Tigercat 1045 1055 FORWARDER SERVICE MANUAL - PDF DOWNLOAD

SERVICE MANUAL Tigercat 1045/1055 FORWARDER Issue 1.0, AUGUST, 2006 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, GATE AND SNOW BLADE ............................................. 11 CRANE, GRAPPLE AND MAIN PUMP ........................................................................... 12

1045/1055-SM00

1045/1055 Available Literature Operator's Manual (10550101 to 10550200) ........................................................ Part No. 25900A Operator's Manual (10450101 and 10550201 and up) ......................................... Part No. 29767A Service Manual (10550101 to 10550200) ............................................................. Part No. 25901A Service Manual (10450101 and 10550201 and up) (This Manual) ...................... Part No. 29768A Parts Catalog ......................................................................................................... Part No. 25902A

Tigercat

®

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

ii

Tigercat 1045/1055 Forwarder Tigercat 1045/1055 FORWARDER

Introduction

INTRODUCTION An Operator's manual, Service manual and a Parts catalog are made available by Tigercat to assist the dealer, customer and operator in becoming familiar with the features of the 1045/1055 Forwarder.

Serial numbers:10450101 and up.

10550201 and up.

The operator's manual will assist the operator with the techniques of proper and safe operation of the Forwarder. There is also important information regarding the safe operation of optional equipment and attachments. The service manual contains safety and servicing procedures and a preventive maintenance schedule to ensure optimum machine performance.

Section 1 in both the operator's manual and the service manual contains safety information that must be followed. As well, throughout the rest of the manuals, WARNING and CAUTION notices are displayed where necessary, drawing attention to possible hazards when performing certain procedures.

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

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

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

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

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

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

Tigercat Industries Inc.

1055-028

iii

Tigercat 1045/1055 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 1045/1055 Forwarder SECTION 1 - SAFETY AUGUST, 2006

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 ................................................................................ 1.12 BATTERY DISCONNECT SWITCH ............................................................... 1.7 CAB TILT SUPPORT ................................................................................... 1.10 COOLING SYSTEM ....................................................................................... 1.9 ENGINE HOOD ............................................................................................ 1.11 EXHAUST FUMES ....................................................................................... 1.12 FIRE PREVENTION ..................................................................................... 1.13 FIRE PREVENTION GUIDELINES ........................................................... 1.13 WHAT ELSE TO DO BEFORE YOU EXPERIENCE A FIRE .................... 1.14 WHAT TO DO AFTER A FIRE ................................................................. 1.15 WHAT TO DO IN CASE OF A MACHINE FIRE ........................................ 1.14 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, 1.13 SAFETY SYMBOLS ....................................................................................... 1.2 SIGNAL WORDS ........................................................................................... 1.2

Tigercat 1045/1055 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.

1.2

Tigercat 1045/1055 Forwarder

Safety

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

Follow all instructions from safety inspector and supervisors.

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

Do not let an untrained person operate the machine.

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

Prolonged exposure to loud noise can cause permanent hearing loss.

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 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 their respective message. Keep safety labels in good condition.

Repair or replace damaged labels.

1.3

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.

Tigercat 1045/1055 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.

1.4

Tigercat 1045/1055 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 1045/1055 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.

• BRAKE

STEERING

••

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

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

1014-D153

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.

1.6

Tigercat 1045/1055 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.

ENGINE HOOD

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

BATTERY DISCONNECT SWITCH

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.

••

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.

•• 1055-009

•

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

CAUTION Do not open cab doors or window screens (if equipped) when machine is on a slope.

The doors and screens are heavy and could swing out with considerable force.

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

1.7

Tigercat 1045/1055 Forwarder

Safety

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

•• SWITCH

Check for correct tire air pressure (refer to tire manufacturers specifications 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.

1014-D002

INTERLOCK SWITCH (L.H. DOOR SHOWN)

SAFETY INTERLOCK SWITCHES ON DOORS:

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.

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.

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:

CAUTION

Close both doors, start the engine and press the PILOT RESET switch to activate the MDM computer. Press the PILOT RESET switch again to enable operation of machine functions.

NOTE: The PILOT RESET only needs to be reset twice at engine start-up. Only once is needed after the MDM computer has been turned on.

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.

1.8

Tigercat 1045/1055 Forwarder

Safety

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.

Never use bare hand to check for fluid leaks.

When servicing or repairing equipment, shut the engine down, and disconnect the positive (+) battery cable from both batteries.

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.

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

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.

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

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

Prior to welding on any part of the machine, it should be cleaned and a fire extinguisher should be made available at the welding location. Care must be taken in attaching the welding machine grounding clamp so current does not pass through bearings, especially the center joint bearings. Also, turn off the battery disconnect switch and disconnect the engine computer plug from the computer module on the engine and the engine ground connection from the chassis.

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

1.9

Tigercat 1045/1055 Forwarder

Safety

SERVICING SAFETY PRECAUTIONS continued

WARNING CLOSE cab doors before tilting cab. The doors are heavy and will swing out or closed with considerable force.

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.

SUPPORT LINK IN FULL TILT POSITION.

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.

••

CAB TILT SUPPORT LINK

1075-002

Before working under cab, machine must be parked on level ground. Cab must be fully tilted to the end of the slot in the link, to prevent injury.

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

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.

PARTIAL TILT SUPPORT SLOT

SUPPORT BOLT

• ••

••

SUPPORT LINK IN PARTIAL TILT POSITION.

LONG TERM SUPPORT (HOLE)

1075-003

CAB TILT SUPPORT LINK IN PARTIAL TILT POSITION

NOTE: If partial tilt is required for an operator assistant to be in cab while service work is performed under cab, the cab can be lowerd to the partial tilt positon in the support link.

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.

When using the support link for partial tilt, the support bracket bolt must be bottomed in the partial tilt slot position of the support link.

NOTE: If the cab is to be tilted for an extended period (pump replacement etc.) the cab support bracket bolt can be removed and the cab and support link repositoned, then place the support bolt in the hole at the end of the support link.

This positon is not applicable for six wheel machines, in this position the cab will hit on the tire.

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

1.10

Tigercat 1045/1055 Forwarder

Safety

SERVICING SAFETY PRECAUTIONS continued

WARNING

OPENING ENGINE HOOD

ENGINE HOOD LATCH

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

•

•

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

•

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

•

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

OPENING ENGINE HOOD

1055-008

TO OPEN: Release the over center latch on left side of the engine hood. Pull down on latch handle, lift latch ring off retainer lug on frame.

PULL ON HANDLE

••

PULL HOOD OPEN

ILLY-D012

Locate handle on side of engine hood. Pull on handle and tip engine hood forward to open hood.

SPRING LOCK ENGAGED

•• SPRING LOCK

• LATCH UP

LATCH

•• 1075-035

••

HOOD LATCHED OPEN

A latch on the left side (inside) of hood prevents the hood from closing.

Release the hood latch by partially lifting the hood then pull up on the latch to lock it with the spring lock (see inset picture), then reverse the above procedure to close engine hood.

1.11

Tigercat 1045/1055 Forwarder

Safety

SERVICING SAFETY PRECAUTIONS continued

RETAINING PIN

ARTICULATION LOCK BAR

•• •• 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 1055-003

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.

• ARTICULATION LOCK BAR

1055-002

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.

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

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

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 (if equipped) 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.

1.12

Tigercat 1045/1055 Forwarder

Safety 5. Remove debris and blow out dust regularly from the air intake doors, engine radiator, hydraulic oil cooler and A/C condenser core to prevent overheating of the engine and hydraulics. Refer to CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR in SECTION 2 of the OPERATOR’S MANUAL.

FIRE PREVENTION

6. Blow off all debris and dust accumulated near hot engine exhaust components (turbocharger and exhaust manifold as well as exhaust pipes and muffler) at the completion of each work shift or more frequently depending on logging conditions. Visual inspection after blow off to ensure thorough cleanliness is vital. Engine exhaust systems provide numerous small pockets where saw dust, small wood chips and other flammable forest debris can gather. Even small accumulations close to hot exhaust components can ignite and smolder. If dislodged by vibration this smoldering debris can fall into other areas of the machine and thereby spread a fire.

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

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

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

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

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

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

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

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

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

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

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

1.13

Tigercat 1045/1055 Forwarder

Safety

FIRE PREVENTION continued

•

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.

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

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

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

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

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

*NOTE: Dry chemical fire suppression 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.

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

WHAT TO DO IN CASE OF A MACHINE FIRE •

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

•

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

•

Shut the engine off.

•

Activate the fire suppression system

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

•

Radio or call for help (as appropriate).

•

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

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

•

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

•

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

•

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

•

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

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

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

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

WHAT ELSE TO DO BEFORE YOU EXPERIENCE A FIRE •

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

•

Ensure that your fire suppression system is charged and functional.

•

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

*

1.14

*

Tigercat 1045/1055 Forwarder

Safety

FIRE PREVENTION continued •

•

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

•

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

Use the PASS method with most extinguishers.

•

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

•

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

•

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

•

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

WHAT TO DO AFTER A FIRE •

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

•

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

•

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

•

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

*

*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.

20229A

TYPICAL FIRE EXTINGUISHER ACCESS HOLE

•

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

•

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

•

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

1.15

Tigercat 1045/1055 Forwarder

Safety

1.16

Tigercat 1045/1055 Forwarder Tigercat 1045/1055 Forwarder

Lubrication and Maintenance

SECTION 3 - LUBRICATION & MAINTENANCE AUGUST, 2006

Read and understand the entire manual including Safety section prior to operating any equipment.

Read and understand all manuals for any attachments or accessories.

CONTENTS - SECTION 3 AIR CLEANER CHANGING FILTER ELEMENTS ................................................................... 3.17 MAINTENANCE .............................................................................................. 3.16 SERVICING ..................................................................................................... 3.17 UNLOADER VALVE ........................................................................................ 3.16 AIR CONDITIONING ........................................................................................... 3.18 ARTICULATION JOINT ....................................................................................... 3.15 AXLE LUBRICATION .......................................................................................... 3.25 BELT - ENGINE SERPENTINE .......................................................................... 3.26 CAB LOWERING THE CAB .................................................................................... 3.21 RAISING THE CAB ......................................................................................... 3.20 CAB AIR FILTERS FRESH AIR ..................................................................................................... 3.19 RECIRCULATING AIR - A/C UNIT .................................................................. 3.19 CENTRE JOINT ........................................................................................ 3.14, 3.15 CHARGE PRESSURE FILTER-DRIVE PUMP ................................................... 3.13 CONTROL POD ON ARMREST, R.H. CRANE, ROTATOR AND GRAPPLE MAINTENANCE ....................................... 3.27 DRAINING AND REFILLING BOGIE HOUSING ................................................. 3.26 DRAINING AND REFILLING DIFFERENTIAL .................................................... 3.25 ENGINE HOOD ................................................................................................... 3.22 ENGINE SERPENTINE BELT ............................................................................. 3.26 FILTERS CHARGE PRESSURE .................................................................................... 3.13 FUEL FILTER/WATER SEPARATOR ............................................................. 3.10 HYDRAULIC OIL ............................................................................................. 3.12 REMOVE AND REPLACE ............................................................................... 3.10 RETURN OIL STRAINER ................................................................................ 3.14 SERVICING GUIDELINES FOR OIL FILTERS ............................................... 3.13 FIRE PREVENTION .............................................................................................. 3.4 FUEL TANK STRAINER ..................................................................................... 3.11 GENERAL ............................................................................................................. 3.4 HOT WATER SHUT OFF VALVE ....................................................................... 3.18 HYDRAULIC OILS ................................................................................................ 3.7 INITIAL PRE-DELIVERY INSPECTION ................................................................ 3.3 LINK SNUBBER MAINTENANCE ....................................................................... 3.27 MACHINE STARTUP .......................................................................................... 3.24 NEW MACHINE MAINTENANCE ......................................................................... 3.3 OSCILLATION JOINT ......................................................................................... 3.15 PREVENTIVE MAINTENANCE SCHEDULE ........................................................ 3.3 continued...

3.1

Tigercat 1045/1055 Forwarder

Lubrication and Maintenance

SECTION 3 - LUBRICATION & MAINTENANCE REAR (BOGIE) AXLE PLANETARY DRIVES (4 FILLING POINTS) ................................................... 3.25 SCHEDULED MAINTENANCE 1000 HOURS .................................................................................................... 3.6 125 HOURS ...................................................................................................... 3.5 250 HOURS ...................................................................................................... 3.6 500 HOURS ...................................................................................................... 3.6 8 HOURS .......................................................................................................... 3.5 SEASONAL ....................................................................................................... 3.6 SERVICE AND LUBRICATION POINTS .............................................................. 3.9 SLEW BEARING LUBRICATION ........................................................................ 3.14 SNUBBER TENSION ADJUSTING ..................................................................... 3.27 STARTUP PROCEDURE AFTER MAJOR MACHINE MAINTENANCE ............. 3.23 TEMPERATURE CONTROL - CAB HEATER/AC ............................................... 3.19 TILTING THE CAB .............................................................................................. 3.20 TORQUE CHART ................................................................................................ 3.28 TORQUE, FLUID CONNECTIONS ................................................. 3.30, 3.31, 3.32 TORQUE SPECIFICATIONS - GENERAL .......................................................... 3.29 UNLOADER VALVE ............................................................................................ 3.16

3.2

Tigercat 1045/1055 Forwarder

Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE FOR 1045/1055 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.

TIGHTENING POINTS FOR:-

IMPORTANT!

THE FIRST 50-100 HOUR INSPECTION REPORT:~

__________________________________________

All hydraulic connections Hose clamps Center joint pin securing bolts Transmission securing bolts Engine mounting bolts Pump securing bolts Axle mounting bolts 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.

WHEELS: 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. __________________________________________

HOUR METER ~ MAINTENANCE: Check the hour meter (on the MDM 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.

*OIL LOST FROM LEAKAGE

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

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

_______________________________________________________________________________________

3.3

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

Tigercat 1045/1055 Forwarder

Lubrication and Maintenance

GENERAL Clean away all branches, bark and chips.

Clean up all traces of oil to avoid fires

CAUTION All handles, steps and platforms must be kept free of grease, oil, fuel, mud, snow and ice

Always have a fire extinguisher at hand and know how to use it 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 blade (if equipped). Turn the ignition switch off. Turn the battery disconnect switch off.

Clean around filler caps before checking or adding fluids.

Release hydraulic pressure and clean around hydraulic fittings before breaking connection.

Plug or cap immediately.

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

Clean up ALL spills immediately.

Always use clean oil and containers.

Drain dirty oil while still warm.

_______________________________________________________________________________________

Do not exceed recommended fluid levels.

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

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.

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

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

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

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

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

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

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

3. If equipped, read the fire suppression system manual and have the system serviced regularly by qualified personnel.

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

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

Before welding on machine be sure master switch is disconnected and disconnect multi pin connectors on engine CPU and engine wiring harness.

When welding, secure ground connection as close to working position as possible to prevent arcing across machined surfaces or through bearings 3.4

Tigercat 1045/1055 Forwarder

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 8 HOURS (EVERY SHIFT):~

EVERY 125 HOURS:~

• • • • • • • •

• Perform 8 hour maintenance

Check engine coolant level Check engine oil level Drain fuel/water separator Check air cleaner unloader valve Check engine air filter restriction indicator Check hydraulic oil level in hydraulic tank Check transmission oil level with dipstick Lubricate mid drive shaft 1-fitting, purge Note: Lubrication of mid drive shaft slip joint should be done with machine fully articulated.

• Lubricate fixed center joint drive shaft, 1-fittings, purge • Lubricate rear drive shaft bearing, 2-fittings, purge • Lubricate center joint articulation bearings, 2-fittings, purge • Lubricate center joint oscillation bearings, 2-fittings, purge • Lubricate center joint oscillation lock cylinder ends, 4-fittings, purge • Lubricate steering cylinder ends, 4-fittings, purge • Lubricate ladder pivots (if equipped), 1-fitting, purge • Lubricate snow blade cylinders and pivots (if equipped), 6-fittings, purge • Lubricate and adjust link snubber, 4-fittings, purge Clean:~ • Potentially damaging limbs or sticks from machine • 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. 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 belt.

• Exhaust system for leaks.

• Conduct an overall visual inspection.

