018-D091

REAR BRAKE SOLENOID PRESSURE RELIEF VALVE PRESSURE REDUCING VALVE

'P1' TEST PORT

BRAKE VALVE MANIFOLD

3. SERVICE BRAKES The service brakes in both front and rear axles are controlled by the HTC (Hydrostatic Transmission Controller). The HTC monitors the input from the brake pedal control, and sends a proportional electrical signal to the front and rear service brake solenoids (C1 and C2) installed in the brake valve manifold.

When the solenoids are energized, they shift the spool in the valve and allow oil to flow to the brake pistons in each axle. The service brakes are applied by oil pressure pushing on the back of the brake piston in the axle, which directly applies a force on the steel and friction disks. When the signal is removed, the spool in the valve is spring returned to its original position and allows oil from the brake housing to drain back through the circuit and return to tank.

The parking brakes in both front and rear axles are spring applied. A pair of cup springs apply force to the back of the piston, which in turn applies a clamping force on the steel and friction disks. The release of the spring applied parking brakes is controlled by the HTC (Hydrostatic Transmission Controller).

The HTC monitors the input from the drive pedal control, and sends an electrical signal to the parking brake release solenoid (C3) installed in the brake valve manifold. When the solenoid is energized, it shifts the spool in the valve and allows oil to flow to the brake pistons in each axle. The parking brakes are released by oil pressure pushing on the front of the brake piston in the axle, which overcomes the force applied by the cup springs and frees the steel and friction disks.

When the signal is removed, the spool in the valve is spring returned to its original position applying the parking brakes and allowing oil from the brake housing to drain back through the circuit and return to tank.

Refer to AXLES - SERVICE/PARKING BRAKE in SECTION 8 of THIS MANUAL and BRAKE BLEEDING in THIS SECTION for more information.

PARKING BRAKE RELEASE PORT

Refer to AXLES - SERVICE/PARKING BRAKE in SECTION 8 of THIS MANUAL and BRAKE BLEEDING in THIS SECTION for more information.

CUP SPRINGS (PARKING BRAKE) OUTER CAP PISTON 1018-16

9.8

HOUSING

INNER CAP

SERVICE BRAKE PORT

BRAKE HOUSING ASSEMBLY

Tigercat 1018 Forwarder

1018-21

Brakes

BRAKE CIRCUIT 9.9

Tigercat 1018 Forwarder

Brakes

EMERGENCY BRAKE VALVE

Pull the knob UP fully to engage the parking brake. This shifts the valve spool and permits oil on the front side of the brake piston to drain to tank. The removal of oil pressure allows the cup springs installed in the brake housings to push against the steel and friction disks and applies the parking brakes.

The emergency brake valve is located on the instrument panel in the cab. This control is a 2-position manually actuated hydraulic valve which activates the parking brake, regardless of the condition of the parking brake release solenoid (C3 on the brake valve manifold). In case of emergency, this control can be engaged to stop the machine at any time.

Push down on the knob to release the brakes.

This shifts the valve spool and permits oil from the parking brake release solenoid valve (C3 on the brake valve manifold) to apply and release pressure as determined by the HTC.

CHECK VALVE

The emergency brake control may be applied at anytime whether the machine is stationary or in motion.

A pressure switch is installed in this hydraulic circuit, which signals the HTC (Hydrostatic Transmission Controller) when the parking brake release circuit when the parking brakes are applied (ie: parking brake release circuit has less than 6.2bar (90psi) of pressure). If the operator attempts to drive the machine when the parking brakes are applied, a Park Brake alarm will be triggered on the T220 display terminal in the cab.

This alarm warns the operator that the parking brake is ENGAGED while attempting to drive.

EMERGENCY BRAKE VALVE PRESSURE SWITCH

EMERGENCY BRAKE VALVE

1018-D130

(ACCESSED THROUGH RH CAB DOOR)

9.10

Tigercat 1018 Forwarder

Brakes

BRAKE BLEEDING

5. Release the BRAKE PEDAL.

The axle assemblies are equipped with brake bleed screws, two for each side (one for service brakes, and one for parking brake release).

Brakes must be bled whenever there has been potential for air to enter the system, such as removal of hydraulic line. All passages must be bled one at a time.

6. Repeat above procedure for each service brake bleed screw (2 per axle).

7. Place the TRANSMISSION switch in HIGH gear (gear 2).

8. Loosen parking brake release bleed screw.

9. Place the FWD.|PARK|REV. switch in either the FWD. or REV. position. Depress service brake pedal fully, and depress the drive pedal enough to release the parking brake.

PROCEDURE 1. Start engine and run at IDLE, press the PILOT RESET switch.

10. Close bleed screw when oil is free of air.

2. Loosen service brake bleed screw.

11. Release the drive pedal.

3. Push and hold service BRAKE PEDAL down.

12. Repeat above procedure for each parking brake bleed screw (2 per axle).

4. Close bleed screw when oil is free of air.

SERVICE BRAKE BLEED SCREW (2 PER AXLE)

PARKING BRAKE BLEED SCREW (2 PER AXLE)

SERVICE BRAKE PRESSURE PORT (2 PER AXLE)

PARKING BRAKE PRESSURE PORT (2 PER AXLE)

INPUT SIDE VIEW OF AXLE

9.11

Tigercat 1018 Forwarder

Brakes

BRAKE ADJUSTMENT The following procedure applies to both the front and rear bogie axles. Adjustment should be done as required. Both front and rear axles should be adjusted at the same time. Each axle has two brakes which require adjustment.

DOWEL REMOVAL BOLT

PROCEDURE:

1. Park the machine on level ground, place the crane in the park position, and lower the snow blade to the ground (if equipped).

BRAKE ADJUSTING NUT

DOWEL RETAINING BOLTS

LOCKING DOWEL

BRAKE ADJUSTMENT PARTS 4. Remove the two dowel retaining bolts from the locking dowel.

WARNING Hydraulic circuits with accumulators store hydraulic oil under pressure, therefore the system may remain pressurized after the engine is turned off.

5. Tighten the dowel removal bolt in the center of the locking dowel. This bolt is used to make removal of the locking dowel easier.

6. Pull out the locking dowel.

2. Stop the engine and release pilot system pressure by performing the following steps:

7. Use a pry bar through the locking dowel hole between the adjusting nut teeth to move the adjusting nut. The teeth are approximately 30mm(1 1/8") apart.

a. Close both doors. Turn key switch to the ON position. Do not start the engine.

Press pilot reset switch.

8. First tighten the adjusting nut as much as possible by turning the adjusting nut clockwise.

b. Fully apply brake foot pedal 50 times or more.

9. Then loosen the nut again by turning the adjusting nut counterclockwise one half turn.

c. Pressure may remain in the system after completing all of the above steps.

Use caution when loosening hydraulic connections.

10. Repeat steps 4 through 8 for the second brake on the axle.

3. To adjust the brakes it is necessary to release the two spring applied parking brakes. This is done by applying hydraulic pressure to the parking brake lines with a manual hydraulic pump. Connect a hand pump at the parking brake tee fitting to allow release of both parking brakes. Always use caution when loosening hydraulic connections.

11. Repeat steps 4 through 10 for the second axle.

12. Brakes are now correctly adjusted.

13. Release all pressure and remove the hydraulic hand pump from the parking brake tee connection. Always use caution when loosening hydraulic connections.

14. Reconnect the hyraulic hose to the parking brake tee.

15. Bleed the brakes to remove any air which may have entered the hydraulic system while hoses were removed. Refer to BRAKE BLEEDING in THIS SECTION.

PARKING BRAKE TEE CONNECTION

16. Start the engine and check for leaks.

17. Test brakes for proper operation. Refer to TEST DRIVE - SERVICE BRAKE OPERATION in SECTION 8 of THIS MANUAL.

PARKING BRAKE TEE CONNECTION (REAR AXLE SHOWN)

1018-D152

9.12

Tigercat 1018 Forwarder SECTION 10 - OIL COOLER/RADIATOR, FAN AND HYDRAULIC TANK SEPTEMBER, 2002

CONTENTS - SECTION 10 FAN DRIVE ..................................................................................................... 10.6 CIRCUIT DESCRIPTION AND OPERATION .............................................. 10.9 CIRCUIT DIAGRAM ..................................................................................... 10.9 FAN DRIVE PUMP ...................................................................................... 10.7 FAN DRIVE PUMP PRESSURE VERIFICATION ...................................... 10.12 FAN SPEED VERIFICATION / ADJUSTMENT .......................................... 10.10 HYDRAULIC TANK VACUUM PUMP .......................................................................................... 10.6 OIL COOLER .................................................................................................. 10.2 CIRCUIT DESCRIPTION AND OPERATION .............................................. 10.4 CIRCUIT DIAGRAM ..................................................................................... 10.5 COOLER PACKAGE INSTALLATION ......................................................... 10.3

Tigercat 1018 Forwarder

Oil Cooler/Radiator, Fan and Hydraulic Tank

OIL COOLER The hydraulic oil cooler is part of the side by side by side oil cooler / radiator / charge air cooler package. The cooler package is mounted between the fan and the air conditioner condenser coil. The fan draws air from the front of the machine through the hood screen, A/C condenser, and cooler package and then blows it out either side of the machine.

The cooling assembly should be checked daily and cleaned as required. The areas between the condenser and cooler package should be checked frequently, depending on operating conditions.

The A/C condenser can be swung out of the way to clean the front of the radiator/oil cooler/charge air cooler package. The A/C condenser can also be lifted from its hinges to provide additional access for cleaning.

Refer to CLEANING A/C CONDENSER, OIL COOLER, RADIATOR AND CHARGE AIR COOLER in SECTION 2 of the OPERATOR S MANUAL. COOLER PACKAGE

WINGNUT

A/C CONDENSER

1018-D061

A/C CONDENSER AND COOLER PACKAGE

10.2

Tigercat 1018 Forwarder

Oil Cooler/Radiator, Fan and Hydraulic Tank

OIL COOLER BYPASS VALVE A/C CONDENSER

OIL COOLER 'OUT' CONNECTION TO DOUBLE FILTER

RADIATOR TOP HOSE

CHARGE AIR COOLER

SURGE TANK

RADIATOR

FAN SHROUD

FAN FINGER GUARD

OIL COOLER

RADIATOR BOTTOM HOSE

RADIATOR AND OIL COOLER MOUNTS

FAN MOTOR

1018-42

FAN DRIVE SUPPORT

COOLER PACKAGE INSTALLATION 10.3

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

Tigercat 1018 Forwarder

Oil Cooler/Radiator, Fan and Hydraulic Tank

OIL COOLER CIRCUIT DESCRIPTION AND OPERATION Oil from the hydraulic systems first passes through the return strainer before being pumped through the oil cooler. The main hydraulic systems which create a great deal of heat are the hydrostatic pump and motor, the main pump, and the fan drive pump and motor. The purpose of the return strainer is to collect any debris, should a problem occur with one of the hydraulic systems. The return strainer is also connected to the hydraulic tank, thus completing a loop and allowing oil from the reservoir to be cooled.

Access is gained to the return strainer by removing the panel immediately in front of the axle below the front chassis.

RADIATOR DRAIN VALVE

BYPASS VALVE

1018-D121

RETURN STRAINER ASSEMBLY

CHARGE PUMP

1018-D122 1018-D117

OIL COOLER BY-PASS

COOLING PUMP

STRAINER OUTLET (COOLING PUMP)

BYPASS MANIFOLD

RETURN STRAINER

COOLING PUMP

Oil passes from the oil cooler through a double element return filter and returns to the reservoir.