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

And in addition:~ • Lubricate axles – shaft bearings, 1-fitting; 8places, purge • Lubricate front drive shaft, 1-fitting, purge • Lubricate rear drive shaft, 1-fitting, purge • Lubricate ladder pivots (if equipped), 1-fitting, purge Check:~ • Check fuel tank filler screen • Fluid level in batteries unless maintenance free • Engine rpm • All hydraulic pressures • Hydraulic pump and motor securing bolts • Torque tightening points as per new machine maintenance Visually check for damage to:~ • Bunks and load gate • Front and rear frame • Center joint area • Crane, link, rotator, and grapple Make repairs immediately Visually inspect for:~ • Frayed electrical wiring and hydraulic hose • Wear in any other components Clean/replace:~ • Air conditioner re-circulation filter • Cab fresh air filter • Refer to diesel engine service manual and attachment manual for additional required maintenance at this scheduled time period. ______________________________________________

3.5

Tigercat 1045/1055 Forwarder

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 250 HOURS:~

EVERY 1000 HOURS:~

• Perform 8 hour maintenance

• Perform 8 hour maintenance

• Perform 125 hour maintenance

• Perform 125 hour maintenance

And in addition:~

• Perform 250 hour maintenance

• Replace engine oil and change oil filter

• Perform 500 hour maintenance

• Replace engine fuel filter

And in addition:~

• Replace fuel/water separator

• Replace air cleaner unloader valve

• Replace air intake primary element

• Drain and refill front and rear axle differentials, planetaries and bogie and/or straight axle housings with SAE 90/API-GL-5 gear oil.

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

• Replace oil in transmission • Check oil level in bogie axle differentials, 2-places • Check oil level in bogie axle housings, 4-places • Check oil level in planetary axles, 8-places

• Lubricate axle slew bearings, 2-fittings; 4places, purge. See SLEW BEARING LUBRICATION procedure in this section.

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

• 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.

______________________________________________

SEASONAL:~

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

• 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.

EVERY 500 HOURS:~ • Perform 8 hour maintenance • Perform 125 hour maintenance

______________________________________________

• Perform 250 hour maintenance And in addition:~ • Replace air intake safety element • Replace all hydraulic oil double element filters (4 elements) † 3 white, high performance element.

1 blue, water absorbing element.

• Replace charge pressure filter † • Refer to diesel engine service manual and attachment manual for additional required maintenance at this scheduled time period. † Use of hydraulic oil filters other than the Tigercat brand could lead to severe wear and rapid failure of hydraulic system components. ______________________________________________ 3.6

Tigercat 1045/1055 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. ®

Tigercat

HYDRAULIC OIL OPERATING RANGE (Not suitable for axle applications)

OPERATING TEMP. RANGE LOWEST START-UP TEMP.

HYDRAULIC OIL TEMPERATURE -40

OIL TYPE

-40

-30 -20

-20 0

-10

0 20

10 40

20 60

30 80

40

50

60

70

100

120

140

160

80 180

90 200

100

˚C 220˚F

CITGO MYSTICK HVI 32 MYSTICK HVI 46 MYSTICK HVI 68 CHEVRON RYKON PREMIUM 32 RYKON PREMIUM 46 RYKON PREMIUM 68 ESSO / EXXON UNIVIS N22 UNIVIS N32 UNIVIS N46 UNIVIS N68 IRVING OIL HYDRAULIC LP 22 HYDRAULIC LP 32 HYDRAULIC LP 46 HYDRAULIC LP 68 MOBIL MOBIL DTE 12M (ISO 22) MOBIL DTE 13M (ISO 32) MOBIL DTE 15M (ISO 46) MOBIL DTE 16M (ISO 68) PETRO-CANADA HYDREX MV 22 HYDREX MV 36 HYDREX MV 60 SHELL TELLUS T22 TELLUS T32 TELLUS T46 TELLUS T68 TEXACO RANDO HDZ 22 RANDO HDZ 32 RANDO HDZ 46 RANDO HDZ 68

CAUTION

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

5168AR03

3.7

Tigercat 1045/1055 Forwarder

Lubrication and Maintenance

31930BR2.AI

3.8

Tigercat 1045/1055 Forwarder

Lubrication and Maintenance Tigercat® Mode l 1045/1055

1

COOLING SY STEM

CHK

2

ENGINE OIL/FILTER

CHK

3 4 5 6

FUEL FILTER (ENGINE) FUEL/WA TER SEPA RA TOR FUEL TA NK FILLER SCREEN A IR INTA KE A IR INTA KE PRIMA RY ELEMENT A IR INTA KE SA FETY ELEMENT A IR CLEA NER UNLOA DER V A LV E

7 8 9

10

11 12 13 14 15 16 17 18

19

20

21 22 23 24 25

HY DRA ULIC OIL RESERV OIR (LEV EL INDICA TOR ON TA NK) HY DRA ULIC FILTER, FULL FLOW, INCLUDES: 1 BLUE WA TER A BSORBING ELEMENT* 3 WHITE HIGH PERFORMA NCE ELEMENTS CHA RGE PRESSURE FILTER (DRIV E PUMP) 1045 TRA NSMISSION 1055 TRA NSMISSION 1045 A XLE - DIFF (IF EQUIPPED) 1055 A XLE - DIFF (IF EQUIPPED) 1045 A XLE - PLA NETA RIES (IF EQUIPPED) 1055 A XLE - PLA NETA RIES (IF EQUIPPED) 1045 BOGIES - DIFF 1055 BOGIES - DIFF 1045 BOGIES - A RM HOUSINGS 1055 BOGIES - A RM HOUSINGS 1045 BOGIES - PLA NETA RIES 1055 BOGIES - PLA NETA RIES BOGIES - SLEW BEA RINGS

CHA NGE COOLA NT EV ERY 2 Y EA RS REP

26.5

7

29

7.6

REP REP

DRN CHK

REP REP REP

CHK

120

CHK CHK

LUB ***

DRIV E SHA FT, CENTER JOINT DRIV E SHA FT, FRONT SHA FT DRIV E SHA FT, REA R SHA FT DRIV ESHA FT REA R BEA RING CENTER JOINT A RTICULA TION CENTER JOINT OSCILLA TION CENTER JOINT OSCILLA TION LOCK CY LINDER ENDS CENTER JOINT BEA RING PRELOA D STEERING CY LINDERS SNOW BLA DE CY LINDER & PIV OTS (IF EQUIPPED) LA DDER PIV OT (IF EQUIPPED) CRA NE/ROTA TOR/GRA PPLE LINK SNUBBER DOOR HINGES

LUB

1

D/R D/R D/R D/R D/R D/R D/R D/R D/R D/R LUB

LUB LUB LUB LUB

LUB LUB

1

REP †

LUB LUB

CHK

32

4

D/R D/R

LUB LUB

SEE ENGINE MA NUFA CTURERS MA INTENA NCE MA NUA L

REP †

CHK CHK CHK CHK CHK CHK CHK CHK CHK CHK

DRIV E SHA FT, MID SHA FT

60% A NTIFREEZE / 40% DISTILLED WA TER

1 1 1 1 1 1 1

CHK

CHK

DESCRIPTION Qty

USG

Liters

500

250

125

8

ITEM

1000

SERVICE POINT NO.

SERV ICE AND LUBRICATION POINTS REFER TO Tige r cat OPERA TOR'S MA NUA L FOR FURTHER INFORMA TION CAPACITY SERV ICE EV ERY

4.5 1.2 5.1 1.3 28 7.4 30 8 4 1 5 1.3 12 3.2 12 3.2 19 5 20 5.3 3.5 1 5 1.3 PURGE

1 1 1 1 2 2 2 2 4 4 8 8 8

PURGE

1

PURGE PURGE PURGE PURGE PURGE PURGE PURGE

1 1 1 1 2 2 6

CLEA N A S REQUIRED CHECK FILTER RESTRICTION INDICA TOR WITH ENGINE RUNNING REFER TO SECTION 3 OF MA NUA L DRA IN A ND REFILL A S REQUIRED BY SEA SONA L OIL CHA NGE (SEE HY DRA ULIC OIL CHA RT) CHECK FILTER RESTRICTION INDICA TOR ON FILTER WITH ENGINE RUNNING A T FULL A ND WITH OIL FLOW

FILL WITH MIL-L-2105 OR A PI-GL-4 OR GL-5 USE SA E 80/90

REFER TO A XLE SERV ICE IN SECTION 3 OF THE OPERA TORS MA NUA L FOR PROCEDURE ~ USE SA E 90/A PI-GL-5

LITHIUM BA SE EP2 GREA SE REFER TO SECTION 3 OF MA NUA L

LITHIUM BA SE EP2 GREA SE

LITHIUM BA SE EP2 GREA SE

REFER TO SECTION 3 OF THE MA NUA L 4 LITHIUM BA SE EP2 GREA SE PURGE 6 LITHIUM BA SE EP2 GREA SE PURGE 1 LITHIUM BA SE EP2 GREA SE PURGE SEE MA NUFA CTURER'S MA INTENA NCE SCHEDULE 4 LITHIUM BA SE EP2 GREA SE PURGE PURGE LUB 19 LITHIUM BA SE EP2 GREA SE

31930BR2.AI SERVICE AND LUBRICATION POINTS

3.9

Tigercat 1045/1055 Forwarder

Lubrication and Maintenance

FILTERS - REMOVE AND REPLACE PRIMER PUMP

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.

FUEL WATER SEPARATOR

•• GASKET WATER SEPARATOR BOWL

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 nonfunctional. For service and replacement intervals refer to SERVICE AND LUBRICATION POINTS in THIS SECTION. PRIMER PUMP

•

FUEL/WATER SEPARATOR

6. Remove and discard the gasket from the filter head.

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.

•• BOWL DRAIN

•

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

• 1014-D072

1014-D073

• ••

8. Clean the water sediment bowl, seating area for the gaskets on the filter head and the sediment bowl and close bowl drain.

FUEL WATER SEPARATOR

WATER SEPARATOR BOWL

BOWL DRAIN

•

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

VENT PLUG

•

GASKET

FUEL/WATER SEPARATOR

11. 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.

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.

12. Use primer pump to refill filter until fuel free of air flows from vent on top of filter head, then tighten vent plug.

13. Start the engine and check for leaks.

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

3. Attach a hose to the spout on the bowl drain and place a suitable drain pan under separator bowl drain hose.

4. Loosen vent plug on filter head, open drain on separator bowl and drain fuel into pan.

5. Remove the water separator filter and bowl from the filter head.

3.10

Tigercat 1045/1055 Forwarder

Lubrication and Maintenance

IMPORTANT

•• •

FILL CAP & TUBE

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.

Tier III engines typically use filters with a very fine micron rating. If the fuel supply is dirty, the fuel filter must be replaced more frequently than recommended in the owner’s manual. Operating the machine with a clogged fuel filter will result in low engine power. It is also recommended that the fuel/water separator bowl be drained daily.

FUEL TANK DRAIN PLUG

•• 1014-D016

FUEL TANK DRAIN PLUG DIPSTICK

• •

When installing a new fuel filter, DO NOT pre-fill with diesel fuel, or engine fuel pump damage will result. This type of failure is not warrantable by the engine manufacturer.

•

To prolong the operating life of the fuel filter, ensure that the fuel supply storage tank is clean and free of water and that the fuel is pre-filtered prior to adding it to the machine.

FILL CAP

•• FILLER SCREEN

FUEL TANK FILL SPOUT

•• ••

FUEL SHUT-OFF TURNED ON (UP)

••

FUEL TANK STRAINER 1014-D064

FUEL TANK COVER

FUEL TANK LOCATION

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.

7. Reinstall the strainer using the hex on end.

Changing or cleaning the strainer:

8. Reinstall fuel tank cover plate with new “O” ring.

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

9. Reinstall drain plug.

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

2. Remove filler cap. Install a suitable container below fuel tank, remove drain plug and drain the fuel tank.

3. Remove the cover from the fuel tank and “O” ring from the access hole.

4. 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.

3.11

Tigercat 1045/1055 Forwarder

Lubrication and Maintenance

HYDRAULIC OIL FILTERS

Changing the filters: 1. Park machine on level ground, install articulation lock bar, lower the 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 CHARGE PUMP FILTER

• FULL FLOW FILTER ELEMENTS

• •• • ••

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

FULL FLOW FILTER ELEMENT

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

1014-D015

HYDRAULIC RESERVOIR AND FILTER LOCATION

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

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 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.

WARNING

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

Discard the square section gasket.

FILTER HEAD

• • 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.

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

•

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

•

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

•

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

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.

3.12

Tigercat 1045/1055 Forwarder

Lubrication and Maintenance

CHARGE PRESSURE FILTER-DRIVE PUMP

HYDRAULIC FILTER SERVICING GUIDELINES

CHARGE PUMP FILTER

IMPORTANT

•

NEVER PRE-FILL ANY HYDRAULIC FILTERS ON FORWARDERS

• HYDRAULIC RESERVOIR

HYDRAULIC RESERVOIR AND FILTER LOCATION 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.

1014-D015

Changing a pressure 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.

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.

3.13

Tigercat generally does not recommend the prefilling of spin-on filters due to the risk of damage to the hydraulic system caused by unfiltered oil.

Unfiltered oil used to pre-fill filters enters directly into the hydraulic circuit. Contaminants in unfiltered oil can cause significant and costly damage to hydraulic valves, pumps and motors.

The cleanliness of hydraulic oil cannot be guaranteed unless it is always prefiltered before use.

IMPORTANT Direct contact with oil implies a risk of skin complaints. Oil on skin should be washed off immediately with soap and water. Refer also to WORKING WITH OIL in SECTION 1 of THIS MANUAL.

Tigercat 1045/1055 Forwarder

Lubrication and Maintenance Clean the area around the grease nipples and outlet plugs (pos. 90/92).

IMPORTANT

Open outlet plug, first the one on side A (pos. 92; covered with white plastic cap).

Contaminated hydraulic fluid can lead to premature failure of hydraulic components and costly repairs. Filters must be replaced at the recommended time intervals, Refer to SCHEDULED MAINTENANCE in THIS SECTION. Use of hydraulic oil filters other than the Tigercat brand could lead to severe wear and rapid failure of hydraulic system components.

BOGIE 3

Fill at both grease nipples per side (pos. 90; covered with white plastic caps) standard grease.

Lubricate with hand grease gun until grease squeezes out with thumb wide from the outlet opening (pos. 92). Then close this outlet hole with plug and cap.

1

• RETURN OIL STRAINER HYDRAULIC RETURN OIL STRAINER 1014-D169

This strainer (1) is located beside the hydraulic pumps in the front chassis. The strainer is provided as a safety device to trap contaminants in the event of a pump failure.

The strainer only requires replacement if it is damaged or a pump failure has occurred.

SLEW BEARING LUBRICATION BOGIE AXLES The slew bearing has a lifetime lubrication in the raceway grease chamber and needs no service.

The only service work is the replacement of soiled grease in pre-chamber (buffer chamber).

BOGIE 2

Then open the opposite outlet plug (also pos. 92 covered with white plastic cap).

Grease with a hand grease gun, at both grease nipples per side, until grease squeezes out thumb wide from the outlet opening (pos. 92). Then close this outlet hole with plug and cap.

When grease squeezes out from the gap, the gap has sealed itself with grease all the way around the circumference. Leave the excess grease built up to protect against dirt.

Cover the grease nipples with plastic caps.

BOGIE 1

3.14

Tigercat 1045/1055 Forwarder

Lubrication and Maintenance

CENTER JOINT

REAR CHASSIS

FRONT CHASSIS

MAINTENANCE OF ARTICULATION JOINT Maintenance in this area is usually limited to:

CENTER JOINT

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 MDM 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.

CHECK FOR MOVEMENT IN THIS JOINT AREA

1055-027

••

CENTER JOINT

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.

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 1045/1055 Forwarder

Lubrication and Maintenance

AIR CLEANER MAINTENANCE SENDING UNIT FOR WARNING ALARM

AIR CLEANER

•

ENGINE AIR INTAKE

••

••

••

UNLOADER VALVE FILTER RESTRICTION INDICATOR

• 1014-D056

ENGINE AIR CLEANER

1075-009

AIR CLEANER 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.

SAFETY ELEMENT PRIMARY ELEMENT

•

• OUTLET TUBE 1018-D068

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.

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.

AIR FILTER ELEMENTS

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

Warning lights in the cab 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 on the engine intake tube side of the filter, this should show green when the engine is running at high RPM. Service is required if the indicator shows red.

1055-048

ENGINE AIR INTAKE HOSES

AIR INTAKE AND EXHAUST HOSES Inspect air intake and exhaust hoses and pipes for leaks wear or loose connections.

3.16

Tigercat 1045/1055 Forwarder

Lubrication and Maintenance

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

IMPORTANT STEPS TO FOLLOW WHEN CHANGING FILTER ELEMENTS

The most common and damaging servicing problems are:

1. Thoroughly clean the air cleaner housing and surrounding area before opening air cleaner.

OVER SERVICING

2. Release the cover latch gently to reduce the amount of dust dislodged.

Filter elements increase in dust cleaning efficiency as dust builds up on the media. Looks can be deceiving. A filter that looks dirty is actually more efficient than one that is clean. A filter with dust build up on the media reaches nearly 100% dust cleaning efficiency. Only when a filter is so clogged with dirt that air restriction goes beyond engine manufacturer’s guidelines, should a filter be replaced.

NOTE: This does not apply to oil filters.

IMPROPER SERVICING

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

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

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

6. 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.

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.

7. Inspect the new filter for damage.

8. Insert the new filter properly. Apply pressure to the outer rim of the filter not the flexible centre.

9. 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.

3.17

Tigercat 1045/1055 Forwarder

Lubrication and Maintenance

CHECKING THE AIR CONDITIONING SYSTEM

COOLER PACKAGE

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 CONDENSER

A/C SYSTEM TOTAL CAPACITIES PAG OIL R134a REFRIGERANT (polyalkylene glycol) 3 LBS. 8 OZ.

•

••

CHARGE AIR COOLER

2 OZ.

•• RADIATOR

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.

••

OIL COOLER

Use this checklist to maintain system between service intervals. a. Check and adjust compressor drive belt tension.

1055-040

COOLER PACKAGE

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

NOTE: Cooler package shown above with engine hood open.

Check the condenser core for dirt and debris.

Clean as required. Refer to CLEANING A/C CONDENSER, AND COOLER PACKAGE in SECTION 2 of this manual.

HOSE TO A/C HEATER UNIT

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.

Check to see that compressor clutch will engage.

IMPORTANT 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

1014-152

HOT WATER SHUT OFF VALVE

HOT WATER SHUT OFF VALVE (ENGINE) 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.

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

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

3.18

Tigercat 1045/1055 Forwarder

Lubrication and Maintenance

CAB AIR FILTERS

FRESH AIR FILTER

CAP SCREWS

•••

•• ••

•

RECIRCULATING AIR FILTER

CAP SCREWS

• • 1014-D196

Remove the four hex head cap screws and remove the cover panel to gain access to the filter in the cab roof.

R.H. SIDE OF CAB FILTER, RECIRCULATING AIR - A/C UNIT 1014-D074

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. It should be cleaned or replaced every 125 hours. This is done by removing two threaded knobs on the front cover and lift out the filter.

CAP SCREWS

Remove four cap screws, two brackets and lift the filter out. It should be cleaned or replaced every 125 hours.

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

FRESH AIR FILTER

• ••

FREASH AIR FILTER LOCATION

CAP SCREWS

• •• •• 1014-D196

•

FREASH AIR FILTER

TEMPERATURE CONTROL

FILTER - FRESH AIR When the Heater/AC Blower control switch is in the ON position, outside air is drawn into the cab air conditioning unit through the air filter and mixed with interior air from the cab. To reduce dust in the cab area, use the Heater/AC Blower control 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 left side of the cab roof.

1014-D075

A/C AND FAN CONTROLS

HEAT - VARIABLE/TEMPERATURE CONTROL This electronic temperature control automatically adjusts the temperature of air in the cab for both heating and air conditioning. The blue area of the scale indicates cooler temperatures the red area indicates warmer temperatures.

This control will automatically regulate cooling or heating to maintain the requested temperature

3.19

Tigercat 1045/1055 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.

Close all cab doors.

9. Lift the locking plate out of the slots in the pins and turn the cab locking pins so the flat surfaces are vertical and in line with the slots on the cab locking lugs.

RAISING THE CAB

SUPPORT LINK IN FULL TILT POSITION.

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 and secure all loose articles in cab. Close all cab doors.

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

CAB TILT SUPPORT LINK

1075-002

CAB LOCKING PINS

•• •

10. Operate pump until the cab tilt is just at over centre position and stop pumping. Use the RAISE/LOWER CONTROL LEVER to meter the hydraulic flow at the cab tilt cylinder, slowly tilting the cab all the way until the support link stops the cab tilt.

••• •

PIN LOCK PLATES

WARNING

LEFT SIDE BELOW CAB

1055-073

Before working under cab;

5. Loosen the pin lock plate cap screws (located above the cab locking pins).

LEFT SIDE HYDRAULIC TANK ACCESS DOOR

PUMP LEVER

CAB TILT LEVER

• 1014-D079

Machine must be parked on level ground.

Cab must be fully tilted with tilt cylinders fully extended.

PARTIAL TILT SUPPORT SLOT

• ••

• ••

•• ••

SUPPORT BOLT

SUPPORT LINK IN PARTIAL TILT POSITION.

LONG TERM SUPPORT (HOLE)

CAB TILT PUMP

CAB TILT PUMP

6. Locate the cab tilt pump inside the left side hydraulic tank access door.

1075-003

7. Locate the cab tilt pump handle inside the cab and insert handle in pump lever.

8. Place tilt pump control lever in RAISE position.

Pump the lever until the cab weight is just off the locking pins.

CAB TILT SUPPORT LINK IN PARTIAL TILT POSITION

NOTE: If partial tilt is required for an operator assistant to be in cab while service work is performed under cab, the cab can be lowered to the partial tilt positon in the support link.

3.20

Tigercat 1045/1055 Forwarder PARTIAL TILT SUPPORT SUPPORT SLOT BOLT

•

••

• •• •

Lubrication and Maintenance NOTE: When the cab locking pins are seated in the locking plates, rotate the pins so the flat surfaces of the locking pins are horizontal.

SPRING LOCK SUPPORT LINK IN PARTIAL TILT POSITION.

CAB LOCKING PINS

LONG TERM SUPPORT (HOLE)

1075-003

•• •

CAB TILT SUPPORT LINK IN PARTIAL TILT POSITION

1055-073

11. For partial tilt, lower cab all the way down, then raise the cab, as the cab is raised the support link will slide along the support bolt. When the link partial tilt slot is just over the support bolt the link will begin to fall onto the support bolt.

At this point lower the cab until the support bolt bottoms in the partial tilt slot of the support link.

PIN LOCK PLATES

•• •

LEFT SIDE BELOW CAB

4. Place the locking plates back in the slots on the locking pins and tighten the cap screws.

5. Place the cab tilt control lever in the LOWER position and remove tilt pump handle.

6. Place the pump handle back in the storage location.

7. Close the left side hydraulic tank access door.

NOTE: When using the support link for partial tilt, the support bracket bolt must be bottomed in the partial tilt slot position of the support link.

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

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

2. Place tilt pump control lever in LOWER position.

NOTE: If the cab is in the partial tilt position, the cab must first be raised to the full tilt position to release the support link. Then it can be lowered.

(Otherwise it will lock in the partial tilt position.)

3. Operate pump until the cab is all the way over in the ride position onto the locking pins.

3.21

Tigercat 1045/1055 Forwarder OPENING ENGINE HOOD

Lubrication and Maintenance

ENGINE HOOD LATCH

••

OPENING ENGINE HOOD

1055-008

TO OPEN: Release the over center latch on left side of the engine hood. Pull down on latch handle, lift latch ring off retainer lug on frame.

PULL ON HANDLE

••

PULL HOOD OPEN

ILLY-D012

Locate handle on side of engine hood. Pull on handle and tip engine hood forward to open hood.

SPRING LOCK ENGAGED

•• SPRING LOCK

•• LATCH UP

LATCH

•• 1075-035

••

HOOD LATCHED OPEN

A latch on the left side (inside) of hood prevents the hood from closing.

Release the hood latch by partially lifting the hood then pull up on the latch to lock it with the spring lock (see inset picture), then reverse the above procedure to close engine hood.

3.22

Tigercat 1045/1055 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

DRIVE MOTOR Loosen hose on top of drive motor.

1075-030

1. Ensure all filters are in place. Do not pre-fill the filters.

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

• •

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

•

Watch for oil leaking from each hose fitting previously loosened and tighten each 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.

3. Check coolant level in the radiator.

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./NEUTRAL/REV. to NEUTRAL. 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 HOSE ON TOP OF DRIVE PUMP

••

1014-D081

LOOSEN HOSE ON SIDE OF MAIN PUMP

••

MAIN AND DRIVE PUMPS

•

Loosen hose on the top of hydrostatic drive pump.

•

Loosen hose on the side of the main pump.

3.23

Tigercat 1045/1055 Forwarder

Lubrication and Maintenance

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

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

CHARGE PRESSURE TEST PORT

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

• 1075-029

5. 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.

STOP BUTTON

•

1075-048

CHARGE PRESSURE TEST

ENGINE STOP BUTTON

6. 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.

7. With engine speed at IDLE run each function for 2 minutes to purge air from circuit.

8. Set engine speed to 1400 rpm and run each 2. Hold the STOP button on the left side of the function again for 2 minutes to flush circuit. engine cover and have an assistant crank engine using the key switch in the cab for 10 9. Top up the radiator with clean coolant. seconds, wait for 10 seconds. Repeat 6 times 10. With cylinders fully retracted, top up the to pump oil into pumps. Do not start engine. hydraulic oil reservoir with clean hydraulic 3. Install a 0-1000 psi. gauge on the 'CHARGE' oil. test port to check charge pressure. Watch NOTE: The steer and drive functions may not be gauge closely during startup. properly purged or flushed. Remove the 4. Start engine. If charge pressure does not articulation lock pin and at LOW IDLE, slowly rise within 5 to 10 seconds, TURN ENGINE operate the steer function right and left a few OFF. Refer to CHARGE PUMP in SECTION 8 times. With the emergency brake released, slowly of THE SERVICE MANUAL. operate the drive function forward and reverse a few times.

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.

3.24

Tigercat 1045/1055 Forwarder

Lubrication and Maintenance

AXLE LUBRICATION Each bogie axle has seven separate oil reservoirs that require individual draining/filling, there are nine drain points and nine fill points. The axle must be level when draining/filling lubricant. Perform scheduled oil change in the axles when doing the seasonal hydraulic oil change. Refill the axle differentials and bogie housings with SAE 90/API-GL 5 gear oil.

BREATHER BOGIE HOUSING FILL & LEVEL PLUG (4 PLACES)

DIFFERENTIAL FILL PLUG (1 PLACE) DIFFERENTIAL DRAIN PLUG (1 PLACE)

•

••

• ••

•

(DIPSTICK 1 PLACE) BOGIE HOUSING DRAIN PLUG (4 PLACES)

PLANETARY FILL PLUG (4 PLACES)

BOGIE HOUSING CONTAMINATED DRAIN PLUG (4 PLACES - LOWER)

1055-016

WHEEL HUB IN PLANETARY DRAIN POSITION

PLANETARY LEVEL/DRAIN PLUG (4 PLACES)

• •

•

WHEEL HUB IN PLANETARY FILL POSITION

BOGIE AXLE FILL, DRAIN AND LEVEL PLUGS 8. Refill the differential by pumping oil into the fill/ level plug on the differential. Stop adding oil when the oil level reaches the bottom of the differential level fill/level plug.

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.

9. Replace the differential fill/level plug.

PLANETARY DRIVES (4 FILLING POINTS) 10. Position the wheel hub for draining the planetary, with the drain plug in the lowest possible position as shown.

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

11. Remove the PLANETARY FILL PLUG.

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

12. Remove the PLANETARY DRAIN/LEVEL PLUG and drain the oil into a suitable container for disposal.

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

13. Reposition the wheel hub for filling the planetary, with the PLANETARY DRAIN/ LEVEL PLUG at 9 o’clock and the fill plug at 1 o’clock as shown.

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

6. Clean any filings from the magnetic drain plug.

7. Replace the differential housing drain plug.

3.25

Tigercat 1045/1055 Forwarder

Lubrication and Maintenance REPLACING THE ENGINE SERPENTINE BELT

14. Refill the planetary with new oil until the level reaches the bottom of the PLANETARY DRAIN/LEVEL PLUG. (Note: To get a correct filling level the wheel hub must be in the planetary fill position as shown.)

Replace the engine serpentine belt as follows:.

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

15. Repeat steps 10 to 14 for each of the four planetary drives.

DRAINING AND REFILLING BOGIE HOUSING: (2 PER AXLE) 16. Remove the bogie housing fill plugs located on the top of the bogie housing.

SERPENTINE BELT

17. Remove the bogie housing level plugs located on the inside of the housing.

•• ••

Note: There are two bogie housing level plugs to be removed per axle.

18. Remove the bogie housing drain plugs 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.

1

1075-012

19. Clean any filings from the magnetic drain plugs.

SERPINTINE BELT

2. Install a 1/2" Johnson bar with a 15mm socket on the hex head bolt (1) of the belt tensioner.

20. Replace the bogie housing drain plugs in all locations.

3. Rotate the tensioner away from the belt to release belt tension. This will provide enough

21. Refill the bogie housings by pumping oil into the fill plug on the bogie housings. Stop adding oil when the oil level reaches the bottom of the bogie housing level plug. Note, each of the bogie housings must be filled separately.

22. Replace the bogie housing level plugs.

23. Replace the bogie housing fill plugs.

Note: There are 9 drain points and 9 fill points CAPACITIES For front and rear axle oil fill capacities, refer to the table: SERVICE AND LUBRICATION in THIS SECTION of THIS MANUAL.

1014-071

SERPENTINE BELT INSTALLATION

clearance to replace the serpentine belt.

4. Reverse removal procedure to replace the belt.

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

3.26

Tigercat 1045/1055 Forwarder CRANE, ROTATOR AND GRAPPLE MAINTENANCE Refer to the manufacturer’s maintenance and service manual for information on your crane, rotator and grapple.

Lubrication and Maintenance LINK SNUBBER MAINTENANCE

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

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

The link provides a double direction snubbing action. There are 4 grease fittings on the link, for daily lubrication of the sleeves, bushings and housing.

NUT

COLLAR

•• •• 1014-D082

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

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

LINK SNUBBER (CY049) MAINTENANCE NOTE: The following adjusting procedure applies to snubber type links only. All other links require lubrication only. See Service and Lubrication Points chart in this section for lubrication details.

ADJUSTING SNUBBER TENSION Tension is adjusted by turning the adjusting nut.