The cooling pump draws oil from the return strainer and sends it to the oil cooler via the cooler bypass manifold. The cooler bypass manifold is a component of the 2-pass oil cooler.

The cooler bypass ensures that the differential pressure between the oil cooler inlet and outlet does not exceed 6.9bar (100 psi). The cooler bypass protects the coolers from pressure increases that occur in cold weather conditions when oil temperatures at start up are very low.

Oil entering the hydraulic reservoir passes through one of two strainers situated inside the reservoir below the oil surface.

HYDRAULIC OIL HAND FILL PUMP Oil is added to the hydraulic reservoir using the hydraulic oil fill pump located in the rear of the hydraulic tank. This oil is pumped through a double element return filter and directly into the reservoir. Refer to HYDRAULIC OIL FILL PUMP in SECTION 2 of the OPERATOR S MANUAL more information about operating the fill pump.

10.4

Tigercat 1018 Forwarder

1018-23

Oil Cooler/Radiator, Fan and Hydraulic Tank

OIL COOLER CIRCUIT 10.5

Tigercat 1018 Forwarder

Oil Cooler/Radiator, Fan and Hydraulic Tank

VACUUM PUMP The hydraulic oil vacuum pump, located in the rear of the hydraulic tank is used to hold a vacuum in the hydraulic system while the machine is being serviced. When turned ON, this pump creates a vacuum in the hydraulic tank, reducing the possibility of leakage while repairs are taking place.

With the ignition switch OFF, turning the vacuum switch to the ON position energizes the vacuum pump and the tank breather closed solenoid. An external relay in the vacuum pump circuit will not allow the pump to operate with the ignition switch in the ON position. Energizing the breather closed solenoid eliminates the breather from the circuit, allowing the vacuum to be held. The pump should remain ON during the time the repairs are in progress. Turning the vacuum switch OFF will stop the vacuum pump, and shift the tank breather closed solenoid, opening the tank to atmosphere via the breather. A gauge incorporated in the system indicates the level of vacuum being held. Always turn the vacuum switch OFF when work is complete.

FAN DRIVE PUMP

1018-D073

COOLER PACKAGE

The fan is hydraulically driven by the fan drive pump and fan drive motor in a dedicated closed loop circuit. The fan drive is electronically controlled by the HTC (Hydrostatic Transmission Controller). Fan speed is infinitely adjusted based on HTC inputs.

When operated in the forward direction the fan provides normal cooling operation. The fan draws air from the front of the machine through the hood screen, the A/C condenser, and the cooler package then blows it out the either side of the machine.

When operated in the reverse direction the fan provides flow for cleaning debris from the cooling system. By reversing the direction of air flow dust and debris are forced out of the charge air cooler, radiator, oil cooler, A/C condenser and hood screen.

VACUUM PUMP ON/OFF SWITCH

1018-D051

FAN DRIVE MOTOR

FAN

VACUUM PUMP

COOLER PACKAGE

VACUUM GAUGE

FAN DRIVE

For additional information regarding the operation of the fan refer to FAN CONTROL SWITCH, FAN SPEED SWITCH and CLEANING A/C CONDENSER, OIL COOLER, RADIATOR AND CHARGE AIR COOLER in SECTION 2 of THE OPERATOR S MANUAL.

R.H. HYDRAULIC TANK COMPARTMENT

For more information on the hydraulic reservoir, refer to HYDRAULIC OIL RESERVOIR in SECTION 2 of the OPERATOR S MANUAL.

10.6

Tigercat 1018 Forwarder

Oil Cooler/Radiator, Fan and Hydraulic Tank

FAN DRIVE PUMP The fan drive pump is located at the front of the engine, behind the cooling system assembly. The fan drive pump is accessed from either side of the machine by raising the hood. A splined adapter connects the input driveshaft of the pump directly to the engine.

CHARGE PRESSURE RELIEF VALVE

FAN PUMP CONTROLLER

1018-D096

FAN DRIVE PUMP

The fan drive pump is actually two separate pumps mounted in a common case and driven by the same input driveshaft. The primary pump acts as the fan drive pump and the secondary pump acts as a fan drive charge pump.

The primary pump is a variable displacement, swashplate axial piston pump. This pump is made variable by slipping the pump pistons against a tiltable swashplate cradle. The volume and direction of oil flow from the piston pump is determined by the angle of this swashplate.

When the swashplate is stroked to a maximum displacement angle, the piston pump will produce maximum flow in one direction in the closed loop.

As the swashplate is destroked the flow smoothly SWASHPLATE

DRIVE SHAFT

•

The HTC (Hydrostatic Transmission Controller) sends an electrical current output to the proportional solenoids installed in the fan pump controller. The proportional solenoids shift the spool in the swashplate control valve. This changes the position of the control cylinder, which is directly connected to the swashplate of the piston pump. The angle and direction that the swashplate moves determines the speed and direction of the fan.

The fan drive pump is equipped with two high pressure relief valves. These relief valves are factory set and non-adjustable.

'M3' CHARGE PRESSURE (FAN)

decreases until there is no flow at an angle of zero (0°). Continuing to angle the swashplate past this neutral position steplessly reverses the direction of flow from the piston pump.

PISTON(S)

•

•

The secondary pump is a fixed displacement internal gear pump which provides charge oil (make-up oil) for the fan drive pump and motor in the closed loop fan drive circuit. Charge flow also provides cooling for the circuit and pressure for the pump control system.

The fan drive charge pump is equipped with a charge pressure relief valve to maintain the charge pressure. The charge pressure relief valve is adjustable.

Refer to FAN DRIVE PUMP PRESSURE VERIFICATION AND ADJUSTMENT in THIS SECTION. Refer to FILTERS-REMOVE AND REPLACE: CHARGE PRESSURE FILTER - FAN DRIVE PUMP in SECTION 3 of THIS MANUAL for information regarding charge pressure filter replacement.

VALVE PLATE

••

• AP117-1

FAN DRIVE PUMP CROSS SECTION 10.7

CHARGE PUMP

Tigercat 1018 Forwarder

Oil Cooler/Radiator, Fan and Hydraulic Tank

FAN DRIVE MOTOR The fan drive motor is a fixed displacement inline swashplate axial piston motor. The fan drive motor is driven by hydraulic pressure from the fan drive pump and in turn it directly drives the fan.

ASSEMBLY NOTE: Before re-installing a fan drive motor, pack spline area of fan hub and motor shaft with multipurpose lithium grease.

Refer to illustration 630B-10 on this page.

FAN DRIVE MOTOR

1018-D123

FILL HATCHED AREA WITH MULTIPURPOSE LITHIUM GREASE AS SHOWN PRIOR TO INSTALLING MOTOR DO NOT FILL THIS AREA WITH GREASE

• •

• •

•

• •

•

•

•

• MOTOR

BOLT

WASHER

RETAINING RING

FAN FAN SHAFT

•

BEARINGS

FAN SUPPORT

630B-10

FAN DRIVE MOTOR INSTALLATION

10.8

Tigercat 1018 Forwarder

Oil Cooler/Radiator, Fan and Hydraulic Tank

FAN DRIVE CIRCUIT DESCRIPTION AND OPERATION The fan drive circuit is a closed loop system. The circuit consists of the fan drive pump and fan drive motor connected together by two hydrostatic hoses. The pump converts the mechanical power of the diesel engine into hydraulic power. This high pressure flow of hydraulic oil is then transmitted to the motor through the first connecting hose the motor then reconverts the hydraulic power back into mechanical power to rotate the fan. Low pressure hydraulic oil then returns from the motor to the pump through the other connecting hose to complete the circuit.

The charge pump provides make up oil to the circuit to compensate for internal leakage in the closed loop and provide a cooling effect. All make up hydraulic oil entering the closed loop first passes through the charge pressure filter to ensure that no debris enters the closed loop.

1018-24

Fan speed and direction is controlled electronically by the HTC (Hydrostatic Transmission Controller). The HTC monitors inputs such as engine water temperature (B10), hydraulic oil temperature (B12), air conditioning operation (B32), and the positions of the fan control (B30 & B31) and fan speed (B33) switches. It then calculates fan speed required in the forward direction (drawing air in through the coolers) and sends the appropriate proportional signal (from A31) to the solenoids on the fan drive pump controller. If the fan requires "reverse" operation (either automatically by the HTC, or by the CLEAN ON position of the fan control switch) power is sent from the HTC (A24) to relay 13 which reverses the output to the fan drive pump.

Note that relay 4 will also be energized which will declutch the A/C compressor while the fan is running in reverse.

FAN DRIVE CIRCUIT

10.9

Tigercat 1018 Forwarder

Oil Cooler/Radiator, Fan and Hydraulic Tank

FAN SPEED VERIFICATION / ADJUSTMENT NOTE: A calibrated electronic photo tachometer is required for this procedure.

1. Park the machine on level ground. Place the FWD.|PARK|REV. switch in the PARK position. Place the crane in the park position, and lower the snow blade (if equipped) to the ground. Shut engine off.

2. Place a piece of reflecting tape on the fan hub.

b. Adjust the FORWARD MAXIMUM DISPLACEMENT ADJUSTING SCREW (accessed from the right hand side of the machine). Loosen the locknut. Turn the screw COUNTERCLOCKWISE to INCREASE speed. Turn the screw CLOCKWISE to DECREASE fan speed. c. Tighten locknut and recheck the FORWARD fan speed as in step 6 above.

8. Increase the engine speed to 2200 rpm using the ENGINE WORKING RPM DIAL. 9. Verify that the fan speed remains at 2100-2220 rpm. This feature is controlled electronically by the HTC, which reduces the current signal sent to the fan pump (causing it destroke as engine speed increases).

3. Start the engine. Press the PILOT RESET SWITCH. Leave the FWD.|PARK|REV. switch in PARK. 4. Using the ENGINE WORKING RPM DIAL, adjust the controls until the engine is running at 1500 rpm.

5. Place the FAN SPEED SWITCH in the MAX. position. Place the FAN CONTROL SWITCH in the AUTO position.

6. With the aid of an assistant use a photo tachometer to check the forward fan speed.

FORWARD fan speed should be 2100-2200 rpm.

10. Place the FAN SPEED SWITCH in the VARIABLE position.

11. Using the ENGINE WORKING RPM DIAL, continue to operate the engine at 2200 rpm.

12. Place and hold the FAN CONTROL SWITCH in the CLEAN ON position.

13. With the aid of an assistant use a photo tachometer to check the reverse fan speed.

REVERSE fan speed should be 1700-1800 rpm.

7. If adjustment is required: a. Stop the engine. The engine should not be running when adjustments are being made to the fan drive pump.

14. If adjustment is required: a. Stop the engine. The engine should not be running when adjustments are being made to the fan drive pump.

CAUTION Do not adjust displacement limiting screws with the engine running. Always stop the engine. Failure to do so may result in component damage.

CAUTION Do not adjust displacement limiting screws with the engine running. Always stop the engine. Failure to do so may result in component damage.