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

3.27

Tigercat 1045/1055 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 seal cap bolts Articulation pin retaining bolts Oscillation end cap bolts

M12 x 1.75 M20 x 2.5 M16 x 2.0

110 530 275

80 400 200

Engine mounting Rear Bolts Front Bolt

M20 x 2.5 M20 x 2.5

530 530

400 400

Main/Drive Pump mounting Drive plate to flywheel Bell housing Rear engine mounting brackets Front engine mounting brackets

M10 x 1.5 M10 x 1.5 M16 x 2.0 M16 x 1.5

63 63 275 275

47 47 200 200

1 1/4" x 18 UNEF 1/2" UNF

640-711 163-179

475-525 120-132

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

800

600

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 Universal joint bolts

REV 2 06/2006

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

3.28

Tigercat 1045/1055 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 8 BOLTS

GRADE 5 BOLTS

IMPERIAL BOLT TORQUE SPECIFICATIONS GRADE 5 BOLTS GRADE 8 BOLTS COARSE THREAD 1/4" - 20 5/16" - 18 3/8" - 16 7/16" - 14 1/2" - 13 9/16" - 12 5/8" - 11 3/4" - 10 7/8" - 9 1" - 8 1 1/8" - 7 1 1/4" - 7 FINE THREAD 1/4" - 28 5/16" - 24 3/8" - 24 7/16" - 20 1/2" - 20 9/16" - 18 5/8" - 18 3/4" - 16 7/8" - 14 1" - 14 1 1/8" - 12 1 1/4" - 12

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

LUBRICATED lbf-ft Nm 8 - 10 11 - 13 20 - 28 27 - 38 33 - 36 45 - 49 52 - 57 71 - 77 80 - 88 109 - 119 115 - 127 156 - 172 159 - 175 216 - 237 282 - 310 393 - 420 455 - 501 617 - 679 682 - 750 925 - 1016 966 - 1062 1310 - 1441 1360 - 1496 1844 - 2027 LUBRICATED lbf-ft Nm 10 - 13 14 - 17 18 - 25 25 - 33 37 - 41 50 - 55 58 - 64 79 - 86 90 - 99 122 - 134 128 - 141 174 - 191 180 - 198 244 - 268 315 - 347 427 - 470 501 - 550 679 - 745 746 - 821 1012 - 1113 1083 - 1191 1469 - 1613 1509 - 1660 2046 - 2250

DRY LUBRICATED COARSE THREAD lbf-ft Nm lbf-ft Nm 1/4" - 20 7- 8 10 - 11 8 - 10 11 - 13 5/16" - 18 14 - 18 19 - 24 10 - 15 13 - 20 3/8" - 16 31 - 34 42 - 46 23 - 25 31 - 34 7/16" - 14 49 - 54 66 - 73 37 - 41 50 - 55 1/2" - 13 75 - 83 102 - 112 57 - 63 77 - 85 9/16" - 12 109 - 120 148 - 162 82 - 90 111 - 122 5/8" - 11 150 - 165 204 - 223 113 - 124 152 - 168 3/4" - 10 266 - 293 360 - 397 200 - 220 271 - 298 7/8" - 9 394 - 433 535 - 586 296 - 326 402 - 441 1" - 8 591 - 649 802 - 879 443 - 489 601 - 663 1 1/8" - 7 794 - 873 1077 - 1183 596 - 656 808 - 889 1 1/4" - 7 1120 - 1232 1519 - 1670 840 - 924 1139 - 1252 FINE DRY LUBRICATED lbf-ft Nm lbf-ft Nm THREAD 1/4" - 28 9 - 10 12 - 13 9 - 10 12 - 13 5/16" - 24 17 - 22 23 - 29 16 - 20 21 - 27 3/8" - 24 35 - 39 48 - 53 26 - 29 35 - 39 7/16" - 20 55 - 61 75 - 83 41 - 45 56 - 61 1/2" - 20 85 - 94 116 - 127 64 - 70 87 - 95 9/16" - 18 121 - 133 164 - 180 91 - 100 124 - 135 5/8" - 18 170 - 187 231 - 253 128 - 141 174 - 191 3/4" - 16 297 - 327 403 - 443 223 - 245 303 - 332 7/8" - 14 434 - 477 589 - 646 326 - 359 442 - 486 1" - 14 646 - 711 876 - 965 484 - 534 657 - 724 1 1/8" - 12 891 - 980 1208 - 1328 668 - 735 906 - 996 1 1/4" - 12 1240 - 1364 1682 - 1849 931 - 1024 1262 - 1387

METRIC

METRIC BOLT TORQUE SPECIFICATIONS SIZE

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

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

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

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

M6 M8 M10

4.8 12.0 23.0

3.5 8.5 17.0

6.0 15.0 29.0

4.5 11.0 21.0

9.0 22.0 43.0

6.5 16.0 32.0

11.0 28.0 55.0

8.5 20.0 40.0

13.0 32.0 63.0

9.5 24.0 47.0

17.0 40.0 80.0

12.0 30.0 60.0

15.0 37.0 75.0

11.5 28.0 55.0

19.0 47.0 95.0

14.5 35.0 70.0

M12 M14 M16

40.0 63.0 100.0

29.0 47.0 73.0

50.0 80.0 125.0

37.0 60.0 92.0

75.0 120.0 190.0

55.0 88.0 140.0

95.0 150.0 240.0

70.0 110.0 175.0

110.0 175.0 275.0

80.0 130.0 200.0

140.0 225.0 350.0

105.0 165.0 225.0

130.0 205.0 320.0

95.0 150.0 240.0

165.0 260.0 400.0

120.0 190.0 300.0

M18 M20 M22

135.0 190.0 260.0

100.0 140.0 190.0

175.0 240.0 330.0

125.0 180.0 250.0

260.0 375.0 510.0

195.0 275.0 375.0

330.0 475.0 650.0

250.0 350.0 475.0

375.0 530.0 725.0

275.0 400.0 540.0

475.0 675.0 925.0

350.0 500.0 675.0

440.0 625.0 850.0

325.0 560.0 460.0 800.0 625.0 1,075.0

410.0 580.0 800.0

M24 M27 M30

330.0 490.0 675.0

250.0 360.0 490.0

425.0 625.0 850.0

310.0 650.0 450.0 950.0 625.0 1,300.0

M33 900.0 M36 1,150.0

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

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

TORQUECHARTGENERAL.XLS

3.29

Tigercat 1045/1055 Forwarder

Lubrication and Maintenance

Par ker ark

Assemb que Assemblly Tor orque

3.30

Tigercat 1045/1055 Forwarder

Lubrication and Maintenance

Par ker ark

Assemb que Assemblly Tor orque

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

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

Tube Connection FFWR

NPTF Swivel or Hose Connection FFWR

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

SAE Dash Size

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

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

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

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

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

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

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

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

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

Swivel or Hose Connection TFFT

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

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

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

Tube Connection TFFT

Thread Size

BSPT

Swivel or Hose Connection FFWR

SAE Dash Size

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

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

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

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

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

3.31

Swivel or Hose Connection TFFT

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

Tigercat 1045/1055 Forwarder

Lubrication and Maintenance

Assemb que Assemblly Tor orque

EATON Aeroquip Recommended Parallel Connection Assembly torque

Eaton recommends that a

The values listed are for

Torque wrench be used to

steel connections. Contact

assure proper fitting

Eaton Aeroquip for torques values for

assembly of these

other materials

connections.

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

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

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

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

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

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

ORS

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

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

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

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

SAE 37º (JIC)

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

Swivel Nut Torque lb.-ft.

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

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

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

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

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

Swivel Nut Torque lb.-ft.

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

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

BSPP lb.-ft.

13-15 15-19 19-23 33-40 37-44 52-66 55-70 81-96 96-111 162-184 170-192 258-347

Straight Adapter or Locknut Torque Newton Meters 18-20 20-25 25-30 45-55 50-60 70-90 75-95 110-130 130-150 220-250 230-260 350-470

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

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

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

3.32

Tigercat 1045/1055 Forwarder SECTION 6 - ELECTRICAL & COMPUTERS CONTENTS - SECTION 6 AIR FILTER RESTRICTION WARNING ................. 6.41 BRAKE PRESSURE WARNING ............................. 6.41

AUGUST, 2006

GET ERROR/EVENT LOG using A pc/laptop .............................................. 6.63 using a pda ....................................................... 6.62 GRAPHING AND MEASUREMENT OF CHANNELS USING A PC/LAPTOP ...................................... 6.61 USING A PDA .................................................. 6.60 PDA REGISTRATION .......................................... 6.52 UPDATING THE IQAN APPLICATION FROM A PC/LAPTOP .................................... 6.56 FROM A PDA ................................................... 6.54

CAB MODULE ......................................................... 6.10 COLD IDLE RPM ..................................................... 6.36 COMPUTER CONTROL SYSTEM ............................................ 6.2 COMPUTER SYSTEM COMPONENTS .................. 6.20 CONDITIONAL MESSAGES ................................... 6.39 COOLANT LEVEL WARNING ................................. 6.42 L.H. JOYSTICKS & COMPUTER DISPLAY ............ 6.4 CRANE MODULE .................................................... 6.16 LOW BRAKE PRESSURE WARNING .................... 6.41 CRANE START (CM) .............................................. 6.39 CURRENT OUTPUT SETTINGS ............................ 6.27 MACHINE MODEL .................................................. 6.35 MAIN SYSTEM ERRORS ....................................... 6.43 DATE TIME SETTINGS .......................................... 6.26 LX-A0 MODULE OFFLINE ERROR .................... 6.45 DIAGNOSTICS ADJUSTMENT MENUS ................. 6.21 MDM MODULE BLANK SCREEN ........................ 6.43 DOWNLOADING APPLICATIONS FROM DEALER MODULE IS OFFLINE ......................................... 6.43 WEBSITE ................................................................ 6.52 XP2-A0 MODULE OFFLINE ERRORS ................ 6.47 DRIVE START (CM) ................................................ 6.39 XS-A0 MODULE OFFLINE ERROR ................... 6.44 XT2-A0 MODULE OFFLINE ERROR ................. 6.46 ENGINE MAXIMUM TRAVEL SPEED (CM) .......................... 6.40 COOLANT LEVEL WARNING ............................. 6.42 MEASURE MENU DESCRIPTION .......................... 6.22 OIL PRESSURE WARNING ................................ 6.41 MINIMUM CURRENT .............................................. 6.27 OVERSPEED (CM) .............................................. 6.40 MODE MENU ..........................................................

6.21 TEMPERATURE WARNING ............................... 6.37 MODULE IS OFFLINE .............................................

6.43 ENGINE MODULE .................................................. 6.12 MOTOR BEGIN DISP.............................................. 6.35 ERROR MESSAGES AND ALARMS MAIN SYSTEM ERRORS .................................... 6.43 MOTOR MAX ACCE TIME ...................................... 6.35 FINE CONTROL ...................................................... 6.28 FOOT PEDAL CONTROLS ..................................... 6.8 FRAME MODULE .................................................... 6.14 FUEL LEVEL WARNING ............................................... 6.42 FUNCTION PARAMETERS SETTINGS ................. 6.33 FUSE AND RELAY PANELS ................................... 6.48 GET APPLICATION ................................................ 6.58 GET ERROR/EVENT LOG ...................................... 6.62 GRAPPLE MODULE ............................................... 6.18 HYDRAULIC OIL LEVEL WARNING ........................................ 6.41 OIL TEMPERATURE WARNING ......................... 6.37

NO GEAR ENGAGED WARNING ........................... 6.38 NO MOTOR SPEED (CM) ....................................... 6.40 PARK BRAKE/LADDER DOWN WARNING ........... 6.37 PDA REGISTRATION ............................................. 6.52 PROPERTIES MENU .............................................. 6.27 PUMP DISP ............................................................. 6.36 SCHEMATIC L.H. JOYSTICK AND POD .................................. 6.5 R.H. JOYSTICK AND POD .................................. 6.7 XP2-A0 FRONT FRAME MODULE ..................... 6.15 XP2-A1 CRANE MODULE ................................... 6.17 XP2-A2 GRAPPLE MODULE .............................. 6.19 XT2-A0 ENGINE MODULE .................................. 6.13 SELECTING A FUNCTION TO ADJUST ................ 6.28 SETTINGS MENU ................................................... 6.24 START/STOP SLOPE ............................................. 6.28 STEER CHECK ERROR (CM) ................................ 6.40 SYSTEM BYPASSED WARNING ........................... 6.39 SYSTEM COMPONENTS ....................................... 6.20 SYSTEM WARNING MESSAGES .......................... 6.37

INFORMATION MENU ............................................ 6.22 INFORMATION MENU DESCRIPTION .................. 6.22 IQAN MDM COMPUTER DISPLAY WARNING MESSAGES MODULE IS OFFLINE ..................................... 6.43 IQAN SOFTWARE .................................................. 6.52 DOWNLOADING APPLICATIONS FROM DEALER WEBSITE ......................................................... 6.52 THROTTLE AND BRAKE FOOT PEDALS .............. 6.8 TIRE ROLLING CIRCUMFERENCE ....................... 6.34 GET APPLICATION (DOWNLOAD FROM MDM) USING A PC/LAPTOP ...................................... 6.59 UPDATE APPLICATION ......................................... 6.54 USING A PDA .................................................. 6.58

Tigercat 1045/1055 Forwarder

Electrical & Computers

MDM COMPUTER DISPLAY AND CONTROL SYSTEM XS MODULE

••

JOYSTICK MODULES

•• ••

DISPLAY MODULE

•

1014-i01.ai

Machine operation is controlled electronically by the MDM computer system. During operation of the electronic joysticks, foot pedals or control switches, the computer system provides integrated control of the engine, main pump, hydrostatic drive and all of the proportional valve functions.

The MDM display and control module (1) located in the L.H. Joystick Pod is connected in series to the L.H. Joystick (2), through the L.H. Joystick to the R.H. Joystick (3), through the R.H. Joystick to the CAN 1 terminal on the cab module (4 located in the R.H. upper cab roof compartment), the cab module is connected via the CAN 2 terminal to the engine module (5), frame and crane modules (6, 7 and 8).

The operator can view input and output information and enter function parameter settings for the engine, transmission and crane modules using the MDM Display Terminal.

SYSTEM COMPONENTS 5 1014-D018

The computer monitors and analyzes engine and transmission inputs and produces outputs (as defined in its program) to control the engine and drive functions.

4 6

The computer also monitors and analyzes inputs and produces outputs (as defined in its program) to control the machine proportional valve functions.

Proportional valve functions are:

3

7 2

8

•

Steering

•

Blade (if equipped)

•

Crane Rotate

•

Main Boom

•

Stick Boom

•

Telescope Boom

•

Grapple Rotate

•

Grapple Open/Close

•

Gate Up/Down

Inputs:

1

The computer monitors analogue, digital, and frequency inputs (CAN Bus inputs). CAN Bus is a data bus system that allows several input signals to be sent to the MDM through a reduced number of wires.

Outputs:

1. MDM Display/Control Module 2. L.H. Joystick 3. R.H. Joystick 4. (XS-A0) Cab Module

The computer directs a proportional output (24 Volt electrical current) to the solenoids on the steer valve, boom valve, charge accumulator, drive pump, brake valve and controls engine RPM by sending appropriate signals to the engine’s control computer.

5. (XT2-A0) Engine Module 6. (XP2-A0) Front Frame Module 7. (XP2-A1) Crane Module 8. (XP2-A2) Grapple Module 6.2

Tigercat 1045/1055 Forwarder

Electrical & Computers

The IQAN MDM computer display is the operator interface with the IQAN control system. The IQAN MDM (master display module) is the central unit in the IQAN control system which works as both a master and a display unit. It has a backlit graphic LCD display. Three function buttons (F1, F2 and F3), a scrolling up/down button and an escape button are used by the operator to move through menus and adjust the settings of the IQAN control system.

GAUGES SWITCH

DISPLAY

F1

F2

F3

SCROLL UP/DOWN

SYSTEM COMPONENT LOCATIONS MDM DISPLAY MODULE

••

1014-140

L.H. JOYSTICKS & COMPUTER DISPLAY

•

•

ESCAPE SWITCH

XS-A0 CAB MODULE

•• 1014-002

L.H. JOYSTICKS & COMPUTER DISPLAY The GAUGES switch to the left of the IQAN-MDM display is used to select between the gauge menus and the diagnostic and function adjustment menus.

XS-A0 CAB MODULE

1065-002

Press the top of the GAUGES switch to display the gauge menus.

Press the bottom of the GAUGES switch to display the IQAN-MDM diagnostic and function adjustment menus.

Note: Whenever an alarm is activated, the gauge display menus are replaced with the alarm warning message. When the alarm function is cleared, diagnostic and function adjustment menus appear.

Press the top of the GAUGES switch to display the gauge menus.

1065-003

FUSE & RELAY COMPARTMENT IN CAB XT2-A0 ENGINE MODULE

••

Refer to IQAN MDM COMPUTER DISPLAY in SECTION 2 of the OPERATOR’S MANUAL for more information.

1014-137

L.H. SIDE ENGINE COMPARTMENT

XP2-A0 FRONT FRAME MODULE

XP2-A1 CRANE MODULE

••

1014-001

••

XP2-A2 GRAPPLE MODULE

••

R.H. JOYSTICK & CONTROL SWITCHES 1014-139

REAR CHASSIS HYDRAULIC COMPARTMENT 6.3

Tigercat 1045/1055 Forwarder

Electrical & Computers MDM MODULE WIRING PIN ASSIGNMENT

COMPONENT REPLACEMENT MDM DISPLAY MODULE

•

••

RELEASE TABS

MDM MODULE REPLACEMENT

1014-035

1. Turn battery disconnect switch OFF. 2. Remove the bottom panel on the joystick pod to access the wiring and back of the MDM module.

3. Disconnect the wiring harness at the module.

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

5. Install module in reverse order as removed.

NOTE: Refer to Tigercat Product Support Bulletin 1443 for procedure to Update the Application in an MDM Module.

REAR OF MDM MODULE 1014-031

6

5

2

5

3

1. CAN LOW

••

••

•• •

2. ALARM OUT

••

3. BATTERY GROUND 4. CAN HIGH 5. POWER SUPPLY - Real Time Clock

•• •• 1014-032

1

• 5

4

6. POWER SUPPLY

••

NOTE: Refer to the L.H. JOYSTICK and MDM MODULE wiring schematic and Electrical schematics in this section for detailed pin and wiring assignment.

5

The back of the MDM Module consists of the following:

DISPLAY MODULE

GAUGES SWITCH

1. Tag with serial number and part number.

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

•

3. Voltage supply indicator. LED with green light ON indicates supply voltage is activated. LED light OUT indicates supply voltage is OFF.

•

•

STEERING JOYSTICK

• CRANE JOYSTICK

4. Main connector for voltage supply, CAN communication and alarm output.

5. Snap on attachment for mounting in panel.

1014-002

6. Membrane valve for condensation prevention inside unit.

L.H. JOYSTICKS & COMPUTER DISPLAY 6.4

Tigercat 1045/1055 Forwarder

Electrical & Computers

L.H. JOYSTICK and POD SCHEMATIC

1014-001.AI

STEERING JOYSTICK

1055-070

6.5

Tigercat 1045/1055 Forwarder

Electrical & Computers I.

COMPONENT REPLACEMENT CONT’D JOYSTICK MODULES XS MODULE

••

JOYSTICK MODULES

•• ••

Status indicator LED. LED yellow flashing light indicates status is correct.

LED flashing red light indicates error status as follows:

DISPLAY MODULE

•

•

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

•

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

•

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

•

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

•

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

•

Continuous flashing indicates the fault is related to software.

1014-IA1.AI

The R.H. and L.H. joystick module components are as follows:

Error code

Blink (red light)

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

JOYSTICK MODULE WIRING PIN ASSIGNMENT

1014-039

A. Handle B. Rocker Switch C. Bellows D. Mounting Flange

•

E. Lower Body F.

C2 INPUT/OUTPUT CONNECTOR

C1 CAN-BUS CONNECTOR

••

C1 CAN-bus connector

G. C2 Input/Output connector H. Supply Voltage LED. LED with green light ON indicates supply voltage is ON. LED OFF indicates supply voltage is OFF.

1014-040

NOTE: Refer to the R.H. and L.H. JOYSTICK and MODULE Wiring Schematics and Electrical Schematics in this section for detailed pin and wiring assignment.

6.6

Tigercat 1045/1055 Forwarder

Electrical & Computers

R.H. JOYSTICK and POD SCHEMATIC

1055-071

6.7

Tigercat 1045/1055 Forwarder

Electrical & Computers

THROTTLE AND BRAKE FOOT PEDALS 2

2

1

1

•

•

••

••

Pressing down on the foot pedal (1) activates the lever (2) connected to a potentiometer (3) which sends out a voltage signal (0 to 3.2 volts) to the cab module then to the MDM Display and Control Module that is proportional to pedal position.

Depending on which pedal is being operated the MDM Display and Control Module will activate or deactivate the service brakes or increase/decrease engine and travel speed.

1014-D007

FRONT FOOT PEDAL CONTROLS

1014-D008

REAR FOOT PEDAL CONTROLS

FOOT PEDAL CONTROLS The machine is equipped with two sets of electronic foot pedal controls. Front foot pedal controls and rear foot pedal controls. The operator’s seat can be rotated 225° from a forward facing position to a rearward facing position. The two sets of foot pedal controls provide the operator with throttle control (1) and brake control (2) with the seat in either position.

The seat position is monitored by a sensor located in the seat frame. The sensor provides the computer control with the seat position signal. The computer control activates or deactivates the foot pedal controls relative to the seat position. Refer to COMPUTER CONTROL FUNCTIONS in SECTION 2 for more detail.

AH082

FOOT PEDAL PIN ASSIGNMENT 1. PEDAL SS SIGNAL 2. POWER INPUT 3. OUTPUT SIGNAL

Note: The front and rear foot pedal controls operate 4. GROUND the same function, THROTTLE FOOT PEDAL (1) 5. POWER AND BRAKE FOOT PEDAL (2).

6. NOT USED

1

••

2

• 3

•• 4

1014-D154

•• FOOT PEDAL CONTROL

The foot pedal control consists of foot pedal (1), lever (2), potentiometer (3) and mounting plate (4).

The resistance of the potentiometer (3) in the neutral position (58° to 62°) is 1.4 kΩ and fully depressed (0°) is o.5 kΩ.

6.8

DT04-6P.AI

Tigercat 1045/1055 Forwarder

Electrical & Computers

THROTTLE AND BRAKE FOOT CONTROL SCHEMATIC

1055-076

6.9

Tigercat 1045/1055 Forwarder

Electrical & Computers

XS-A0 CAB MODULE COMPONENTS

XS-A0 CAB MODULE REPLACEMENT

XS-A0 CAB MODULE

••

1065-002

1014-038

A. Supply Voltage LED. LED OFF indicates supply voltage is OFF. LED ON solid green light indicates supply voltage is ON.

XS-A0 CAB MODULE

1. Turn battery disconnect switch OFF. 2. Open the top front compartment door.

3. Disconnect the wiring harness connectors on the module.

B. Arrow and Heart Status Indicator LEDs. LED for Heart and Arrow flash alternately (solid green) indicates Status is Correct.

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

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

•

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

•

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

•

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

1014-037

XS Module Error code

4. Remove the two hex nuts and lift the module out.

Blink (Arrow only green light)

I/O and voltage errors Low/High temperature CAN error VREF error

C. Connectors CAN1 and CAN2 for CAN-bus.

D. C1 connector for inputs and outputs.

E. Module assembly.

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

1014-036

5. Reverse procedure to install module.

6.10

Tigercat 1045/1055 Forwarder

Electrical & Computers

XS-A0 CAB MODULE SCHEMATIC

1055-077

6.11

Tigercat 1045/1055 Forwarder

Electrical & Computers

XT2-A0 ENGINE MODULE

XT2-A0 MODULE WIRING PIN ASSIGNMENT

XT2-A0 ENGINE MODULE

••

1014-041

L.H. SIDE ENGINE COMPARTMENT

1014-137

XT2-A0 ENGINE MODULE LED INDICATORS 2 1

•• • XT2-AO MODULE LED INDICATORS

1014-042

1014-043

1. Supply Voltage LED. LED with green light ON indicates supply voltage is ON. LED OFF indicates supply voltage is OFF.

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

2. Status indicator LED. LED yellow flashing light indicates status is correct.

LED flashing red light indicates error status as follows: •

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

•

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

•

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

•

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

•

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

•

Continuous flashing indicates the fault is related to software.

Error code

Blink (red light)

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

6.12

Tigercat 1045/1055 Forwarder

Electrical & Computers

XT2-A0 ENGINE MODULE SCHEMATIC

1055-075

6.13

Tigercat 1045/1055 Forwarder

Electrical & Computers

XP2-A0 FRAME MODULE XP2-A0 FRONT FRAME MODULE

XP2-A0 MODULE WIRING PIN ASSIGNMENT

XP2-A1 CRANE MODULE

•

•

XP2-A2 GRAPPLE MODULE

••

1014-041 1014-139

REAR CHASSIS HYDRAULIC COMPARTMENT XP2-A0 FRAME MODULE LED INDICATORS 2 1

• • 1014-043

XP2-AO MODULE LED INDICATORS

1014-042

NOTE: Refer to the XP2-A0 FRAME MODULE Wiring Schematic and Electrical Schematics in this section for detailed pin and wiring assignment.

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

LED flashing red light indicates error status as follows: •

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

•

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

•

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

•

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

•

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

•

Continuous flashing indicates the fault is related to software.

Error code

Blink (red light)

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

6.14

Tigercat 1045/1055 Forwarder

Electrical & Computers

XP2-A0 FRONT FRAME MODULE SCHEMATIC

1055-072

6.15

Tigercat 1045/1055 Forwarder

Electrical & Computers

XP2-A1 CRANE MODULE XP2-A0 FRONT FRAME MODULE

XP2-A1 MODULE WIRING PIN ASSIGNMENT

XP2-A1 CRANE MODULE

•

•

XP2-A2 GRAPPLE MODULE

••

1014-041 1014-139

REAR CHASSIS HYDRAULIC COMPARTMENT XP2-A1 CRANE MODULE LED INDICATORS 2 1

• • 1014-043

XP2-A1 MODULE LED INDICATORS

1014-042

NOTE: Refer to the XP2-A1 CRANE MODULE Wiring Schematic and Electrical Schematics in this section for detailed pin and wiring assignment.

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

LED flashing red light indicates error status as follows: •

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

•

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

•

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

•

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

•

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

•

Continuous flashing indicates the fault is related to software.

Error code

Blink (red light)

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

6.16

Tigercat 1045/1055 Forwarder

Electrical & Computers

XP2-A1 CRANE MODULE SCHEMATIC

1055-073

6.17

Tigercat 1045/1055 Forwarder

Electrical & Computers

XP2-A2 GRAPPLE MODULE XP2-A0 FRONT FRAME MODULE

XP2-A2 MODULE WIRING PIN ASSIGNMENT

XP2-A1 CRANE MODULE

•

•

XP2-A2 GRAPPLE MODULE

••

1014-041 1014-139

REAR CHASSIS HYDRAULIC COMPARTMENT XP2-A2 GRAPPLE MODULE LED INDICATORS 2 1

• • 1014-043

XP2-A2 MODULE LED INDICATORS

1014-042

NOTE: Refer to the XP2-A2 GRAPPLE MODULE Wiring Schematic and Electrical Schematics in this section for detailed pin and wiring assignment.

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

LED flashing red light indicates error status as follows: •

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

•

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

•

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

•

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

•

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

•

Continuous flashing indicates the fault is related to software.

Error code

Blink (red light)

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

6.18

Tigercat 1045/1055 Forwarder

Electrical & Computers

XP2-A2 GRAPPLE MODULE SCHEMATIC

1055-074

6.19

Tigercat 1045/1055 Forwarder

Electrical & Computers

COMPUTER DISPLAY AND CONTROL SYSTEM COMPONENTS

2 1

3 10

4

9

8 7

1. Display Module

6

2. XT2-A0 Engine Module

5

3. XS-A0 Cab Module 4. R.H. Joystick 5. XP2-A0 Frame Module 6. XP2-A1 Crane Module 7. XP2-A2 Grapple Module 8. Foot Pedals 9. L.H. Joystick 10. Steering Joystick

1014-01 PLT. DWGPB

COMPUTER DISPLAY AND CONTROL SYSTEM COMPONENT LOCATION

6.20

Tigercat 1045/1055 Forwarder

Electrical & Computers

SYSTEM DIAGNOSTICS AND FUNCTION ADJUSTMENT MENUS DISPLAY GAUGES SWITCH

•

•

1014-002

1014-D001B

L.H. JOYSTICKS & COMPUTER DISPLAY

Press the ESCAPE button to display one of 5 menus (MODE, INFORMATION, SETTINGS, MEASURE AND PROPERTIES) that access system diagnostics and function adjustment menus. Use the up and down arrow buttons to scroll through the menus. Use the “F1, F2, and F3 buttons to select the highlighted boxes located above the buttons in the LCD display.

Press the bottom of the GAUGES switch to display the IQAN-MDM system diagnostics and function adjustment menus.

TIME

SOFTWARE VERSION

•

• •• •• F1 BUTTON

1014-D157

OPERATOR MODE

DATE

•• •• F2 BUTTON

•

SCROLL BUTTON

•• ••

F3 BUTTON

ESCAPE BUTTON

MDM COMPUTER MODULE

The display should show the current date, time, operator mode and software version identification.

1014-D94

1. MODE MENU DESCRIPTION A. One of 4 operator modes can be selected.

Each operator mode can be djusted by the individual operator.

B. Operator modes can be copied from one mode to another.

C. Operator modes can also be reset to factory defaults in this menu.

6.21

Tigercat 1045/1055 Forwarder

Electrical & Computers

1014-D097

1014-D095

2. INFORMATION MENU DESCRIPTION

4. MEASURE MENU DESCRIPTION

This menu is for trained service technicians only. See Service Manual for detailed information.

A. Input and output VOLTAGE and CURRENT can be measured.

B. J1939 CANBUS DATA can be viewed.

See Service Manual for detailed information.

WARNING Do not make adjustments in this menu.

Machine warning alarms can be disabled in this menu.

1014-D098

5. PROPERTIES MENU DESCRIPTION Adjustable machine functions can be changed for the current operator mode.

1014-D096

3. SETTINGS MENU DESCRIPTION

••

A. Display CONTRAST and BRIGHTNESS can be adjusted.

CURRENT OPERATOR MODE (1)

B. Computer SOUND volumes can be adjusted.

C. Computer DATE and TIME can be adjusted.

1014-D094

D. The LANGUAGE that the text is displayed in can be selected.

1. MODE MENU OPERATION The crane, steering, gate and blade function speeds and start/stop ramps can be adjusted by the operator. The settings can be saved for up to 4 different operators. These are called modes.

The settings in one mode can be copied to another mode. A mode can also be reset to factory default settings.

The machine is shipped from the factory with default settings in modes 1 through 4.

6.22

Tigercat 1045/1055 Forwarder

Electrical & Computers

SELECTING AN OPERATOR MODE DESIRED OPERATOR MODE (4)

• 1014-D103

Press the F1 button located under the “OK” box in the LCD display. The current mode settings have now been overwritten with the selected mode numbers settings.

1014-D099

Press the F1 button located under the “SELECT” box in the LCD display.

Press the UP or DOWN arrow button to change the mode number to the desired mode number.

RESETTING THE CURRENT OPERATOR MODE

Press the F1 button located under the “OK” box in the LCD display.

••

CURRENT OPERATOR MODE (4)

1014-D104

Press the F3 button located under the RESET box in the LCD display.

1014-D101

The current forwarder operator mode number in the upper right corner of the display should now show the new mode number (4). The settings in the displayed mode number will now control the crane, steering, gate and blade functions.

COPYING TO THE CURRENT OPERATOR MODE 1014-D105

Press the F1 button located under the “OK” box in the LCD display. The current mode (1) settings have now been RESET to the preset factory default settings.

1014-D102

First select the mode you want to change, then press the F2 button located under the COPY box in the LCD display.

Press the UP or DOWN arrow button to select the mode that the current mode will be copied from.

6.23

Tigercat 1045/1055 Forwarder

Electrical & Computers

2. SETTINGS MENU OPERATION

CHANGE LIGHT

The computer sound volume, display contrast, light, date, time and language can be adjusted in this menu.

CHANGE CONTRAST

1014-D106

Press LIGHT (F2) to select the function LCD LIGHT. 1014-D096

Press LCD (F1) to select LCD SETTINGS.

1014-D108

Change to desired BRIGHTNESS using UP/ DN and press OK (F1) to save setting and return to previous menu.

1014-D106

Cancel (F2) or ESC returns the character window to the previous window without saving any new setting.

Press CONTRAST (F1) to select the function LCD CONTRAST.

Reset Light RESET (F3) resets the character window’s light to the preset factory value which corresponds to 100.

1014-D107

Change to desired CONTRAST using UP/DN and press OK (F1) to save setting and return to previous menu.

Cancel (F2) or ESC returns the character window to the previous window without saving any new setting.

Reset Contrast RESET (F3) resets the character window’s contrast to the preset factory value which corresponds to 30.

6.24

Tigercat 1045/1055 Forwarder

Electrical & Computers CHANGE ALARM VOLUME

LANGUAGE SETTINGS

•

Change LANGUAGE on Menu Text.

1014-D112

Press ALARM (F1) to select the function for setting the volume for the alarm signal.

1014-D096

CHANGE LANGUAGE Press LANGUAGE (F2) to select the function LANGUAGE.

1014-D111

Change to desired VOLUME using UP/DN. There are Ten volume levels. 0 implies that sound is turned OFF. 100 is the loudest.

Thereafter, press OK (F1) to save setting and return to previous menu.

1014-D109

Change to desired LANGUAGE using UP/ DN and press OK (F1) to save setting and return to previous menu.

Cancel (F2) or ESC returns the character window to the previous menu without saving any new setting.

Cancel (F2) or ESC returns the character window to the previous window without saving any new setting.

Reset the Volume RESET (F3) resets the alarm volume to the preset factory value which corresponds to 50.

SOUND SETTINGS •

Adjusting BUZZER VOLUME and change BUTTON SOUND.

CHANGE BUTTON SOUND

1014-D110

1014-D110

To shift to the tab SOUND, press MORE (F3).

Press SOUND (F1) to select the function SOUND SETTINGS.

Press SOUND (F1) to select the function SOUND SETTINGS.