VIEWED FROM RIGHT SIDE OF MACHINE

VIEWED FROM RIGHT SIDE OF MACHINE

FORWARD MAXIMUM DISPLACEMENT ADJUSTMENT REVERSE MAXIMUM DISPLACEMENT ADJUSTMENT

1018-D124

FAN DRIVE PUMP 1018-D126

10.10

FAN DRIVE PUMP

Tigercat 1018 Forwarder

Oil Cooler/Radiator, Fan and Hydraulic Tank

b. Adjust the REVERSE maximum displacement adjusting screw (access is gained from the left hand side of the machine). Loosen the locknut and turn the screw counterclockwise to increase speed and clockwise to decrease fan speed.

WARNING Do not allow the fan to revolve faster than 2000 rpm in reverse. c. Tighten locknut and recheck the REVERSE fan speed as in step 11 above.

15. When forward and reverse fan speeds are correct make sure the locknuts are tight on both maximum displacement adjusting screws.

16. Re-check the fan speed settings to make sure that they have not changed.

10.11

Tigercat 1018 Forwarder

Oil Cooler/Radiator, Fan and Hydraulic Tank

FAN DRIVE PUMP PRESSURE VERIFICATION 1. Park the machine on level ground. Place the FWD.|PARK|REV. SWITCH in the PARK position. Place the crane in the park position, and lower the snow blade (if equipped) to the ground. Shut engine off.

2. Install two 0-5000 psi gauges on M1 and M2 test ports on the fan pump. Install one 0500 psi gauge on M3 test port on the fan pump.

REVERSE

FORWARD

4 POLE CONNECTOR

FAN DRIVE PUMP CONTROL LEVER

1018-D125

FAN DRIVE PUMP CONTROLLER

4. Disconnect the four pole connector at the fan drive pump controller.

5. Start the engine. Press the PILOT RESET SWITCH. Leave the FWD.|PARK|REV. switch in the PARK position.

'M1'TEST PORT

1018-D100

6. Using the ENGINE WORKING RPM DIAL, adjust the controls until the engine is running at 2200 rpm.

'M2'TEST PORT

7. Verify that the fan drive charge pump pressure, M3 gauge, reads 13.8-14.4 bar (200-210 psi).

FAN DRIVE PUMP

8. If necessary adjust the charge pump pressure using the charge pressure adjusting screw.

9. Adjust engine speed to idle by placing the WORKING RPM switch in the OFF position.

10. Manually shift the fan drive pump control lever (located on the front face of the controller) fully toward the LEFT side of the machine (forward). Note the pressure has a tendency to drop slightly while holding the level shifted fully, this is acceptable.

FAN PUMP CONTROLLER

1018-D096

'M3' CHARGE PRESSURE (FAN)

FAN DRIVE PUMP

CAUTION

3. Mark (A and B) then disconnect the main hoses going into the fan motor and plug using two 12ORS plugs.

WARNING Monitor hydraulic oil temperature and engine coolant temperature closely when the fan motor is disconnected. Do not allow the hydraulic oil, or engine to overheat.

Capped hoses will move when shifting the fan drive pump control lever out of neutral.

11. Verify that the M1 gauge reading is 225-235 bar (3260-3400 psi).

12. Manually shift the fan drive pump control lever fully toward the RIGHT side of the machine (reverse). Note the pressure has a tendency to drop slightly while holding the level shifted fully, this is acceptable.

13. Verify that the M2 gauge reading is 225-235 bar (3260-3400 psi).

10.12

Tigercat 1018 Forwarder

Oil Cooler/Radiator, Fan and Hydraulic Tank

14. If M1 and M2 gauge readings are incorrect contact Tigercat Customer Service for more information. Relief valves on the fan drive pump are not adjustable.

15. Release the manual fan drive pump control lever to the neutral position and turn off the engine.

16. Reconnect the four pole connector at the fan drive pump controller.

17. Reconnect the fan motor hoses.

18. Check for hydraulic leaks.

10.13

Tigercat 1018 Forwarder

Oil Cooler/Radiator, Fan and Hydraulic Tank

10.14

Tigercat 1018 Forwarder SECTION 11- CENTER JOINT, STEERING, CAB ROTATE AND SNOW BLADE SEPTEMBER, 2002

CONTENTS - SECTION 11 CAB ROTATE BEARING RE-ASSEMBLY ...................................................... 22 CAB ROTATE MOTOR ................................................................................... 21 CENTER JOINT ................................................................................................ 3 ARTICULATION JOINT DIAGRAM ............................................................... 5 ARTICULATION JOINT PRELOAD ADJUSTMENT ...................................... 4 CHECKING ARTICULATION JOINT PRELOAD ........................................... 4 CHECKING/ADJUSTING THE OSCILLATION JOINT PRELOAD ................. 6 GREASE SEALS ........................................................................................... 6 LUBRICATION ............................................................................................... 3 MAINTENANCE OF ARTICULATION JOINT ................................................ 3 MAINTENANCE OF OSCILLATION JOINT ................................................... 3 OSCILLATION JOINT DIAGRAM .................................................................. 6 CIRCUIT DIAGRAM ........................................................................................ 13 ELECTRONIC SYSTEM ................................................................................... 8 ELECTRONIC SYSTEM DIAGRAM .................................................................. 8 LOAD SENSING HYDRAULIC SYSTEM ................................................................................. 10 LOAD SENSING BASIC DESCRIPTION ..................................................... 10 LOAD SENSING BASIC PRINCIPALS ........................................................ 10 LOAD SENSING OPERATING TIPS ........................................................... 11 SET MARGIN PRESSURE .......................................................................... 15 MAIN PUMP .................................................................................................... 13 MARGIN PRESSURE .................................................................................. 15 SET COMPENSATOR PRESSURE ............................................................ 14 SET MARGIN PRESSURE .......................................................................... 15 MARGIN PRESSURE ..................................................................................... 15 STEER VALVE ................................................................................................ 17 ADJUSTING STEER VALVE FEED REDUCTION VALVE SETTING .......... 20 PROPER FEED REDUCTION VALVE SETTINGS ...................................... 19 REPLACING MAIN PRESSURE RELIEF VALVE ........................................ 20 REPLACING PORT RELIEFS ..................................................................... 20 STEERING, CAB ROTATE AND SNOW BLADE FUNCTIONS ....................... 8 ELECTRONIC SYSTEM ................................................................................ 8 ELECTRONIC SYSTEM DIAGRAM .............................................................. 8 HYDRAULIC SYSTEM - LOAD SENSING ................................................... 10

Tigercat 1018 Forwarder

Center Joint, Steering, Cab Rotate and Snow Blade

11.2

Tigercat 1018 Forwarder

Center Joint, Steering, Cab Rotate and Snow Blade

CENTER JOINT

OSCILLATION JOINT CHECK FOR MOVEMENT IN THIS JOINT AREA

REAR CHASSIS

MAINTENANCE OF ARTICULATION JOINT

B

Maintenance in this area is usually limited to: a) Regular lubrication of the two center joint articulation grease fittings to purge the articulation pivot bearings of debris and water.

Refer to SERVICE AND LUBRICATION POINTS in SECTION 3 for lubrication intervals. Use only high quality, lithium based EP2 grease containing molybdenum disulphide. b) Visually checking the center joint articulation for looseness every 250 hours. With an observer on the ground, keeping well clear of the center joint area, perform the following test to check for looseness of center joint articulation.

1. Have operator lift the crane out of the park position, and maneuver it 90 degrees to one side of the machine. Fold the stick boom down, and rapidly raise and lower the main boom several times to bounce machine (it may be necessary to adjust the boom up and boom down parameters using the T220 Display Terminal).

2. As the machine bounces, check for motion between the front chassis and center joint lugs. Also check for a clunking sound at the center joint area.

3. Have operator place the crane back into the park position and switch the CRANE/ OFF/SNOW BLADE switch to OFF. 4. Movement between front chassis and center joint lugs or clunking of the pivot indicates a loose articulation joint and articulation joint preload must be checked.

Refer to CHECKING ARTICULATION PRELOAD in THIS SECTION.

11.3

CENTER JOINT

ARTICULATION JOINT CHECK FOR MOVEMENT IN THIS JOINT AREA

1018-D089

A FRONT CHASSIS

250 HOUR CHECK

MAINTENANCE OF OSCILLATION JOINT Maintenance in this area is usually limited to: a) Regular lubrication of the two center joint oscillation grease fittings to purge the oscillation pivot bearings of debris and water.

Refer to SERVICE AND LUBRICATION POINTS in SECTION 3 for lubrication intervals. Use only high quality, lithium based EP2 grease containing molybdenum disulphide. b) Visually checking the center joint oscillation for looseness every 250 hours. With an observer on the ground, keeping well clear of the center joint area, perform the following test to check for looseness of center joint.

1. Have operator place the crane into the park position. Drive the machine in forward and reverse rapidly several times.

2. Check for motion between the center joint and rear chassis. Also check for a clunking sound at the center joint area.

3. Movement between center joint and rear chassis or clunking indicates a loose oscillation joint and oscillation joint preload must be checked. Refer to CHECKING/ ADJUSTING OSCILLATION PRELOAD in THIS SECTION.

Tigercat 1018 Forwarder

Center Joint, Steering, Cab Rotate and Snow Blade

CHECKING ARTICULATION JOINT PRELOAD 1. Park the machine on level ground. Set the FWD.|PARK|REV. in the PARK position, place the crane in the park position, and raise the snow blade fully (if equipped). Shut off engine.

2. Place the magnetic base of a dial indicator on the top surface of the bottom pin A as close to the center pin as possible. It may be necessary to remove the mid driveshaft, depending upon the style of dial indicator.

3. Partially depress the plunger end of the dial indicator against the bottom surface of the top articulation pin B as close to center pin as possible (not steer cylinder pins).

4. Remove the 6 top pin retainer bolts, and remove the retainer plate.

5. Place a jack under the front chassis (do not use jack on center joint components, including the retainer plates, and pins ONLY USE JACK ON FRONT CHASSIS).

FRONT CHASSIS

CENTER JOINT

9. Torque the 6 top and 6 bottom retainer bolts (items 1 and 2, respectively) to 400Nm (300 lbf-ft).

10. Place the magnetic base of a dial indicator on the top surface of the bottom pin A as close to the center pin as possible.

CHECK FOR MOVEMENT IN THIS JOINT AREA

REAR CHASSIS

B

CENTER JOINT CHECK FOR MOVEMENT IN THIS JOINT AREA

1018-D070

A FRONT CHASSIS

250 HOUR CHECK

11. Partially depress the plunger end of the dial indicator against the bottom surface of the top pin B as close to center pin as possible. Zero the dial indicator.

12. Fully loosen only the 6 top pin retainer bolts (item 1) that were torqued in step 9. DO NOT REMOVE BOLTS. 13. The dial indicator should now show a change of 0.025" to 0.030" between pin A and B .

This is the proper bearing preload setting.

If the reading is within this range re-torque the 6 top and 6 bottom retainer bolts, then lower the jack.

PLACE JACK HERE 1018-D128

ARTICULATION JOINT

6. Using the jack, apply a force to remove the loading on the top pin. As the rear of the front chassis is raised, the top pin should fall into the bore, then begin to rise again. This is noticeable on the dial indicator, as it will rotate in one direction while the pin falls into the bore, then stop and begin to rotate in the opposite direction while the pin begins to rise.

7. Raise and lower the chassis as described above until the point at which the dial indicator changes direction is found. This indicates that the pin is at the lowest point in the bore. The pin should also rotate freely in the bore at this point. DO NOT ADJUST THE JACK. 8. Reinstall the top pin retainer plate, and 6 top pin retainer bolts.

A change of less than 0.025" indicates that the bearing preload is too low. No change on the dial indicator is the result of a loose center joint. In these cases, proceed to ARTICULATION JOINT PRELOAD ADJUSTMENT. ARTICULATION JOINT PRELOAD ADJUSTMENT Before making any adjustments to the articulation joint, please follow CHECKING THE ARTICULATION JOINT PRELOAD procedure in THIS SECTION. With dial indicator still in place; 14. Remove the 6 top pin retainer bolts (item 1), the top pin retainer plate (item 3) and all of the shims in the shim pack (items 4).

15. Remove the thinnest shim from the pack.

11.4

Tigercat 1018 Forwarder

Center Joint, Steering, Cab Rotate and Snow Blade c) It is possible that the total thickness of two shims is too great and a single shim, of lesser thickness than these two, must be removed.

16. Reinstall the remaining shims, the retainer plate and the bolts. Leave the bolts loose.

17. Zero the dial indicator again and torque the 6 top bolts in sequence to 400Nm (300 lbf-ft).

ORIENTATION OF GREASE SEALS

18. A change of 0.025" to 0.030" should register on the dial indicator.

The articulation pivot bearings installed in the center joint (item 5) are sealed on both sides by grease seals (items 6 and 7). These seals have proven to have a long life.

This is the proper articulation bearing preload setting. If the reading is within this range re-torque the 6 top and 6 bottom retainer bolts, then lower the jack.

If replacement becomes necessary, new seals must be installed in the proper orientation. Refer to the center joint diagram and follow these guidelines for correct installation;

a) If change in dial indicator reading is greater than 0.030", the shim removed (in step 8) may not have been the thinnest shim in the pack. Repeat steps 7 through 11, replacing this shim and removing only the thinnest shim from the bottom shim pack (item 4).

The two seals installed on either side of the top and bottom bearings must be installed with the seal lips facing away from the bearings.

Apply blue 243 Loctite (removable) and torque the six bolts (item 8) for the bearing retainer plate (item 9) to 270Nm (200 lbf-ft).

b) If the change in the dial indicator reading is less than 0.025", another shim will have to be removed. Repeat steps 7 through 11, removing additional shims but only the thinnest shim each time, until the change in the reading on dial indicator is within the proper range.

1 3

4

8 9

6

7

5

1 6

2 1018-37

3

ARTICULATION JOINT 11.5

5 4

2

BOLT TIGHTENING SEQUENCE

Tigercat 1018 Forwarder

Center Joint, Steering, Cab Rotate and Snow Blade

11.6

Tigercat 1018 Forwarder

Center Joint, Steering, Cab Rotate and Snow Blade

CHECKING/ADJUSTING THE OSCILLATION JOINT PRELOAD

OSCILLATION END CAP

1. Park the machine on level ground. Set the FWD.|PARK|REV. in the PARK position, place the crane in the park position, and raise the snow blade fully (if equipped). Shut off engine.

2. Disconnect the rear driveshaft from the center joint driveshaft. Remove the rear driveshaft yoke (item 1) from the rear of the center joint assembly. Be careful not to damage seal (item 3).

3. Loosen the 6 oscillation end cap fasteners (item 4) evenly, and remove the oscillation end cap (item 2). CAUTION: Uneven loading of bolts can result in damage. Be careful not to damage Seal (Item 6) while removing the oscillation end cap.

4. Remove the shim pack (item 5).

5. With the shim pack removed, install the oscillation end cap (item 2) using six washers and bolts (item 4). Evenly torque to 400Nm (300 lbf-ft). Be careful not to damage Polypak Seal (item 6) while installing the oscillation end cap (item 2).

6. Measure distance from rear face of oscillation end cap (item 2) to rear face of centre joint through each of the small holes in oscillation end cap (2 places).

7. NOTE: The bearings are now PRE-LOADED! Loosen the six oscillation end cap fasteners (item 4) evenly, and remove the oscillation end cap (item 2). CAUTION: Uneven loading of bolts can result in damage. Be careful not to damage Polypak Seal (item 6) while removing the oscillation end cap (item 2).

1

3

6

5 4

VERNIER CALIPER

OSCILLATION JOINT PRELOAD 1018-D114 8. Measure the thickness of the oscillation end cap (item 2).

9. Calculate the thickness of shims required.

Subtract the oscillation end cap thickness measured in step 8 from the average distance measured in step 6.

For example: Measured distance (step 6): 1.127 0.998 Measured thickness (step 8): Total thickness of shims required: 0.129 10. Select an arrangement of shims (item 5) that add up to the thickness of shims required calculated in step 9.

11. Install selected shims (item 5), and oscillation end cap (item 2) using washers and bolts (item 4). Torque these fasteners to 540Nm (400 lbf-ft). Be careful not to damage Seal (item 6) while installing the oscillation end cap (item 2).

12. Re-assemble the rear driveshaft yoke (item 1) on the rear of the centre joint assembly. Be careful not to damage the seal. Reconnect the rear driveshaft to the center joint driveshaft.

BOLT TIGHTENING SEQUENCE

4 2 5

2

6

1 3

OSCILLATION JOINT 1018-38

11.7

Tigercat 1018 Forwarder

Center Joint, Steering, Cab Rotate and Snow Blade

STEERING, CAB ROTATE AND SNOW BLADE FUNCTIONS

ELECTRONIC SYSTEM

The steering, cab rotate and snow blade functions are proportional valve functions. Each of them is controlled electro-hydraulically from a common valve assembly located in the front chassis. The term proportional means that the electronic signal sent to the proportional valve from the computer will vary comparably with the input joystick movement.

Steering speed is controlled by the amount the steering joystick is moved to the right or left. A small movement of the joystick will turn the machine slowly and a large movement of the joystick will turn the machine very rapidly. For example, when the steering joystick is moved 60% of its full travel towards the right, the signal sent to the boom valve will be enough to shift the spool for 60% of its full flow, which will result in the machine steering at 60% of its maximum steering speed .

The cab rotate and snow blade functions operate proportionally with respect to function speed in the same manner as the steering function.

HINGED ACCESS PANEL

HTC

PVC

HTC (HYDROSTATIC TRANSMISSION CONTROL) & PVC (PROPORTIONAL VALVE CONTROL) 1018-D116

The steer, cab rotate and snow blade functions are all controlled by the PVC (Proportional Valve Controller). The PVC monitors and analyzes inputs, then produces outputs (as defined in its program) to control the machine. The operator may adjust settings for all functions controlled by the PVC program using the T220 Display Terminal.

Refer to the following details in SECTION 2 of the OPERATOR S MANUAL: DRIVER MEMORIES SELECTING AN ACTIVE DRIVER COPYING DRIVER SETTINGS ADJUSTING THE PARAMETERS OF DRIVERS. Inputs: The computer monitors variable signals from the STEERING JOYSTICK and the LEFT and RIGHT MINI JOYSTICKS. The PVC also reacts to digital signals from the CRANE/ OFF/SNOW BLADE switch, the STEER/DRIVE switch, and the CAB ROTATE pedals.

Outputs: The computer directs an output (24 Volt proportional electrical current) to the steer valve solenoids to operate the various functions.

11.8

ELECTRONIC SYSTEM

Center Joint, Steering, Cab Rotate and Snow Blade

1018-25

Tigercat 1018 Forwarder

11.9

Tigercat 1018 Forwarder

Center Joint, Steering, Cab Rotate and Snow Blade

HYDRAULIC SYSTEM The proportional valve functions depend on a load sense hydraulic system composed of the following major components; 1.

2.

3.

4.

Main pump.

Steer Valve Boom Valve Working Components

LOAD SENSING BASIC PRINCIPALS

LOAD SENSING BASIC DESCRIPTION Load sensing systems use variable flow pumps and only flow oil when required. When in neutral, no oil flows through the control valve to tank and the pump output flow is zero. The pump s output flow is controlled by a control cylinder which is connected to the pump output, and to the valve s workport or load . This sense line to the actual working load defines the system as load sensing.

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

Figs. 3 & 4 In an attempt to recover some of the wasted energy, variable volume pumps evolved.

These pumps are power regulated or horsepower controlled and since they reduce the pumps output to maintain a constant system hp, oil flow over the relief valve is less, therefore reducing the wasted power losses and heat generation. SEE FIGS. 3 & 4.

FLOW

WASTED

853SM18

W USED

FIG. 1

FIXED DISPLACEMENT PUMP

PRESSURE FIG. 2 853SM16

HP

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

=CO NST ANT

FLOW

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

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

SEE FIGS. 5 & 6.

W USED 853SM19

FIG. 3

HP REGULATED PUMP

HP =C ON ST AN

FLOW

T

∆p LS W USED PRESSURE

1018-26

FIG.5

WASTED WASTED

LOAD SENSING (FLOW ON DEMAND) 11.10

FIG.6

853SM16

PRESSURE FIG. 4 853SM16

Tigercat 1018 Forwarder

Center Joint, Steering, Cab Rotate and Snow Blade

The key component in the simplified system described is the spring in the control cylinder. The pump s output pressure must be 20bar (290 psi) higher than the load pressure to compress the spring and reduce the flow of the pump. This 20bar (290 psi) is the differential or margin pressure.

differential resulting from flow through the valve, not the actual load pressure level.

853sm22

853sm22

In the figure above the control valve is closed blocking the pump from the load. With the load at zero the pump will maintain 20bar (290 psi) of standby pressure and pump flow is zero.

853sm22

The following are key features of this load sensing system; 1. The load sensing valve s maximum flow is not equal to the pumps maximum flow. The valves maximum flow is determined by the maximum size of opening or orifice it provides.

853sm22

When the control joystick is moved to actuate a cylinder or motor, the control valve opens the pump to the load. In this case the load is zero and the pump output pressure falls as the oil escapes through the valve. The 20bar (290 psi) that was holding the spring in the compressed state is reduced and the spring moves the pump to increase flow. Flow will increase to a level that requires 20bar (290 psi) to force the oil through the valve opening. At this point the load pressure combined with the spring force will be high enough to oppose the pump output pressure, and the control cylinder will stop moving.

Changing the control joystick position changes the size of the opening in the valve and upsets the balance of the control cylinder. The control cylinder then adjusts the flow of the pump to find a new balance point. The stroking piston will change the pump s flow until pump pressure is 20bar (290 psi) higher than load pressure.

In the figures below note that even though the load pressure may change, (as illustrated by the extra restriction) the flow remains constant. This is because the difference in pressure, or differential pressure, between the pump and load pressures can be maintained by the control cylinder regardless of load. It is important to remember the pump is really responding to the pressure

2. The speed of the load does not change as the load changes. If the load increases on a boom cylinder the pump pressure will increase automatically to maintain the load s original speed.

3. A load sensing system provides the speed the operator selects with the lever, and automatically adjusts the pressure to match the load.

LOAD SENSING OPERATING TIPS When using the controls on a load sensing system think of what the system is trying to do. If the joystick is moved 20% of its total angle, the system will provide whatever pressure it takes (up to its maximum capacity if needed) to operate the function at 20% of full function speed .

Load sensing systems respond to rough operation by amplifying these movements. If you find the function is jerky or always giving feedback , you re probably too active on the controls. Adjust the driver parameters on the T220 Display Terminal to suit the operator and conditions. The margin pressure setting may be too high and should be checked and reset if needed.

Refer to SET MARGIN PRESSURE in this section.