6.25

Tigercat 1045/1055 Forwarder

Electrical & Computers

CHANGE BUTTON SOUND CONT’D

1014-D110

Press SET CLOCK (F2) to select the function for setting the DATE and TIME.

1014-D112

Press BUTTON (F2) to select the function to change the button sound.

1014-D114

Browse using UP/DN and thereafter press SELECT (F1) to select alternative from list.

1014-D113

Change to desired BUTTON SOUND using UP/DN. There are Ten button beep levels. 0 implies that the button beep is turned OFF. 100 is the loudest. Thereafter, press OK (F1) to save setting and return to previous menu.

YEAR - MONTH - DAY - HOUR - MINUTE

Cancel (F2) or ESC returns the character window to the previous menu without saving any new setting.

Reset the Button Sound Level RESET (F3) resets the button sound level to the preset factory value which corresponds to 50.

1014-D115

Change to desired value using UP/DN and press OK (F1) to save setting and return to previous menu.

DATE TIME SETTINGS •

Setting DATE and TIME.

Cancel (F2) or ESC returns the character window to the previous menu without saving any new setting.

1014-D096

To shift to the tab SET CLOCK, press MORE (F3).

6.26

Tigercat 1045/1055 Forwarder

Electrical & Computers CURRENT OUTPUT SETTINGS DESCRIPTION There are five different settings of minimum and maximum current for a current output. These settings (defined below) fine tune the operating speeds and start/stop ramps for the crane, steering, gate and blade functions.

MINIMUM CURRENT

1014-D098

3. PROPERTIES MENU OPERATION Changes can be made to the settings for adjustable machine functions. Adjustments will only affect the settings in the current operator mode.

Press F2 OUTPUTS to select CURRENT OUTPUT menu. Adjustments in this menu are:

1014-DMIN

•

STEERING FORWARD

•

STEERING REVERSE

•

BLADE

•

CRANE SLEW

•

MAIN BOOM

•

STICK BOOM

•

TELESCOPE

•

GRAPPLE ROTATE

•

GRAPPLE OPEN/CLOSE

•

GATE UP/DOWN

•

CRANE TILT

•

PUMP (+) FORWARD BEGIN OF REG

•

PUMP (-) REVERSE BEGIN OF REG

•

MOTOR MIN CURRENT BEGIN OF REG

•

MOTOR MAX CURRENT END OF REG

Minimum current settings control function start speed. Coils on hydraulic valves require a certain amount of current before they begin to operate the valve. The Min current value is the current that will be sent to the hydraulic valve coil when the joystick is moved a very small amount.

The min current is adjusted to a value that causes the function to just begin to move.

MAXIMUM CURRENT

Press F3 OTHER to select FUNCTION PARAMETERS menu. Adjustments in this menu are: •

WORKING RPM

•

CRANE MAXIMUM SPEED

•

TIRE ROLLING CIRCUMFERENCE

•

MOTOR SPEED BYPASS

•

GEAR CHANGE OUTPUT

•

BLADE ON/OFF

1014-DMAX

Maximum current settings control the maximum speed the function will operate.

NOTE: See CURRENT OUTPUT, START/STOP SLOPE AND FINE CONTROL DEFAULT SETTING VALUES at the end of this section.

Select scroll UP button to view PWM OUTPUT. There are no adjustable functions in this menu.

6.27

Tigercat 1045/1055 Forwarder

Electrical & Computers

CURRENT OUTPUT SETTINGS DESCRIPTION

SELECTING A FUNCTION TO ADJUST

START/STOP SLOPE

There are two methods of selecting a function for adjustment: 1) Manual Selection or 2) Direct Selection 1. MANUAL SELECTION

1014-DSTOP

Start and stop slope is the time it will take for the current to rise from minimum to maximum and maximum to minimum respectively.

1014-D098

Press F2 OUTPUTS to choose CURRENT OUT menu.

FINE CONTROL

CURRENT OUT

1014-D121

Press F1 SELECT to display SELECT FUNCTION menu.

1014-DFINE

SELECT FUNCTION

Fine Control changes the current output to joystick position curve from being a straight line to being close to a type of curved line. Lower numbers make the first 50% of joystick movement create more output. Higher numbers make the first 50% of joystick movement create less output.

MANUAL

1014-D121

CURRENT OUT ADJUSTMENTS

Press F3 MANUAL to display the adjustable functions.

With the seat facing the crane, start the engine and set the CRANE/BLADE switch to WORKING RPM. The hydraulic system must be warmed up before making any adjustments. See SYSTEM TEST AND WARM-UP procedure in this section.

All functions in this menu adjust in the same way.

MAIN BOOM UP function has been chosen as an example.

These functions can be reset to the factory defaults using the reset feature in the MODE menu.

1014-D133

Use UP/DN buttons to scroll to desired function.

6.28

Tigercat 1045/1055 Forwarder

Electrical & Computers

CURRENT OUT

1014-D121

1014-D121

Press F1 SELECT to display SELECT FUNCTION menu.

Press F1 SELECT (+) to select the BOOM UP function for adjustment. (NOTE: Pressing the F2 SELECT (-) selects the BOOM DOWN function.)

MIN CURRENT (+) MAIN BOOM OK

MANUAL

360

mA

CANCEL

1014-D187

Operate the BOOM UP joystick to select it for adjustment.

1014-D121

Use the UP/DN buttons to select desired adjustment, Min Current, Max Current, Start Slope, Stop Slope or Fine Controls. See CURRENT OUTPUT SETTINGS DESCRIPTION in this Section.

Shown above MIN CURRENT (+) MAIN BOOM UP function has been selected.

1014-D186

2. DIRECT SELECTION

(+) Main Boom appears in the display. Press F1 “SELECT” to confirm selection of boom up.

1014-D098

Press F2 OUTPUTS to choose CURRENT OUT menu.

1014-D134

Use the UP/DN buttons to select desired adjustment, Min Current, Max Current, Start Slope, Stop Slope or Fine Controls. See CURRENT OUTPUT SETTINGS DESCRIPTION in this Section.

Shown above MIN CURRENT (+) MAIN BOOM UP function has been selected.

6.29

Tigercat 1045/1055 Forwarder

Electrical & Computers

MIN CURRENT SETTING

MIN CURRENT (+) MAIN BOOM OK

365

mA

CANCEL

1014-D121 1014-D134

1. Use the UP/DN buttons to scroll to the MIN CURRENT adjustment menu. Press F1 SELECT.

5. While holding the BOOM UP function ON, use the UP/DN button to decrease the MIN CURRENT value until the Boom function just stops moving.

6. Press OK (F1) to save and return to previous menu.

MIN CURRENT (+) MAIN BOOM OK

Pressing CANCEL (F2) or ESC returns the display to the previous menu without saving any changed value.

250

mA

CANCEL

The MIN CURRENT value has now been saved.

1014-D121

2. Use UP/DN buttons to adjust the MIN CURRENT to a value of 250ma.

3. Slowly operate BOOM UP joystick to full on position. The boom should not move.

MIN CURRENT (+) MAIN BOOM OK

370

mA

CANCEL

1014-D121

4. While holding the BOOM UP function ON, use the UP/DN button to increase the MIN CURRENT value until the Boom function just begins moving.

6.30

Tigercat 1045/1055 Forwarder

Electrical & Computers

MAX CURRENT SETTING

MAX CURRENT (+) MAIN BOOM

START SLOPE SETTING

STARTSLOPE

625

mA

(+) MAIN BOOM

SELECT

1014-D121

ms

1014-D121

1. Scroll using UP/DN buttons to select MAX CURRENT menu. Press F1 SELECT.

MAX CURRENT (+) MAIN BOOM OK

450

SELECT

1. Scroll using UP/DN buttons to select START SLOPE menu. Press F1 SELECT.

STARTSLOPE

625

(+) MAIN BOOM

mA

OK

CANCEL

450

ms

CANCEL

1014-D121

1014-D121

2. Shown above MAX CURRENT (+) MAIN BOOM UP function has been selected.

2. Shown above START SLOPE (+) MAIN BOOM UP function has been selected.

3. With the engine running at Working RPM, adjust the MAX CURRENT value using the UP/DN buttons to increase (speed up boom speed) or decrease (slow down boom speed) value. Pull the Boom Up joystick back to its maximum position to test boom speed.

3. With the engine running at Working RPM, adjust the START SLOPE value using the UP/ DN buttons to adjust acceleration rate by increasing or decreasing value. Pull the Boom Up joystick back to test ACCELERATION speed.

4. Continue to adjust the MAX CURRENT value using the UP/DN buttons until the desired speed is obtained.

4. Continue to adjust the START SLOPE value using the UP/DN buttons until the desired ACCELERATION is obtained.

5. Press OK (F1) to save and return to previous menu.

5. Press OK (F1) to save and return to previous menu.

Pressing CANCEL (F2) or ESC returns the display to the previous menu without saving any changed value.

Pressing CANCEL (F2) or ESC returns the display to the previous menu without saving any changed value.

The MAX CURRENT value has now been saved.

The START SLOPE value has now been saved.

6.31

Tigercat 1045/1055 Forwarder

Electrical & Computers

STOP SLOPE SETTING

FINE CONTROL SETTING

1014-D188

1014-D189

1. Scroll using UP/DN buttons to select STOP SLOPE menu and press F1 to select (+) MAIN BOOM.

STOPSLOPE (+) MAIN BOOM OK

1. Scroll using UP/DN buttons to select FINE CONTROL menu and press F1 to select (+) MAIN BOOM.

FINE CONTROL

600

(+) MAIN BOOM

ms

OK

CANCEL

60

%

CANCEL

1014-D121

1014-D121

2. Shown above STOP SLOPE (+) MAIN BOOM UP function has been selected.

2. Shown above FINE CONTROL (+) MAIN BOOM UP function has been selected.

3. With the engine running at Working RPM, adjust the STOP SLOPE value using the UP/ DN buttons to adjust deceleration rate by increasing or decreasing value. Pull the Boom Up joystick back and release to test DECELERATION speed.

3. With the engine running at Working RPM, adjust the FINE CONTROL value using the UP/DN buttons to adjust CONTROL by increasing or decreasing value. Pull the Boom Up joystick back to test CONTROL. 4. Continue to adjust the FINE CONTROL value using the UP/DN buttons until the desired CONTROL is obtained.

4. Continue to adjust the STOP SLOPE value using the UP/DN buttons until the desired DECELERATION is obtained.

5. Press OK (F1) to save and return to previous menu.

5. Press OK (F1) to save and return to previous menu.

Pressing CANCEL (F2) or ESC returns the display to the previous menu without saving any changed value.

Pressing CANCEL (F2) or ESC returns the display to the previous menu without saving any changed value.

The FINE CONTROL value has now been saved.

The STOP SLOPE value has now been saved.

6.32

Tigercat 1045/1055 Forwarder

Electrical & Computers

FUNCTION PARAMETERS SETTINGS

BLADE ON/OFF

1014-D098

From the PROPERTIES main menu, press F3 OTHER to select FUNCTION PARAMETERS menu.

Blade On/Off is used to allow the blade to function when the optional blade is installed.

When the value is 0, the blade outputs won’t operate. This is done to provide a common program for machines with or without blades.

If the blade on/off is left on (value of 1) when no blade is installed, and the operator tries to operate the blade, alarms and messages will activate to indicate there is a problem with the blade (even though there isn’t one). Use the UP/Down buttons to change value to 0 to avoid unnecessary alarms.

1014-D122

WORKING RPM

Press F1 SELECT to display SELECT FUNCTION menu.

WORKING RPM is the constant engine speed setting that will occur when crane WORKING RPM is selected and operator is facing the crane.

Use the UP/DN buttons to scroll through the menu. Press F1 SELECT to select function.

1014-D127

Use the UP/DN buttons to scroll to the WORKING RPM menu. Press F1 SELECT to select function.

MOTOR SPEED BYPASS The Motor Speed Bypass value has a default value of 1. The only valid values are 1 and 0.

1 means the drive motor speed sensor functions as normal. When the value is changed to 0, the drive system bypasses the motor speed sensor value. This makes the drive very slow to respond. It is intended to be used only when there is a failure of the motor speed sensor. Motor Speed Bypass is displayed when there is a possible failure of the motor sensor. Use the UP/Down buttons to change the parameter to 0.

continued on next page

6.33

Tigercat 1045/1055 Forwarder

Electrical & Computers GEAR CHANGE OUTPUT %

1014-D128

Use the UP/DN buttons to scroll to the desired idle speed. Range is 1250 rpm to 1800 rpm, factory default setting is 1450 rpm.

1014-D190

When a gear change is taking place, the drive motor is rotated forward and reverse to allow the transmission gears for the selected speed range to engage. The gear change output is the percent of maximum pump flow that is used to rotate the drive motor during the gear change.

Press OK (F1) to save and return to previous menu.

CRANE SPEED

TIRE ROLLING CIRCUMFERENCE

1014-D132

CRANE SPEED PERCENT is a single adjustment that will reduce the maximum crane speeds of all the crane functions (except grapple open or close). The new speeds will be the maximum speed setting of each crane function multiplied by the percentage displayed.

1014-D129

For accurate reading of speed and distance, use the UP/DN buttons to scroll to the TIRE ROLLING CIRCUMFERENCE menu. Press F1 SELECT to select function.

Use the UP/DN buttons to scroll to the CRANE SPEED menu. Press F1 SELECT to select function.

Use the UP/DN buttons to scroll to the desired % of MAX CRANE SPEED. Press OK (F1) to save and return to previous menu.

1014-D130

Use the UP/DN buttons to scroll to the desired TIRE ROLLING CIRCUMFERENCE. TIRE ROLLING CIRCUMFERENCE SPECIFICATIONS TIRE SIZE

6.34

CIRCUMFERENCE

600/55-26.5

3995

650/65-26.5

4398

700/50-26.5

4036

750/55-26.5

4398

Tigercat 1045/1055 Forwarder MACHINE MODEL

Electrical & Computers MOTOR BEGIN DISP %

Machine model number can be selected and changed. This should be set for the model of machine owned to provide accurate speedometer and odometer readings.

This function is for the drive motor begin of displacement. Minimum is 0% and maximum is 20%. Increasing the value from 0 to 20% increases machine acceleration from a stop, by making the motor start displacement smaller. Decreasing, makes the machine acceleration from a stop softer (slower).

1055-057

Use the UP/DN buttons to scroll to the MACHINE MODEL menu. Press F1 SELECT to select function.

1075-043

Use the UP/DN buttons to scroll to the MOTOR BEGIN DISPLACEMENT % menu.

Press F1 SELECT to select function.

Use the UP/DN buttons to scroll to the desired model.

Press OK (F1) to save and return to previous menu.

Use the UP/DN buttons to scroll to the desired setting (0 to 20%).

1 MOTOR MAX ACCE TIME (ms)

Press OK (F1) to save and return to previous menu.

This function sets the drive motor maximum acceleration time. Minimum is 3000ms and maximum is 4000ms. Increasing this number gives slower acceleration and is more suitable to rough terrain. Decreasing the maximum acceleration time gives faster acceleration and better pedal response.

1075-042

Use the UP/DN buttons to scroll to the MOTOR MAXIMUM ACCELERATION TIME menu. Press F1 SELECT to select function.

Use the UP/DN buttons to scroll to the desired acceleration time.

Press OK (F1) to save and return to previous menu.

continued on next page 6.35

Tigercat 1045/1055 Forwarder

Electrical & Computers

PUMP DISP (cc)

COLD IDLE RPM

This function is for the main pump displacement. Minimum is 120cc and maximum is 180cc. Tigercat forwarders employ an oil sharing feature on the crane which divides the available oil between the operating functions. Increasing the pump displacement reduces this effect (a very high value may result in a ‘jerky’ crane). Decreasing the pump displacement increases this effect (a very low value may slow down the crane speed).

This function is to provide a higher idle speed to assist in faster warm up of the engine during cold weather start-up operation. Minimum is 850 rpm and maximum is 1200 rpm.

1075-044

Use the UP/DN buttons to scroll to the COLD IDLE menu. Press F1 SELECT to select function.

Use the UP/DN buttons to scroll to the desired speed.

1075-045

Press OK (F1) to save and return to previous menu.

Use the UP/DN buttons to scroll to the PUMP DISPLACEMENT menu. Press F1 SELECT to select function.

Use the UP/DN buttons to scroll to the desired pump setting.

Press OK (F1) to save and return to previous menu.