11.11

Tigercat 1018 Forwarder

Center Joint, Steering, Cab Rotate and Snow Blade

11.12

Tigercat 1018 Forwarder

1018-27

Center Joint, Steering, Cab Rotate and Snow Blade

STEER CIRCUIT 11.13

Tigercat 1018 Forwarder

Center Joint, Steering, Cab Rotate and Snow Blade

MAIN PUMP All proportional valve hydraulic functions are powered by the main pump mounted on the flywheel housing of the engine. The main pump is mounted in tandem with the drive pump.

DRIVE PUMP

MAIN PUMP

MAIN PUMP SCHEMATIC

1018-28

CONTROL

ßFRONT

1018-D086

PUMPS

The main pump is an axial-piston, variabledisplacement pump with load sensing, and pressure compensating controls. The main pump operates in an open-loop hydraulic circuit, meaning that hydraulic oil is always returned to tank.

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

When a proportional valve function is operated, the valve sends a load sense signal to the main pump load sense regulator. This signal shifts the load sense regulator spool, located in the controller installed on the pump. With the load sense regulator spool shifted, the oil behind the control cylinder is released to tank. The opposite side of the control cylinder has full pump pressure acting on it. The control cylinder shifts, changing the angle of the swashplate (increasing the displacement of the pump or stroke ). Main pump pressure also acts on the load sense spool, opposing the load sense signal. The swashplate angle increases and the pump builds more pressure, until main pump pressure overcomes load sense pressure (and the spring force applied by the margin pressure adjustment). At this point, the load sense spool shifts the opposite direction, and main pump pressure is sent to both sides of the control cylinder. The control cylinder has the same amount of pressure on each side. However, the area of the de-stroke side of the control cylinder is larger than the area of the stroke side .

THROUGH DRIVE FOR DRIVE PUMP

DRIVE SHAFT SWASHPLATE 1018-28

PISTON ASEMBLY

MAIN PUMP

Therefore, the pump will begin to destroke (decrease swashplate angle), until the load sense spool shifts once again. A spring is installed on one side of the swashplate control cylinder to smooth out the operation of the control cylinder, and provide a relatively stable operating condition.

The pump is constantly reacting to the changes in the load sense signal, and 0never produces more pressure or flow than required for the functions being operated.

The pressure compensator limits the maximum pressure that the pump can build. The pressure compensation spool is held in its normal position by a spring force applied by the pressure compensator adjustment. Main pump pressure acts against the opposite end of the spool. When the main pump pressure exceeds the compensator pressure setting of 230-235 bar (3335-3410 psi) the pressure compensator spool shifts. This allows main pump pressure to act on both sides of the control cylinder, forcing the pump to destroke as described above.

11.14

Tigercat 1018 Forwarder

Center Joint, Steering, Cab Rotate and Snow Blade MAIN PUMP

NOTE SPRING ORIENTATION WHEN SERVICING MAIN PUMP AND/OR DRIVE PUMP DRIVE PUMP

1018-39

DRIVE PUMP AND MAIN PUMP CONNECTION CROSS SECTION (NOTE SPRING ORIENTATION AT THE CONNECTION BETWEEN PUMPS)

11.15

Tigercat 1018 Forwarder

Center Joint, Steering, Cab Rotate and Snow Blade

SET COMPENSATOR PRESSURE

WARNING

COMPENSATOR PRESSURE is the pressure at which the main pump will begin to automatically destroke to reduce the risk of damage to the pump, valves, and other components in the circuit.

The compensator pressure setting should be 230235 bar (3335-3410 psi).

Before working under cab; Machine must be parked on level ground.

Cab must be fully tilted with tilt cylinders fully extended, or cab support brace must be installed.

Refer to TILTING THE CAB in SECTION 3 of THIS MANUAL for more information.

1. With hydraulic oil at operating temperature, connect a 0-5000 psi gauge to the PX test port.

If the compensator pressure requires adjustment, use a 17mm wrench to loosen the locknut on compensator pressure adjusting screw (located on main pump controller). Turn the adjusting screw using a 5mm Allen key until the reading on gauge is correct. Turning the adjusting screw IN (Clockwise) will increase compensator pressure, turning the screw OUT (Counterclockwise) will decrease compensator pressure.

5. When the compensator pressure is correct, tighten the locknut on adjusting screw. Repeat above procedure to verify the compensator pressure setting is still correct.

TEST PORTS

1018-D134

PX MAIN PUMP PRESSURE

2. Start the engine and press the pilot reset switch.

MARGIN PRESSURE When a function control is used to activate a function, load sense pressure increases to the point where it is equal to the work port pressure which shifts the load sense control valve in the main pump.

3. Set the working RPM switch in the ON position, and adjust the ENGINE WORKING RPM dial to operate the engine at full throttle.

The pump then adjusts its output volume until the pump output pressure exceeds the load sense pressure by a small amount. This difference is known as MARGIN PRESSURE (Also known as differential pressure Delta P).

COMPENSATOR PRESSURE ADJUSTMENT

EN

G IN

E

MAIN PUMP - PRESSURE COMPENSATOR 1018-D119

4. Set CRANE/OFF/ SNOW BLADE switch to the CRANE ON position and maneuver the crane to a position where it is safe to open and close the grapple several times. The compensator pressure is determined by reading the gauge while operating the grapple close function.

Apply and hold the grapple close function, and read the gauge installed at PX . The correct reading should be 230-235 bar(3335-3410psi).

At this point the load sense control valve shifts back to its previous condition and the swashplate control piston will be balanced with the pump output remaining constant until the pressure at the load sense port changes. This is a dynamic system with the swashplate angle changing constantly in response to the load fluctuations. The load sense pressure is always equal to the highest work port pressure.

NOTE: If the machine controls are not responding as they should, for example functions are jerky or sluggish, the margin pressure setting may be out of adjustment. Refer to SET MARGIN PRESSURE in THIS SECTION.

11.16

Tigercat 1018 Forwarder

Center Joint, Steering, Cab Rotate and Snow Blade

SET MARGIN PRESSURE

5. Set CRANE/OFF/SNOW BLADE switch to the CRANE ON position and maneuver the crane to a position where it is safe to rotate the grapple continuously several times. The margin pressure is determined by reading the gauge while operating the grapple rotate.

MARGIN PRESSURE is the difference between the LOAD SENSE pressure and the PUMP OUTPUT pressure while a function (crane, snow blade, steer or cab rotate) is being operated. For the load sensing system to operate correctly the differential pressure between PX and PL should be 19.5-20.5bar (280-295 psi). PX being higher than PL . **NOTE: If the margin pressure is not set correctly, the machine controls may not respond as they should. Response may seem jerky or sluggish.

MARGIN PRESSURE ADJUTMENT

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

The pressure gauge connections are the PX and PL test ports.

The margin pressure is factory set to 19.5-20.5bar (280-295 psi).

MAIN PUMP - MARGIN PRESSURE (DRIVE PUMP REMOVED FOR CLARITY)

1018-D120

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

WARNING

* If a differential pressure gauge is not available, a single 0-5000 psi gauge may be used; First placing it on the PX test port and noting the reading, then on PL test port and noting the reading. PX should be 19.5-20.5bar (280-295 psi) greater than PL .

DIFFERENTIAL PRESSURE GAUGE PX MAIN PUMP PRESSURE

1018-D147

Before working under cab; Machine must be parked on level ground.

Cab must be fully tilted with tilt cylinders fully extended, or cab support brace must be installed.

Refer to TILTING THE CAB in SECTION 3 or THIS MANUAL for more information.

6. If the margin pressure requires adjustment, use a 13mm wrench to loosen the locknut on margin pressure adjusting screw (located on main pump controller). Turn the adjusting screw using a 6mm Allen key until the differential reading on gauge is 19.5-20.5bar (280-295psi). Turning the adjusting screw IN (Clockwise) will increase margin pressure, turning the screw OUT (Counterclockwise) will decrease margin pressure.

PL LOAD SENSE PRESSURE

If only one 0-5000 psi gauge is being used; It should first be connected to the PL test port and the reading noted, it should then be connected to the PX test port and the margin pressure adjusting screw adjusted until reading on PX is 19.5-20.5bar (280-295 psi)** greater than the PL previously noted reading.

MARGIN PRESSURE

2. With hydraulic oil at operating temperature, connect one side of the differential pressure gauge to the PL test port and the other side of the gauge to the pressure PX test port. Make sure that the HI side of the differential pressure gauge is connected to PX and the LO side to PL .

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

3. Start the engine, press the pilot reset switch.

4. Set the working RPM switch to the on position, and adjust the engine working RPM dial to operate the engine at full throttle.

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

11.17

Tigercat 1018 Forwarder

Center Joint, Steering, Cab Rotate and Snow Blade

STEER VALVE DESCRIPTION

INLET SECTION

The steer valve is located in the front chassis, and is most easily accessed from below the machine.

A SIDE SOLENOID

B SIDE PORT RELIEF

INLET SECTION

SPOOL SECTIONS

1018-I02

END SECTION

B SIDE

1018-D113

VALVE SECTIONS (SINGLE VALVE SECTION SHOWN)

Main Pressure Relief Valve

STEER VALVE

The steer valve is a load sensing and pressure compensated proportional valve and consists of three* spool sections (*Note: the valve includes 2 spool sections if the snow blade option has not been selected). The valve also includes an inlet section and an end section.

INLET SECTION The inlet section is equipped with connection ports to the main pump, tank, load sense signal ( LS ) to the main pump, external pilot filter, and test ports ( PL and PX ). Integrated into the inlet section are the steer valve main pressure relief, a load sense signal copy valve, a pressure reducer for the internal pilot-supply, and a counter pressure valve.

The inlet section of the steer valve houses a 250 bar (3625 psi) direct acting port relief. This pressure relief valve is intended to protect the main pump , steer valve and boom valve from pressure peaks in the system. The cartridge also has a make-up function that allows oil to flow from the tank gallery to the pump gallery in the event of underpressure in the pump circuit. The relief cartridge is not adjustable. Refer to REPLACING MAIN PRESSURE RELIEF VALVE CARTRIDGE in THIS SECTION.

OUTLET (RETURN TO MANIFOLD)

INLET (FROM MAIN PUMP)

PRESSURE RELIEF VALVE

LOAD SIGNAL COPY VALVE

PL TEST PORT (NOT COPIED) PX TEXT PORT (PUMP PRESSURE)

LS TEST PORT (COPIED)

INLET SECTION

11.18

COUNTERPRESSURE VALVE

INTERNAL PILOT SUPPLY (PRESSURE REDUCER)

1018-I03

END SECTION

A SIDE PORT RELIEF

B SIDE SOLENOID

A SIDE

SPOOL SECTION

YS PORT (TO PILOT SYSTEM FILTER)

PS PORT (FROM PILOT SYSTEM FILTER)

Tigercat 1018 Forwarder

Center Joint, Steering, Cab Rotate and Snow Blade

Load sensing system

END SECTION

Shuttle valves installed in each spool section of the steer valve provide the load sense signal from the steer valve or boom valve function sending the highest pressure signal. The load sense signal can be read on the PL test port and is then copied by the load signal copy valve located in the inlet section of the steer valve. The load sense signal will always maintain the same pressure as the originating signal ( PL ) but allows flow to vary. The copied load sense signal is sent from the LS port in the steer valve to the main pump load sense cylinder to provide the load sense signal to the pump. The copied load sense signal can be read at the M test port. The copied load sense signal uses oil from the pump connection, allowing for drainage from the load sense cylinder and providing warmer oil for improved cold weather operating characteristics with faster response.

The end section is equipped with a separate tank connection for the pilot circuit. The main tank gallery in the steer valve and the pilot circuit tank gallery are not connected.

Internal Pilot Pressure Supply The internal pilot pressure supply is a steer valve function that works as both a pressure reducer and a pressure relief valve in the pilot circuit. This cartridge has also been equipped with a separate safety valve that prevents the maximum reduced pressure from being exceeded. A check valve prevents pilot oil from leaking back to the main pump. This allows pilot pressure to be maintained in the event of a decrease in main pump pressure.

Pilot pressure is regulated at 35 bar (510 psi), and is not adjustable.

The steer valve internal pilot pressure supply provides pilot oil for the functions operated by both the steer valve and the boom valve. Oil from the main pump passes through the internal pilot pressure supply cartridge which reduces its pressure to the required pilot pressure. Pilot oil then flows out of the steer valve to the external pilot system filter via YS port and is filtered through the external pilot system filter. Filtered pilot oil flows back into the steer valve or on to the boom valve through the PS ports. The pilot system filter protects the pilot system by ensuring that all pilot oil used by the steer and boom valves is clean. Refer also to BOOM VALVE in SECTION 12.

Counterpressure Valve The counterpressure valve, housed in the inlet section, raises the pressure in the steer valve s tank gallery. Raising the counterpressure reduces the risk of cavitation damage (which decreases the risk of damaging cylinder seals).

SEPARATE TANK CONNECTION FOR PILOT SYSTEM

LS-SIGNAL FROM BOOM VALVE

1018-I04

END SECTION

SPOOL SECTIONS All of the steer valve spool sections are equipped with proportional, electro-hydraulic spool actuators.

The actuators are spring centered to the neutral position, and are shifted by sending a 24 volt proportional current signal (from the PVC Proportional Valve Controller) to the appropriate solenoid. Each section has a pilot restrictor installed in the A and B side to create a ramping effect and result in smooth, gentle function operation. Each spool section is equipped with a pressure compensator. Both the cab rotate and snow blade sections are equipped with a feed reduction valve.

Spools Each of the spools installed in the steer valve is selected specifically for the function it is controlling. The steer section , cab rotate section and snow blade section (optional) spools each have different characteristics specific to their function. These spools cannot be interchanged.

Pressure Compensation The primary purpose of pressure compensation is to maintain a constant flow rate to functions (ie: maintain the same speed of movement), regardless of pressure variations in the system.

The pressure compensator also contains a loadhold check valve. An orfice is installed immediately down stream of the pressure compensator to smoothly regulate the response of the compensator.

11.19

Tigercat 1018 Forwarder

Center Joint, Steering, Cab Rotate and Snow Blade

Feed Reduction Valves

Port Reliefs

Feed reduction valves (also known as P.O.R. Pressure Override valves) are installed in the Cab Rotate and Snow Blade sections of the steer valve. The purpose of the feed reduction is to limit the load sense pressure (from the LS port) that the steer valve sends to the main pump. The proper feed reduction settings for the steer valve are shown below: Proper Feed Reduction Valve Settings in Steer Valve

The steer valve is equipped with port reliefs on each side of all spool sections. The function of the port relief is to protect the steer valve and the function cylinder or motor from pressure peaks in the system. The port reliefs also act as anticavitation valves, which means they allow oil to flow from the tank gallery in the valve to the service ports in the event of underpressure. Port reliefs cannot be adjusted. Port reliefs installed each section are specifically designed for use in that section should not be interchanged with port reliefs from other valve sections . Refer to REPLACING PORT RELIEF in THIS SECTION.

Function

A-Side Setting

B-Side Setting

Steering

No Reduction

No Reduction

Cab Rotate 196-200 bar (2850-2900 psi) 196-200 bar (2850-2900 psi) Snow Blade

No Reduction

No Reduction

1018-x01

Refer to ADJUSTING STEER VALVE FEED REDUCTION VALVE SETTINGS in THIS SECTION. PORT RELIEF B SIDE FEED REDUCTION SIDE B

FEED REDUCTION SIDE A

PORT RELIEF A SIDE

24V PROPORTIONAL ELECTRO-HYDRAULIC SPOOL ACTUATORS

SPOOL PRESSURE COMPENSATOR 1018-31

SPOOL SECTION

11.20

Tigercat 1018 Forwarder

Center Joint, Steering, Cab Rotate and Snow Blade

REPLACING MAIN PRESSURE RELIEF VALVE: NOTE: Be sure to replace the relief cartridge with the appropriate replacement, as indicated in the PARTS CATALOG. 1. Park the machine on level ground, place the crane in the park position, and lower the snow blade to the ground (if equipped). Shut off the engine.

2. Switch the vacuum pump ON (refer to HYDRAULIC OIL VACUUM PUMP in SECTION 2 of the OPERATOR S MANUAL).

OUT (counterclockwise) to decrease the pressure. Once the adjustment has been made, tighten the locknut, and install the cover nut.

7. Operate the same function again, and verify that the pressure being read on PL is correct.

8. Repeat steps 5 7 for the same function in the opposite direction.

REPLACING PORT RELIEFS: NOTE: Be sure to replace port relief cartridges with the appropriate replacement, as indicated in the PARTS CATALOG.

3. Remove the plastic cap from the relief to be changed.

4. Remove the relief cartridge using a ½ Allen key.

B SIDE PORT RELIEF

5. Install the replacement relief cartridge, and tighten to 60 Nm (45ftlb).

A SIDE FEED REDUCTION

6. Install the plastic cap.

B SIDE FEED REDUCTION

7. Switch the vacuum pump OFF.

ADJUSTING STEER VALVE FEED REDUCTION VALVE SETTINGS: 1. Park the machine on level ground, place the crane in a secure position, and lower the snow blade to the ground (if equipped). Shut off the engine.

2. Connect a 0-5000 psi gauge to the PL test port.

3. Ensure that the hydraulic oil is at operating temperature. See HYDRAULIC OIL HEATING PROCEDURE in SECTION 8 of THIS MANUAL. 4. Start the engine (and run at idle). Depress the pilot reset switch.

5. Operate the function in one direction, to its full extent. Continue to hold the function at this position.

6. The reading on the 0-5000 psi gauge installed on PL should be as listed in the chart above.

Release the function. Refer to STEER VALVE - PROPER SPEED REDUCTION VALVE SETTINGS in THIS SECTION. If adjustment is required, locate the feed reduction adjusting screws and remove the cover nut and loosen the locknut using a ½ socket. Then turn the adjusting screw using a 3/16 Allen key. Turn the adjusting screw IN (clockwise) to increase the pressure, or turn it

1018-D099 SPOOL SECTION ADJUSTMENTS 1. Park the machine on level ground, place the crane in the park position, and lower the snow blade to the ground (if equipped). Shut off the engine.

2. Switch the vacuum pump ON (refer to HYDRAULIC OIL VACUUM PUMP in SECTION 2 of the OPERATOR S MANUAL).

3. Remove the plastic cap from the relief to be changed.

4. Remove the retaining cap from the valve body using a 1 1/16 wrench or socket.

5. Remove the existing relief, and install the replacement relief cartridge.

6. Install the retaining cap removed in step 4, and tighten to 60 Nm (45ftlb).

7. Install the plastic cap.

8. Switch the vacuum pump OFF.

11.21

Tigercat 1018 Forwarder

Center Joint, Steering, Cab Rotate and Snow Blade

CAB ROTATE MOTOR

1018-D131

CAB ROTATE MOTOR

The cab rotate function is controlled by the cab rotate pedal which sends electronic signals to the PVC (Proportional Valve Controller). The PVC then forwards the appropriate signal to the cab rotate brake release solenoid (C4) on the auxiliary functions valve, as well as a proportional signal to the cab rotate solenoid on the steer valve. The steer valve will then supply oil from the main pump to the cab rotate motor causing it to rotate. Oil flow is reversed through the motor by the cab rotate section of the steer valve to rotate the cab in the opposite direction.

BRAKE RELEASE PORT

The cab rotate motor is a low speed, high torque motor with a spring activated multiple disk brake.

This brake is normally ON. Inside the motor there are springs acting against the back of a piston which pushes the brake disks against each other.

The PVC sends a signal to energize the cab rotate brake release solenoid (C4). This shifts the spool in the auxiliary functions manifold and allows oil to flow from C4 to the brake release port on the motor. When the oil enters the motor, it is acting against the front of the piston. The force of the oil acting on the piston overcomes the spring force applied to the opposite side of the piston, thus releasing the brake. When the signal is removed, the spool in the valve spring returns to its original position and allows the oil from the rotate motor brake to drain to tank. In the event of a loss of electrical power or hydraulic pressure in the system the cab rotate brake will engage (ON) automatically as a result of the spring force.

DRAIN

OUTPUT SHAFT

BRAKE DISKS

1018-31

SPRINGS

BRAKE PISTON

CAB ROTATE MOTOR

11.22

Tigercat 1018 Forwarder

Center Joint, Steering, Cab Rotate and Snow Blade

CAB ROTATE BEARING RE-ASSEMBLY Cab rotate bearing maintenance is normally limited to proper lubrication, as described in SECTION 3 of THIS MANUAL.

9) Rotate inner race and check backlash every 4 bolt holes (approximately 45o of rotation). The backlash should not be greater 0.010 in any location.

POINT OF MINIMUM BACKLASH

However, if it is neccesary to remove the cab rotate bearing from the mounting plate, the following procedure should be followed for proper re-assembly:

1) Using a hydraulic hand pump, apply approximately 14bar (200psi) hydraulic pressure to port E on the cab rotate motor to release the brake.

3) Measure flatness of swing bearing mounting surfaces using a feeler gauge between the top surface of the mounting plate, and the bottom surface of the bearing. The maximum allowable clearance is 0.013 .

4) With a paint pen, mark the point of largest gap.

5) Loosely install flat washers and bolts to secure the bearing to the mounting plate. Do not tighten.

6) Rotate the inner race of the bearing so that the yellow painted teeth are meshed with the pinion teeth (installed on the cab rotate motor).

This position is known as the point of minimum backlash.

PINION

1018-D135

1018-D136

CHECK BACKLASH EVERY 45°

CHECKING BACKLASH

10. Torque all mounting bolts to 540 Nm (400 lbft).

In pairs, in a star sequence.

11. Recheck gear backlash as described in step 9.

12. Rotate the bearing to the point of minimum backlash (ie: yellow painted teeth are meshing with pinion).

13. Release pressure from port E on rotate motor. The bearing will now be secured (ie: cab rotate brake ON), and is positioned for the cab to be installed facing forward.

14. Install the cab facing forward.

BEARING INNER RACE

FRONT OF MACHINE

2) Position bearing on mounting plate.

MESHING TEETH ARE PAINTED YELLOW

POINT OF MINIMUM BACKLASH

7) Slide the bearing on the mounting plate to a position that leaves 0.001 0.003 total clearance between the meshing gear teeth.

This clearance is known as backlash.

8) Starting at the point of largest gap, tighten eight mounting bolts in pairs located 90o apart to 340 Nm (250 lbft). Check the backlash (at point of minimum backlash) again and readjust to 0.001 - 0.003 if required.