6.36

Tigercat 1045/1055 Forwarder

Electrical & Computers

SYSTEM WARNING MESSAGES

1014-D039

3. PILOT RESET WARNING

1014-D032

1. ENGINE TEMPERATURE WARNING

This warning will be displayed and Pilot Reset Indicator Light will turn on if an attempt is made to drive or operate the machine with no pilot reset. The alarm, warning lights and message will be displayed.

This warning will be displayed and warning light will activate when engine temperature exceeds 101°C (214°F). The WARNING MESSAGE will be displayed, WARNING LIGHT will activate and ALARM will sound when engine temperature exceeds 105°C (221°F).

If doors are open or the ladder down/park brake switch “ON” position is selected, the pilot can’t be reset (proximity switches sense doors are open) and machine won’t operate.

When this alarm is activated check for plugged air intake access panel screens or plugged radiator. DO NOT continue to operate machine. Refer to CLEANING A/C CONDENSER, OIL COOLER, RADIATOR and AIR CHARGE COOLER in THIS SECTION.

If door opens while machine is moving (or switch fails), the alarm, warning lights and message will be displayed but functions are allowed to continue until machine stops, then outputs are shut-off.

Close the doors and press Pilot Reset Switch to resume machine operation.

1014-D033

2. HYDRAULIC OIL TEMPERATURE WARNING

1014-D198

This warning will be displayed, warning light will activate and alarm will sound when the oil temperature exceeds normal operating temperatures 84°C (183°F).

4. PARK BRAKE/LADDER DOWN WARNING This warning will be displayed, and warning alarm will sound when the ladder is down and/ or parking brakes are on and the pilot system is on.

If the temperature goes above 84°C (183°F) check the following:

Check that the LADDER is fully UP and the PARK BRAKE LEVER is fully OFF to deactivate this warning.

• Plugged oil cooler • Malfunction in a hydraulic system • High loads on the hydraulic system • Low hydraulic oil level Operation above 84°C (183°F) will shorten hydraulic component life. If the temperature reaches 84°C (183°F) DO NOT continue to operate the machine.

6.37

Tigercat 1045/1055 Forwarder

Electrical & Computers

1014-D030

1014-D045

7. WARNING

5. GEAR NOT ENGAGED WARNING

When an alarm is displayed and “BYPASS” is selected this message will be displayed.

Pressing “OK” when this message is displayed will remove the message from the display. The warning lights will stay on until the alarm condition is corrected.

This warning will be displayed, warning light will activate and alarm will sound when the transmission is not in the requested gear range.

When this alarm ocurrs, the transmission gear switch may be in second gear but second gear is not engaged, or the switch may be in first gear but first gear is not engaged.

When this alarm is activated, change gear selection to engage another drive gear and stop alarm. If bypass is selected, warning lights will remain on and gear selected will be assumed by computer.

If this alarm continues investigate cause, refer to DRIVE SECTION of the Service Manual.

1014-D116

6. GEAR CHANGE WARNING This warning will be displayed, the warning and alarm will sound when transmission gear change is attempted.

STOP machine travel to complete the gear change.

6.38

Tigercat 1045/1055 Forwarder

Electrical & Computers

CONDITIONAL MESSAGES (CM) Conditional messages give the operator information regarding an event or problem condition while the event or problem exists. If the event or condition disappears, so will the message and alarm.

1014-D164

2. CRANE START (CM) If any crane joystick input is high (joystick activated) when crane switch is turned on, Crane Input Is Active message is displayed.

Release the joystick to deactivate the input to operate the crane.

1014-D031

If the operator presses “OK” on the MDM, the message will disappear even if the problem still exists. When this alarm is activated investigate the cause. Refer to ELECTRICAL AND COMPUTER SECTION of Service Manual.

1014-D040

3. DRIVE START (CM) If the drive pedal input is high (pedal activated) before pilot is reset, Drive Pedal Input Is Active message is displayed. Drive is prevented until the pedal is released.

1014-D030

Release the pedal to deactivate the input to enable the drive function.

1. SYSTEM BYPASSED WARNING When an alarm is bypassed, as long as the fault is still active, this warning will be displayed, alarm warning light will flash and horn will sound every 30 seconds.

When this alarm is activated investigate the cause immediately. Once the fault is fixed, warning deactivates and bypass is stopped.

6.39

Tigercat 1045/1055 Forwarder

Electrical & Computers

CONDITIONAL MESSAGES (CM) CONTINUED

1014-D050

7. ENGINE OVERSPEED (CM) 1014-D048

This warning will be displayed, warning light will activate and alarm will sound if the engine speed exceeds the maximum desired speed.

5. STEER CHECK ERROR (CM) This warning will be displayed, warning light will activate and alarm will sound if dual steering joystick outputs don’t match.

When this alarm is activated apply the brakes to slow the machine down.

This condition has no bypass option. Alarm and message will remain on display and steering function will be disabled until fault is fixed.

When this alarm is activated investigate the cause immediately. Refer to the Electrical and Computer Section of the Service Manual.

8. MAXIMUM TRAVEL SPEED (CM) When adjusting the maximum travel speed of the machine, a bar graph appears indicating the current percent of maximum travel speed setting.

This adjustment is used for Travel Crawl Speed setting to control maximum travel speed when travelling over uneven and rough terrain.

1014-D165

6. NO MOTOR SPEED (CM) This warning will be displayed, warning light will activate and alarm will sound when the drive pump has an output, but the drive motor speed measures 0 RPM.

Note: Refer to TRAVEL SPEED SETTING in THIS SECTION.

If the machine is in motion, this condition can be bypassed by holding the pilot reset switch on momentarily to allow machine to be driven temporarily so fault can be fixed. See FUNCTION PARAMETERS SETTINGS earlier in this section to turn alarm OFF. When this alarm is activated investigate the cause immediately. Refer to the Service Manual Drive Section.

6.40

Tigercat 1045/1055 Forwarder

Electrical & Computers

1014-D158

1014-D160

11. HYDRAULIC OIL LEVEL WARNING (CM)

9. BRAKE PRESSURE WARNING (CM)

This warning will be displayed, warning light will activate and alarm will sound when the main hydraulic tank oil level is low.

This warning will be displayed, warning light will activate and alarm will sound when brake pressure falls below 40bar (580 psi). Stop the engine when this alarm is activated. Check brake system. See OPERATING MACHINE in this SECTION for more information.

Stop the engine immediately when this alarm is activated. Operating machine with a low hydraulic oil level can cause hydraulic pumps to fail.

When this alarm is activated stop the engine and look for signs of broken hoses or other leaks. Repair leaks and refill the main hydraulic tank to FULL mark on the sight gauge. Restart engine and inspect for leaks.

1014-D159

10. ENGINE OIL PRESSURE WARNING (CM) This warning will be displayed, warning light will activate and alarm will sound when engine oil pressure falls below 1.03 bar (15 psi) at Low Idle or 2.07 bar (30 psi) at High Idle. Stop the engine when this alarm is activated.

Check engine oil levels. See OPERATING MACHINE in this SECTION for more information.

1014-D162

12. AIR FILTER RESTRICTION WARNING (CM) This warning will be displayed, warning light will activate and alarm will sound when the engine air filter restriction exceeds 6.2 kPa (25” H2O).

Stop the engine immediately when this alarm is activated and service the air cleaner. See AIR CLEANER MAINTENANCE in Section 3 of this manual.

6.41

Tigercat 1045/1055 Forwarder

Electrical & Computers

CONDITIONAL MESSAGES (CM) CONTINUED WARNING DO NOT remove the radiator cap when the engine is hot, release of pressurized coolant can cause serious burns.

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

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

1014-D163

14. FUEL LEVEL WARNING (CM) This warning will be displayed and alarm will sound when fuel level drops below 10%.

1014-D158 1014-D161

15. VOLTAGE WARNING (CM)

13. COOLANT LEVEL WARNING (CM)

This warning will be displayed, warning light will activate and alarm will sound when voltage readings of less than 20 volts or greater than 28 volts are detected.

This warning will be displayed, warning light will activate and alarm will sound when the coolant level drops below a safe operating level. The sensor is located in the radiator surge tank. If this light comes on when the engine is running, stop the engine immediately and correct the fault. With engine running, top up radiator using correct solution of coolant antifreeze.

When this alarm is activated investigate the cause immediately.

6.42

Tigercat 1045/1055 Forwarder

Electrical & Computers

MAIN SYSTEM ERRORS

MODULE IS OFFLINE

MDM MODULE BLANK SCREEN

The MODULE IS OFFLINE warning message indicates a loss of communication with or power to an IQAN module. The offline module is identified on the display screen.

The MDM module is the central unit in the IQAN control system, which works as both a master and a display unit. Faults or failure in this unit will affect all other IQAN components.

Likely causes are: • Power - Fuse (MDM BATTERY or MDM CLOCK) • Ground • LCD display settings too light to read • Faulty MDM module

When a module goes offline all machine functions controlled by that module cease and all alarms and warnings associated with that module are triggered. If the problem is with the CAN wires all modules beyond the problem module will also be affected.

NOTE: It is possible for an operator or service technician to disable this warning message. If the MODULE IS OFFLINE warning function is disabled for a module the first indication of a loss of communication or power to a module will be the loss of all machine functions controlled by the module and the triggering of all alarms and warnings associated with that module. This may cause problems in identifying the source of a control problem, as it will not be immediately obvious that a loss of communication or power to the module is the source of the problem.

To greatly reduce the time required to diagnose a MODULE IS OFFLINE warning, it is recommended that all available modules ALWAYS be set to ENABLED as shown. This screen is accessed through the INFORMATION MENU, which should normally be accessed by Tigercat service technicians only. Refer to INFORMATION CENTER~SYSTEM DIAGNOSTICS MENUS~DIAGNOSTICS MENU OPERATION inTHIS SECTION.

6.43

Tigercat 1045/1055 Forwarder

Electrical & Computers

XS-A0 MODULE OFFLINE ERROR Expect all machine functions controlled by this module to cease and all alarms and warnings associated with this module to be triggered.

1. CHECK FOR OTHER ERROR/ALARM MESSAGES ON SCREEN

1014-038

2. CHECK MODULE STATUS INDICATORS

Press OK to acknowledge each error message. Note that module offline errors will be followed by other alarm messages associated with the module(s) which is(are) offline.

Status lights can also give an immediate indication of the nature of the error.

Supply Voltage LED. LED ON solid green light indicates supply voltage is ON.

If XS-A0 MODULE IS OFFLINE is the only module is offline error message the likely causes are:

LED OFF indicates supply voltage is OFF. Arrow and Heart Status Indicator LEDs.

• Power - Fuse (XS MODULE)

LED for Heart and Arrow flash alternately (solid green) indicates Status is Correct.

• Ground

When Heart LED is off and LED for arrow flashes (green), this indicates the following errors:

• Address (ID-Tag) If the XS-A0 MODULE IS OFFLINE is followed by LX-A0, XT2-A0 and XP2-A0 MODULE IS OFFLINE errors the likely cause is: • CAN wire connection

•

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

•

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

•

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

•

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

XS Module Error code I/O and voltage errors Low/High temperature CAN error VREF error

6.44

Blink (Arrow only green light)

Tigercat 1045/1055 Forwarder

Electrical & Computers

LX MODULE OFFLINE ERROR Expect all machine functions controlled by this module to cease and all alarms and warnings associated with this module to be triggered.

1. CHECK FOR OTHER ERROR/ALARM MESSAGES ON SCREEN Press OK to acknowledge each error message. Note that module offline errors will be followed by other alarm messages associated with the module(s) which is(are) offline.

1014-039

LX-, XP2- and XT2- module

If LX-A0 MODULE IS OFFLINE is the only module is offline error message the likely causes are:

Error code

• Power - Fuse (JOYSTICK)

CAN error

Low/High temperature

Hardware error

• Ground

Address error

• Address (ID-Tag)

Software error

If the XS-A0 MODULE IS OFFLINE is followed by XT2-A0 and XP2-A0 MODULE IS OFFLINE errors the likely cause is:

• •

• CAN wire connection •

2. CHECK MODULE STATUS INDICATORS Status lights can also give an immediate indication of the nature of the error.

•

(1) Supply Voltage LED. LED ON solid green light indicates supply voltage is ON. LED OFF indicates supply voltage is OFF. (2) Status indicator LED (yellow/red).

LED yellow flashing light indicates status is correct.

LED flashing red light indicates error status as follows: • •

Blink (red light)

I/O and voltage errors

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

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

6.45

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

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

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

Continuous flashing indicates the fault is related to software.

Tigercat 1045/1055 Forwarder

Electrical & Computers 2 1

•• •• XT2-A0 MODULE LED INDICATORS

1014-042

2. CHECK MODULE STATUS INDICATORS XT2 MODULE OFFLINE ERROR

Status lights can also give an immediate indication of the nature of the error.

Expect all machine functions controlled by this module to cease and all alarms and warnings associated with this module to be triggered.

(1) Supply Voltage LED. LED ON solid green light indicates supply voltage is ON.

1. CHECK FOR OTHER ERROR/ALARM MESSAGES ON SCREEN

LED OFF indicates supply voltage is OFF.

Press OK to acknowledge each error message. Note that module offline errors will be followed by other alarm messages associated with the module(s) which is(are) offline.

(2) Status indicator LED (yellow/red).

LED yellow flashing light indicates status is correct.

LED flashing red light indicates error status as follows:

If XT2-A0 MODULE IS OFFLINE is the only module is offline error message the likely causes are:

•

• Power - Fuse (XT2 MODULE)

•

• Ground • Address (ID-Tag)

•

If the XT2-A0 MODULE IS OFFLINE is followed by the XP2-A0 MODULE IS OFFLINE error the likely cause is:

•

• CAN wire connection

• •

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

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

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

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

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

Continuous flashing indicates the fault is related to software.

LX-, XP2- and XT2- module Error code I/O and voltage errors Low/High temperature CAN error Hardware error Address error Software error

6.46

Blink (red light)

Tigercat 1045/1055 Forwarder

Electrical & Computers 2 1

•• •• 1014-042 XP2-A0 MODULE LED INDICATORS 2. CHECK MODULE STATUS INDICATORS

XP2 MODULE OFFLINE ERRORS

Status lights can also give an immediate indication of the nature of the error.

Expect all machine functions controlled by this module to cease and all alarms and warnings associated with this module to be triggered.

(1) Supply Voltage LED. LED ON solid green light indicates supply voltage is ON.

1. CHECK FOR OTHER ERROR/ALARM MESSAGES ON SCREEN

LED OFF indicates supply voltage is OFF.

Press OK to acknowledge each error message. Note that module offline errors will be followed by other alarm messages associated with the module(s) which is(are) offline.

(2) Status indicator LED (yellow/red).

LED yellow flashing light indicates status is correct.

LED flashing red light indicates error status as follows:

Note also that the XP2-A0 module is the terminal module in the series connection.

Therefore failure of this module alone will not affect any other modules in the series.

• •

If the XT2-A0 MODULE IS OFFLINE is the only module is offline error message the likely causes are:

•

• Power - Fuse (XP2 MODULE) •

• Ground • Address (ID-Tag)

•

• CAN wire connection If the XT2-A0 MODULE IS OFFLINE error is not the only module is offline error message check other affected modules in order from the MDM connection (XS-A0, LX-A0, XT2-A0).

Refer to MODULE IS OFFLINE ERROR for each module for more detailed information.

•

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

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

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

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

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

Continuous flashing indicates the fault is related to software.

LX-, XP2- and XT2- module Error code I/O and voltage errors Low/High temperature CAN error Hardware error Address error Software error

6.47

Blink (red light)

Tigercat 1045/1055 Forwarder

Electrical & Computers

FUSE AND RELAY PANELS

FUSE AND RELAY PANEL LABEL - CAB

1. FUSE AND RELAY PANEL - CAB

1065-003

FUSE & RELAY COMPARTMENT IN CAB Fuses and relays for the cab electrical controls and computer are located inside the top right compartment in the cab roof.

6.48

Tigercat 1045/1055 Forwarder

Electrical & Computers

FUSE AND RELAY PANELS

FUSE AND RELAY PANEL LABEL- UNDER CAB

2. FUSE AND RELAY PANEL - UNDER CAB

1065-001

Fuses and relays for the engine, hydraulic and machine electrical controls are located in the electrical box under the cab.