11.23

Tigercat 1018 Forwarder

Center Joint, Steering, Cab Rotate and Snow Blade

11.24

Tigercat 1018 Forwarder SECTION 12 - CRANE, GRAPPLE AND LOAD GATE SEPTEMBER, 2002

CONTENTS - SECTION 12 BOOM VALVE ................................................................................................... 4 ADJUSTING BOOM VALVE FEED REDUCTION VALVE SETTING ............ 7 PROPER FEED REDUCTION VALVE SETTINGS ........................................ 6 REPLACING MAIN PRESSURE RELIEF VALVE CARTRIDGE .................... 7 REPLACING PORT RELIEFS ....................................................................... 7 CIRCUIT DIAGRAM .......................................................................................... 3 CRANE & GRAPPLE ......................................................................................... 2 CRANE, GRAPPLE AND LOAD GATE FUNCTIONS ....................................... 2 ELECTRONIC SYSTEM ................................................................................ 2 HYDRAULIC SYSTEM ................................................................................... 4 ELECTRONIC SYSTEM .................................................................................... 2 GRAPPLE ROTATOR ....................................................................................... 2 HYDRAULIC SYSTEM ...................................................................................... 4 LOAD GATE ...................................................................................................... 8 TO ADJUST RELIEF CARTRIDGES IN GATE VALVE ................................. 8

Tigercat 1018 Forwarder

Crane, Grapple and Load Gate

CRANE, GRAPPLE AND LOAD GATE

rotation of the grapple.

All the crane functions listed below are proportionally controlled electro-hydraulically from a common boom valve assembly located in the rear chassis: CRANE ROTATE (Clockwise/Counterclockwise) MAIN BOOM (Up/Down) STICK BOOM (In/Out) TELESCOPE BOOM (Out/In) GRAPPLE ROTATE (Clockwise/Counterclockwise) GRAPPLE (Close/Open) The term proportional means that the electronic signal sent to the proportional valve from the computer will vary comparably with the input joystick movement. A small movement will operate the function slowly and a large movement will operate the function very rapidly.

For example, if the boom up joystick is moved 60% of the full stroke, the signal sent to the boom valve will be enough to shift the spool for 60% of its full flow, which will result in the boom raising at 60% of its maximum boom up speed . All other boom valve functions operate in a similar manner.

HINGED ACCESS PANEL

HTC

HTC (HYDROSTATIC TRANSMISSION CONTROL) & PVC (PROPORTIONAL VALVE CONTROL) 1018-D116

ELECTRONIC SYSTEM All of the boom valve functions are controlled by the PVC (Proportional Valve Controller). The PVC monitors and analyzes inputs and produces outputs (as defined in its program) to control the machine. The operator may interface with the PVC program using the T220 Display Terminal.

Refer to the following sections in SECTION 2 of the OPERATOR S MANUAL:

CRANE & GRAPPLE

DRIVER MEMORIES

The manufacturer s instruction manuals for the crane and grapple installed on your machine has detailed information about operating, inspecting, and servicing your crane. Refer to the appropriate manuals before commencing any work on these components.

SELECTING AN ACTIVE DRIVER

Grapple Rotator The grapple rotator consists of a motor, combined with a rotary manifold. The rotary manifold built into the rotator allows 360 degree, continuous

PVC

COPYING DRIVER SETTINGS ADJUSTING THE PARAMETERS OF DRIVERS. Inputs: The computer monitors variable signals from the STEERING JOYSTICK and the LEFT and RIGHT MINI JOYSTICKS. The PVC also reacts to digital signals from the CRANE/ OFF/SNOW BLADE switch, the STEER/DRIVE switch, and the CAB ROTATE pedals.

Outputs: The computer directs an output (24 Volt proportional electrical current) to the boom valve solenoids to operate the various functions.

12.2

Tigercat 1018 Forwarder

Crane, Grapple and Load Gate

CIRCUIT DIAGRAM 1018-31

12.3

Tigercat 1018 Forwarder

Crane, Grapple and Load Gate

HYDRAULIC SYSTEM

BOOM VALVE DESCRIPTION

The proportional valve functions depend on a load sense hydraulic system composed of the following major components;

The boom valve is located in the rear chassis. It can easily be accessed by opening the valve box enclosure door on the right side of the frame below the crane swing cylinders.

1.

2.

3.

4.

Main pump Steer Valve Boom Valve Working Components

LOAD SENSING Refer to SECTION 11 in THIS MANUAL for a complete description of the load sense system.

PRESSURE RELIEF VALVE INLET SECTION

A SIDE

1018-D098

B SIDE

SPOOL SECTIONS

END SECTIONS

BOOM VALVE

The boom valve, like the steer valve is a load sensing and pressure compensated proportional valve and consists of six* spool sections (*Note: the number of sections installed in the valve will vary with crane options selected). The valve also includes an inlet section and an end section.

INLET SECTION

SPOOL SECTION

END SECTION

1018-I02

VALVE SECTIONS (SINGLE VALVE SECTION SHOWN)

INLET SECTION The inlet section is equipped with connection ports to the main pump, tank, external pilot filter, a load sense signal ( LSP ) to the steer valve, and the load gate valve. Integrated into the inlet section are the boom valve main pressure relief, a load sense signal copy valve, and a counter pressure valve.

12.4

Tigercat 1018 Forwarder

Crane, Grapple and Load Gate

INLET (FROM MAIN PUMP)

OUTLET (TO RETURN MANIFOLD)

PRESSURE RELIEF VALVE

COUNTERPRESSURE VALVE

LOAD SIGNAL COPY VALVE

PL TEST PORT (NOT COPIED)

INLET SECTION

Pilot pressure supply Pilot pressure supply is regulated by the steer valve, and filtered by the external pilot system filter.

The pilot oil leaves the steer valve via the YS port, is filtered through the pilot system filter, and introduced into the boom valve through the PS port. The pilot filter protects the valve s pilot system by providing cleaner oil compared to the rest of the hydraulic system. Refer to STEER VALVE - INTERAL PILOT PRESSURE SUPPLY in THIS SECTION. Main Pressure Relief Valve The inlet section of the steer valve houses a 250 bar (3625 psi) direct acting port relief. This pressure relief valve is intended to protect the main pump , steer valve and boom valve from pressure peaks in the system. The cartridge also has a make-up function that allows oil to flow from the tank gallery to the pump gallery in the event of underpressure in the pump circuit. The relief cartridge is not adjustable. Refer to REPLACING MAIN PRESSURE RELIEF VALVE CARTRIDGE in THIS SECTION. Load sensing system

PS PORT (FROM PILOT SYSTEM FILTER)

LS TEST PORT (COPIED)

PX TEXT PORT (PUMP PRESSURE) 1018-I03X

the steer valve, where it is compared to the needs of the steer valve functions.

Refer to STEER VALVE - LOAD SENSING SYSTEM in SECTION 11 of THIS MANUAL for a complete description of the load sensing system.

Counterpressure Valve The counterpressure valve, housed in the inlet section, raises the pressure in the steer valve s tank gallery. Raising the counterpressure reduces the risk of cavitation damage (which decreases the risk of damaging cylinder seals).

END SECTION The end section is equipped with a separate tank connection for the pilot circuit. The main tank gallery in the boom valve and the pilot circuit tank gallery are not connected. The TP port is connected to the rear chassis drain manifold.

SEPARATE TANK CONNECTION FOR PILOT SYSTEM

Shuttle valves installed in each spool section of the boom valve provide the load sense signal from the boom valve function sending the highest pressure signal. The load sense signal is then copied by the load signal copy valve located in the inlet section of the boom valve. The load sense signal is sent 1018-I04 from the LS port in the boom valve to LSPB port on 12.5

END SECTION

Tigercat 1018 Forwarder

Crane, Grapple and Load Gate

SPOOL SECTIONS

Feed Reduction Valves

All of the boom valve spool sections are equipped with proportional, electro-hydraulic spool actuators.

The actuators are spring centered to the neutral position, and are shifted by sending a 24 volt proportional current signal (from the PVC Proportional Valve Controller) to the appropriate solenoid. Each section has a pilot restrictor installed in the A and B side to create a ramping effect and result in smooth, gentle function operation. Each spool section is equipped with a pressure compensator. Both the stick boom and telescope boom sections are equipped with a feed reduction valve.

Feed reduction valves (also known as P.O.R. Pressure Override) are installed in the Stick Boom and Telescope Boom sections of the boom valve. The purpose of the feed reduction is to limit the load sense pressure (from the LS port) that the boom valve sends to the steer valve, and ultimately to the main pump. The proper feed reduction settings for the boom valve are shown below:

Spools Each of the spools installed in the boom valve is selected specifically for the function it is controlling. For example, the telescope boom section spool has different characteristics than the stick boom spool. These spools cannot be interchanged Pressure Compensation The primary purpose of pressure compensation is to maintain a constant flow rate to function (ie: maintain the same speed of movement), regardless of pressure variations in the system.

The pressure compensator also contains a loadhold check valve. An orifice is installed immediately down stream of the pressure compensator to smoothly regulate the response of the compensator.

PORT RELIEF B SIDE FEED REDUCTION SIDE B

Proper Feed Reduction Valve Settings in Boom Valve Function

A-Side Setting

B-Side Setting

Crane Rotate

No Reduction

No Reduction

K1

Main Boom

No Reduction

No Reduction

KN1 KN1

Stick Boom

138-142 bar (2000-2060 psi)

No Reduction

Grapple Rotate

No Reduction

No Reduction

K1

Grapple Open/Close

No Reduction

No Reduction

K1

Telescope Boom

58-62 bar (840-900 psi)

No Reduction

K1

1018-x02

Refer to ADJUSTING BOOM VALVE FEED REDUCTION VALVE SETTINGS in THIS SECTION. Port Reliefs The boom valve is equipped with port reliefs on each side of all spool sections. The function of the port relief is to protect the boom valve and the function cylinder or motor from pressure peaks in the system. The port reliefs also act as anticavitation valves, which means they allow oil to flow from the tank gallery in the valve to the service ports in the event of underpressure. Port reliefs cannot be adjusted. Port reliefs installed in

FEED REDUCTION SIDE A

PORT RELIEF A SIDE

24V PROPORTIONAL ELECTRO-HYDRAULIC SPOOL ACTUATORS

SPOOL PRESSURE COMPENSATOR

1018-31

SPOOL SECTION (K1 COMPENSATOR SHOWN) 12.6

Compensator

Tigercat 1018 Forwarder

Crane, Grapple and Load Gate

each section are specifically designed for use in that section should not be interchanged with port reliefs from other valve sections . Refer to REPLACING PORT RELIEF in THIS SECTION.

B SIDE PORT RELIEF

REPLACING MAIN PRESSURE RELIEF VALVE CARTRIDGE

A SIDE FEED REDUCTION

NOTE: Be sure to replace the relief cartridge with the appropriate replacement, as indicated in the PARTS CATALOG.

1. Park the machine on level ground, place the crane in the park position, and lower the snow blade to the ground (if equipped). Shut off the engine.

1018-D099

B SIDE FEED REDUCTION

SPOOL SECTION ADJUSTMENTS

(clockwise) to increase the pressure, or turn it OUT (counterclockwise) to decrease the pressure. Once the adjustment has been made, tighten the locknut, and install the cover nut.

2. Switch the vacuum pump ON (refer to HYDRAULIC OIL VACUUM PUMP in SECTION 2 of the OPERATOR S MANUAL).

3. Remove the plastic cap from the relief to be changed.

7. Operate the same function again, and verify that the pressure being read on PL is correct.

4. Remove the relief cartridge using a ½ Allen key.

8. Repeat steps 5 7 for the same function in the opposite direction.

5. Install the replacement relief cartridge, and tighten to 60 Nm (45ftlb).

REPLACING PORT RELIEFS:

6. Install the plastic cap.

NOTE: Be sure to replace port relief cartridges with the appropriate replacement, as indicated in the PARTS CATALOG.

7. Switch the vacuum pump OFF. ADJUSTING BOOM VALVE FEED REDUCTION VALVE SETTINGS: 1. Park the machine on level ground, place the crane in a secure position, and lower the snow blade to the ground (if equipped). Shut off the engine.

2. Connect a 0-5000 psi gauge to the PL test port.

1. Park the machine on level ground, place the crane in the park position, and lower the snow blade to the ground (if equipped). Shut off the engine.

2. Switch the vacuum pump ON (refer to HYDRAULIC OIL VACUUM PUMP in SECTION 2 of the OPERATOR S MANUAL).

3. Ensure that the hydraulic oil is at operating temperature. See HYDRAULIC OIL HEATING PROCEDURE in SECTION 8 of THIS MANUAL.

3. Remove the plastic cap from the relief to be changed.

4. Start the engine (and run at idle). Depress the pilot reset switch.

5. Remove the existing relief, and install the replacement relief cartridge.

5. Operate the function in one direction, to its full extent. Continue to hold the function at this position.

6. The reading on the 0-5000 psi gauge installed on PL should be as listed in the chart above.

Release the function.

4. Remove the retaining cap from the valve body using a 1 1/16 wrench or socket.

6. Install the retaining cap removed in step 4, and tighten to 60 Nm (45ftlb).

7. Install the plastic cap.

8. Switch the vacuum pump OFF.

If adjustment is required, locate the feed reduction adjusting screws and remove the cover nut and loosen the locknut using a ½ socket. Then turn the adjusting screw using a 3/16 Allen key. Turn the adjusting screw IN 12.7

Tigercat 1018 Forwarder

Crane, Grapple and Load Gate

LOAD GATE

such that it will not hit the extended load gate.

The load gate can be extended or retracted (IE: moved UP or DOWN) to accommodate various load sizes, and crane movements. The GATE switch installed in the instrument panel is momentary and must be held in either the UP or DOWN position for the gate to move. The switch is wired directly to the solenoids on the gate valve.

A hydraulic cylinder mounted to the stationary base of the load gate acts on the extension when an electrical signal is sent to a solenoid on the gate valve. The gate valve is supplied with hydraulic oil from the PX port on the boom valve. The oil returned to the gate valve from the load gate cylinder is directed to the rear chassis drain manifold.

The gate valve also contains two relief cartridges.

One of these cartridges controls the pressure made available to the cylinder for extension. The other controls the pressure available for the cylinder to retract.

C2

P

T

SOLENOIDS

1018-D133

C1

RETRACT RELIEF VALVE

6. Operate the GATE UP function, to its full extent. Continue to hold the function at this position.

7. The reading on the 0-5000 psi gauge installed in step 3 should be 31-38 bar (450-550 psi).

Release the function.

If adjustment is required, locate the extend relief valve (bottom) adjusting screws and loosen the locknut using a 3/4 wrench. Then turn the adjusting screw using a 3/16 Allen key. Turn the adjusting screw IN (clockwise) to increase the pressure, or turn it OUT (counterclockwise) to decrease the pressure.

Once the adjustment has been made, tighten the locknut.

9. Operate the GATE UP function again, and verify that the pressure being read is correct.

10. Stop engine.

11. Disconnect the 0-5000 psi gauge from the C1 port on the gate valve and reconnect hoses, then install the same gauge on the C2 port using a 6ORS tee.

12. Ensure that the hydraulic oil is at operating temperature. See HYDRAULIC OIL HEATING PROCEDURE in SECTION 8 of THIS MANUAL. 13. Start the engine (and run at idle). Depress the pilot reset switch.

EXTEND RELIEF VALVE

14. Operate the GATE DOWN function, to its full extent. Continue to hold the function at this position.

GATE VALVE

15. The reading on the 0-5000 psi gauge installed in step 8 should be 69-83 bar (1000-1200 psi).

Release the function.

TO ADJUST RELIEF CARTRIDGES IN GATE VALVE 1. Park the machine on level ground, place the crane in a secure position, and lower the snow blade to the ground (if equipped). Shut off the engine.

2. Remove the cover behind the boom valve compartment on the rear frame to expose the gate valve.

3. Connect a 0-5000 psi gauge to the C1 port on the gate valve using a 6ORS tee.

4. Ensure that the hydraulic oil is at operating temperature. See HYDRAULIC OIL HEATING PROCEDURE in SECTION 8 of THIS MANUAL. 5. Start the engine (and run at idle). Depress the pilot reset switch. Place the crane in a position 12.8

If adjustment is required, locate the retract relief valve (top) adjusting screws and loosen the locknut using a 3/4 wrench. Then turn the adjusting screw using a 3/16 Allen key. Turn the adjusting screw IN (clockwise) to increase the pressure, or turn it OUT (counterclockwise) to decrease the pressure. Once the adjustment has been made, tighten the locknut.

16. Operate the GATE DOWN function again, and verify that the pressure being read is correct.

17. Stop engine.

18. Disconnect the 0-5000 psi gauge from the C2 port on the gate valve, and reconnect hoses.

19. Install the gate valve cover removed in step 2.

Tigercat 1018 Forwarder SECTION 13 - CAB & HOOD TILT SEPTEMBER, 2002

CONTENTS - SECTION 13 CAB TILT PUMP PRESSURE RELIEF VALVE ADJUSTMENT ........................ 4 CIRCUIT DESCRIPTION .................................................................................. 2 CIRCUIT DIAGRAM .......................................................................................... 3 COUNTER BALANCE VALVE ADJUSTMENT .................................................. 5 HYDRAULIC OIL LEVEL ................................................................................... 2

Tigercat 1018 Forwarder

Cab & Hood Tilt

CAB & HOOD TILT SYSTEM VENT PLUG FILL LOCATION

CONTROL VALVE MANIFOLD

1018-D078

POWER HARNESS FROM FUSE BOX

POWER HARNESS TO CAB TILT PUMP

CAB TILT RESERVOIR

24V RELAY

CAB TILT MOTOR

CAB TILT PUMP

CAB TILT RELAY

1018-D132

FRONT RH STEP BOX

(raising and lowering) which maintains precise control of the hood tilting action as the hood passes over-center. Similarly, the cab tilt valve section uses a remote mounted counterbalance valve manifold to maintain precise control when raising and lowering the cab. The cab tilt counterbalance valve manifold is mounted between the cab tilt cylinders on the inside of the front frame.

The cab and hood tilt system is an independent hydraulic circuit operated using the hood tilt and cab tilt controls located inside the left side hydraulic tank access door. Refer to RAISING ENGINE HOOD and TILTING THE CAB in SECTION 3 of THIS MANUAL for complete operating and safety instructions.

The hydraulic oil level in the cab tilt reservoir should be checked regularly. The level in the reservoir should be checked with both the hood and the cab in the lowered position. The level should be approximately ½ from the top of the reservoir. Refer to APPROVED HYDRAULIC OILS in SECTION 3 of THIS MANUAL.

A pressure relief valve is installed in the cab tilt pump to protect the system from high pressure surges.

HOOD TILT COUNTERBALANCE VALVE

CIRCUIT DESCRIPTION

HOOD TILT SOLENOID VALVE

The cab and hood tilt circuit is independent of other hydraulic systems installed on the machine and has its own reservoir . The cab and hood tilt pump will remain operational in the event of contamination or failure of any of the machine s other hydraulic systems.

CAB TILT SOLENOID VALVE

The cab and hood tilt circuit is powered by a 24V electric motor which drives the gear type pump that supplies oil to the directional control valves. The power for the cab tilt motor is drawn from the batteries, through the master disconnect switch.

An 80A fuse is contained in the engine compartment fuse box to protect the system.

1018-D111

13.2

CONTROL VALVE MANIFOLD CAB TILT COUNTERBALANCE VALVE

A 24V relay installed in the circuit supplies power to the electric motor only when a button is pressed on the cab tilt control or the hood tilt control. This relay is located in the battery box.

The cab tilt and hood tilt control valves, equipped with 24 volt electric solenoids, direct oil flow to the cylinders. Should the need arise, the spools can be shifted manually. The hood tilt valve section includes a counterbalance valve for each direction

1018-D109

CAB TILT COUNTERBALANCE VALVE

Tigercat 1018 Forwarder

1018-34

Cab & Hood Tilt

HOOD AND CAB TILT CIRCUIT 13.3

Tigercat 1018 Forwarder

Cab & Hood Tilt

CAB TILT PUMP PRESSURE RELIEF VALVE ADJUSTMENT 1. Park the machine on level ground, place the crane in the park position, and lower the snow blade (if equipped) to the ground . Shut off the engine.

2. Locate the cab tilt pump inside the right front step.

3. Connect a 0-5000 psi gauge to the P port on the cab tilt pump using a 6ORS tee.

P PORT

7. Disconnect the 0-5000 psi gauge from the P port on the gate valve and reconnect hoses.

CAB TILT PUMP

RELIEF VALVE ADJUSTING SCREW

1018-D110

CAB TILT PUMP RELIEF

WARNING Before tilting the cab, ensure that the machine is parked on level ground with the cab facing forward. Lower the snow blade (if equipped) and place the crane in the park position. Turn the ignition switch off.

4. Operate any one of the cab or hood tilt function to its fullest extent. Continue to hold the function in this position. Refer to TILTING THE CAB and RAISING ENGINE HOOD in SECTION 3 of THIS MANUAL for complete operating instructions.

1018-D083

If adjustment is required, locate the relief valve adjusting screw and loosen the locknut using a 9/16 wrench. Then turn the adjusting screw using a 3/16 Allen key. Turning the adjusting screw IN (clockwise) increases the pressure.

Turning the adjusting screw OUT (counterclockwise) decreases the pressure.

Once the adjustment has been made, tighten the locknut.

6. Operate the function again, and verify that the pressure being read is correct.

5. The P port pressure reading should be 205-208 bar (2975-3025 psi). Release the function.

CAB TILT CONTROL

CAB TILT CONTROL

13.4

Tigercat 1018 Forwarder

Cab & Hood Tilt

COUNTER BALANCE VALVE ADJUSTMENT

HOOD TILT COUNTERBALANCE VALVE

The following procedure is used to adjust both the hood tilt and cab tilt counterbalance valves.

1. Locate the counterbalance valve which requires adjustment.

RAISE HOOD

HOOD TILT SOLENOID VALVE

2. Loosen the locknut on the counter balance valve adjusting screw using a 9/16 wrench.

3. Turn the adjusting screw using a 5/32 Allen key. Turning the adjusting screw IN (clockwise) reduces the counterbalance effect.

Turning the adjusting screw OUT (counterclockwise) increases the counterbalance effect. Once the adjustment has been made, tighten the locknut.

4. Operate the function again and verify that the counterbalance is now satisfactory.

LOWER HOOD

HOOD TILT COUNTERBALANCE VALVE

1018-D111

CAB TILT COUNTERBALANCE VALVE

CAB RAISE

CAB LOWER

1018-D109

13.5

CAB TILT COUNTERBALANCE VALVE

Tigercat 1018 Forwarder

Cab & Hood Tilt

13.6