6.49

Tigercat 1045/1055 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)

6.50

Tigercat 1045/1055 Forwarder

Electrical & Computers

CURRENT OUTPUT, START/STOP SLOPE AND FINE CONTROL DEFAULT SETTINGS FUNCTION

MIN CUR mA

MAX CUR mA Start Slope ms Stop Slope ms Fine C%

• STEERING FORWARD (+)

334

550

600

600

45

• STEERING FORWARD (-)

334

550

600

600

45

• STEERING REVERSE (+)

334

550

600

600

45

• STEERING REVERSE (-)

334

550

600

600

45

• BLADE UP (+)

200

500

250

250

0

• BLADE DOWN (-)

200

500

250

250

0

• CRANE SLEW (+)

362

540

500

900

30

• CRANE SLEW (-)

343

540

500

900

30

• MAIN BOOM (+)

360

550

1100

1000

30

• MAIN BOOM (-)

360

540

500

500

20

• STICK BOOM (+)

355

575

600

500

20

• STICK BOOM (-)

355

600

1000

400

20

• TELESCOPE (+)

355

560

250

350

10

• TELESCOPE (-)

350

560

250

300

10

• GRAPPLE ROTATE (+)

365

500

200

200

50

• GRAPPLE ROTATE (-)

365

500

200

200

50

• GRAPPLE OPEN (+)

345

600

100

100

10

• GRAPPLE CLOSE (-)

350

600

100

100

10

• GATE UP (+)

345

400

1000

250

50

• GATE DOWN (-)

400

450

1000

250

0

• CRANE TILT (+)

400

500

700

250

0

• CRANE TILT (-)

400

500

700

250

0

• PUMP (+) B of R & Max Dis

200

620

500

900

0

• PUMP (-) B of R & Max Dis

230

630

500

900

0

• MOTOR (+) B of R & Min Dis 165

455

500

500

0

FUNCTION PARAMETERS SETTING • WORKING RPM • CRANE MAXIMUM SPEED • TIRE ROLLING CIRCUMFERENCE • MOTOR SPEED BYPASS • GEAR CHANGE OUTPUT • BLADE ON/OFF • MACHINE MODEL • 1 MOTOR MAX ACCEL TIME • MOTOR BEGIN DISP • PUMP DISP • COLD IDLE

Min 900 rpm Max 1800 rpm Min 60% Max 100% Min 1 Max 6000 Min 0 Max 1 Min 5 Max 15 Min 0 Max 1 1045 - 1055 - 1065 - 1075 Min 3000 ms Max 4000 ms Min 0% Max 20% Min 120cc Max 180cc Min 850 Max 1200

Default 1400 rpm Default 100% See chart in Section 2 Default 1 Default 9 Default 0 Default 3000 ms Default 20% Default 140cc Default 1100

NOTE: The actual values may vary from factory settings due to operator preference adjustment.

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IQAN SOFTWARE

NOTE: In the event of a battery failure in a PDA registration information may be lost. If this occurs it will be necessary to re-register the PDA for use.

IQAN software can be downloaded from the Tigercat Dealer Website (click on Customer Service/ Warranty to find Machine Software).

All software required for both PC (laptop) and PDA use is included in this download. A user’s manual in PDF format is also included. Some of the software requires a software key (available from Tigercat).

Contact Tigercat Customer Service or your Tigercat District Manager for more information about registering a PDA.

DOWNLOADING APPLICATIONS FROM THE TIGERCAT DEALER WEBSITE Currently applications (IQAN programs) can be downloaded from the Tigercat dealer website in two formats:

Contact Tigercat Customer Service for more information about specific hardware requirements

1. An executable program can be downloaded.

This will automatically unzip and place the IQAN application file in the required file location. This is the preferred method for downloading as it keeps things simple for the user.

Note however that security settings on some user computers may not allow downloading of executable programs (EXE files). These users will need to use the second method of downloading files or approach their IT administrator to download executable files.

2. The application file itself can be downloaded.

The file must be placed in the required file location by the user in order to be used by the IQAN G3 software.

NOTE: The following downloading instructions apply to the Tigercat dealer website format at the time of printing. If you experience difficulty due to changes on the website contact Tigercat Customer Service for assistance. for PC (laptop) and PDA.

DOWNLOADING APPLICATIONS AS EXE FILES

APPLICATION PROGRAM UPDATES FOR PRODUCT SERVICE BULLETINS Machine program updates are also available on the Tigercat dealer website. These program updates are generally associated with specific Product Service Bulletins. Updating of programs should only be undertaken as part of a PSB or under instruction from Tigercat Customer Service.

The latest version of the application can be run on any machine provided that all applicable Product Service Bulletin updates have been completed.

PDA REGISTRATION In order to use a PDA (personal digital assistant) to perform maintenance procedures the PDA must be registered for authorized use of the software on Tigercat products. Each Tigercat product line has its own application code and must be registered separately for authorized use.

1. Click on the EXE to the right of the file you wish to download.

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Electrical & Computers DOWNLOADING APPLICATIONS AS IDT FILES

2. Click on Open.

1. Click on the IDT to the right of the file you wish to download.

3. The correct folder location will automatically be chosen. Click Unzip.

2. Click on Save.

4. A pop up box will confirm the file has been successfully unzipped. Click on OK

3. The correct folder location must be manually chosen. C:\Program Files\ IQAN software\ G3 Second edition\Applications\To Palm.

4. Click on Save.

5. Click on Close.

6. The IQAN program file has now been downloaded to the correct folder.

5. The IQAN program file has now been downloaded to the correct folder.

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UPDATING THE IQAN APPLICATION A. UPDATING THE IQAN APPLICATION FROM A PDA (PERSONAL DIGITAL ASSISTANT) The following procedure instructs how to send a Tigercat IQAN application from a PDA (Personal Digital Assistant) device to the MDM module.

To perform this procedure you will require: • • •

PDA IQAN data cable for PDA PDA serial port adapter cable (for the PDA being used).

1. Park machine on level ground, lower all implements to the ground, set the park brake ON, and turn the key switch to OFF. 2. Locate the ‘round’ RS232 port connection on the back of the MDM. Do not disconnect the rectangular 6-pin connector.

PDA MAIN IQAN WINDOW

Note: This will require temporary removal of the MDM from its mounting location (4 screws).

5. Turn on power to the PDA, and start the IQANdevelop G3 program.

6. Turn the key switch to ‘RUN’. DO NOT START THE MACHINE.

3. Remove the rubber dust seal from the RS232 port and connect IQAN data cable for PDA.

WARNING Damage may occur to the PDA if the wrong data cable is used. Ensure the appropriate cable is selected when using a PDA; DO NOT USE AN ADAPTER TO MATCH UP SERIAL PORTS. IQAN DATA CABLE FOR PDA

PDA SERIAL PORT ADAPTER CABLE

IQAN - MDM PALM OS PDA

CONNECTING MDM TO PDA PDA DROP DOWN MENU DISPLAY

4. Connect the other end of the cable to the serial port adapter cable for the PDA being used.

7. Select the ‘IQAN’ box from the top left corner of the PDA screen. This will display a drop down menu showing ‘System / Options / Help’.

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8. From the ‘System’ menu, select ‘Update application…’. Note: it will take a moment for the PDA to display available application programs.

9. All IQAN application programs available for upload will be displayed.

10. Highlight the appropriate application program by selecting it on the PDA screen.

18. Start the machine and verify correct operation of the new application.

19. Turn the key switch to ‘OFF’.

20. Turn off power on the PDA. 21. Disconnect the IQAN data cable for PDA from both the MDM and the PDA serial port adapter cable.

22. Reinstall the rubber dust seal on the MDM RS232 port. Reinstall the MDM into the mounting panel (4 screws).

PDA SEND APPLICATION DIALOG BOX 11. Select the ‘SEND’ box. This will display a dialog box titled ‘Send application’.

12. Set the ‘Factory default values’ to ‘Use values from application file’.

13. Set the ‘Adjustable values’ to ‘Use values from application file’.

14. Set the ‘Stored values’ to: For an MDM previously installed: ‘Leave values in master unchanged’.

For a new MDM (field replacement): ‘Reset all values to zero’.

15. Select the ‘SEND’ box. The MDM will display ‘! RECEIVING APPLICATION !’.

Important: The upload process should take less than one minute to complete.

During this time, do not perform any other functions on the PDA, or turn off power to the MDM. DO NOT START THE MACHINE. Should this occur, the upload will be halted and incomplete; starting from the beginning will be required.

16. Once the application is sent, turn off power to the MDM. 17. Select the ‘DONE’ box on the PDA. This will return the PDA display to the IQANdevelop G3 main screen.

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B. UPDATING THE IQAN APPLICATION FROM A PC/LAPTOP The following procedure instructs how to send a Tigercat IQAN application from a personal computer (PC) or laptop to complete an upload of a Tigercat IQAN application.

code and select the ‘OK’ box. Note: contact the Tigercat Customer Service to acquire the correct application code.

To perform this procedure you will require: • • •

PC/Laptop IQAN data cable for PC/Laptop (no adapter cable required) Hardware key (Parker IQAN component available from Tigercat)

1. Park machine on level ground, lower all implements to the ground, set the park brake ON, and turn the key switch to OFF. 2. Locate the ‘round’ RS232 port connection on the back of the MDM. Do not disconnect the rectangular 6-pin connector.

9. Using the toolbar: select the ‘Send current application to IQAN system’

icon.

OR

Note: This will require temporary removal of the MDM from its mounting location (4 screws).

Using the drop-down menus: select ‘System’, ‘Send application…’.

3. Remove the rubber dust seal from the RS232 port and connect IQAN data cable for PC/Laptop.

4. Connect the other end of the cable to the COM1 serial port on the PC/Laptop.

5. Turn on power to the computer, and start the IQANdevelop G3 program.

6. Turn the key switch to ‘RUN’. DO NOT START THE MACHINE. 7. Open the new application in IQANdevelop G3 on the computer.

10. This will display another dialog box titled ‘Send application’.

11. Set the ‘Factory default values’ to ‘Use values from application file’.

12. Set the ‘Adjustable values’ to ‘Use values from application file’.

13. Set the ‘Stored values’ to: For an MDM previously installed: ‘Leave values in master unchanged’.

For a new MDM (field replacement): ‘Reset all values to zero’.

8. A dialog box titled ‘Enter application code’ will appear. Enter the correct application

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Electrical & Computers 20. Disconnect the IQAN data cable for PC/ Laptop from both the MDM and the computer.

21. Reinstall the rubber dust seal on the MDM RS232 port. Reinstall the MDM into the mounting panel if previously removed.

14. Select the ‘SEND’ box. The MDM will display ‘! RECEIVING APPLICATION !’.

Note: In some cases a dialog box will appear titled ‘IQANdevelop: Confirmation’.

This dialog box states that the current application has a different description than the application loaded in the IQAN system.

Select the ‘Yes’ box to continue.

Important: The upload process should take less than one minute to complete.

During this time, do not perform any other functions on the computer, or turn off power to the MDM. DO NOT START THE MACHINE. Should this occur, the upload will be halted and incomplete; starting from the beginning will be required.

15. When the upload is complete, the computer display will return to the IQANdevelop G3 main screen.

16. Turn off power on the MDM. 17. Start the machine and verify correct operation of the new IQAN application.

18. Turn the key switch to ‘OFF’.

19. Turn off power on the computer.

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GET APPLICATION (DOWNLOAD FROM MDM)

5. Turn on power to the PDA, and start the IQANdevelop G3 program.

A. GET APPLICATION USING A PDA (PERSONAL DIGITAL ASSISTANT) The following procedure instructs how to retrieve a Tigercat IQAN application with a PDA (Personal Digital Assistant) device from the MDM (Master Display Module).

To perform this procedure you will require: • • •

PDA IQAN data cable for PDA PDA serial port adapter cable (for the PDA being used).

1. Park machine on level ground, lower all implements to the ground, set the park brake ON, and turn the key switch to OFF. 2. Locate the ‘round’ RS232 port connection on the back of the MDM. Do not disconnect the rectangular 6-pin connector.

Note: This will require temporary removal of the MDM from its mounting location (4 screws).

PDA MAIN IQAN WINDOW 6. Turn the key switch to ‘RUN’. DO NOT START THE MACHINE.

3. Remove the rubber dust seal from the RS232 port and connect IQAN data cable for PDA.

WARNING Damage may occur to the PDA if the wrong data cable is used. Ensure the appropriate cable is selected when using a PDA; DO NOT USE AN ADAPTER TO MATCH UP SERIAL PORTS.

IQAN DATA CABLE FOR PDA

PDA SERIAL PORT ADAPTER CABLE

IQAN - MDM PALM OS PDA

CONNECTING MDM TO PDA SELECTING AN EMPTY SLOT 4. Connect the other end of the cable to the serial port adapter cable for the PDA being used.

7. Select an <empty slot> from the top right of the PDA screen. This is the location the application program will be downloaded to.

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8. In the IQANdevelop main screen, select the

7. Open the new application in IQANdevelop G3 on the computer.

icon.

9. This will display a new dialog box titled ‘Receiving…’, and the download process will begin.

10. Once the download process is complete, the PDA display will return to the main IQANdevelop G3 window. The downloaded application description will replace the <empty slot> in the top right corner of the PDA. Important: The download process should take less than one minute to complete. During this time, do not perform any other functions on the PDA, or turn off power to the MDM. DO NOT START THE MACHINE. Should this occur, the download will be halted and incomplete; starting from the beginning will be required.

B. GET APPLICATION USING A A PC/LAPTOP

8. A dialog box titled ‘Enter application code’ will appear. Enter the correct application code and select the ‘OK’ box. Note: contact the Tigercat Customer Service to acquire the correct application code.

9. Using the drop-down menus: select ‘System’, ‘Get application’

The following procedure instructs how to retrieve a Tigercat IQAN application with a personal computer (PC), or laptop from the MDM (Master Display Module).

To perform this procedure you will require: • • •

PC/Laptop IQAN data cable for PC/Laptop (no adapter cable required) Hardware key (Parker IQAN component available from Tigercat)

1. Park machine on level ground, lower all implements to the ground, set the park brake ON, and turn the key switch to OFF.

10. Choose a filename and the location you wish to save the file. Click on Save.

2. Locate the ‘round’ RS232 port connection on the back of the MDM. Do not disconnect the rectangular 6-pin connector.

Note: This will require temporary removal of the MDM from its mounting location (4 screws).

3. Remove the rubber dust seal from the RS232 port and connect IQAN data cable for PC/Laptop.

4. Connect the other end of the cable to the COM1 serial port on the PC/Laptop.

5. Turn on power to the computer, and start the IQANdevelop G3 program.

11. A pop-up box will confirm that the file is being downloaded.

6. Turn the key switch to ‘RUN’. DO NOT START THE MACHINE. 6.59

Tigercat 1045/1055 Forwarder 12. When the download is complete, the computer display will return to the IQANdevelop G3 main screen.

13. Turn the key switch to ‘OFF’.

14. Turn off power on the computer.

15. Disconnect the IQAN data cable for PC/ Laptop from both the MDM and the computer.

Electrical & Computers GRAPHING AND MEASUREMENT OF CHANNELS A. GRAPHING AND MEASUREMENT OF CHANNELS USING A PDA The following procedure instructs how to graph and measure channels with a PDA (Personal Digital Assistant) device from the MDM (Master Display Module).

1. Get application from the MDM. Refer to IQAN SOFTWARE ~GET APPLICATION procedure in THIS SECTION.

16. Reinstall the rubber dust seal on the MDM RS232 port. Reinstall the MDM into the mounting panel if previously removed.

2. Tap the channels icon.

3. Select the channel type in popup list and then a channel.

Highlight a channel by tapping on the channel’s name. (Used for graphing) Notice only one channel at a time can be graphed.

Check a channel by tapping on channel box. (Used for measure) You can measure more than one channel at a time.

4. To measure on channels tap the Measure button. The channel you have selected in channels window with checkboxes will show up. Tap the Start button to start measure. Tap the stop button to stop. (The button label changes from start to stop and vice versa). For each channel you will see the value and the status indicator. If the value is ok, OK will show. If not then you see “!!!”. By tapping on the channel you will see the channel name, channel unit, complete status message and pin

assignment at the bottom of screen.

You can change the scale (relates to the type of channel) by taping to top right corner.

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The Clear button is used to deselect all selected channels and return to channels window.

master cycle time. Measurement is typically carried out with a 100ms sample interval on Palm. That means the glitches and spikes on the signal may not be registered.

5. You can also graph a channel. This means you can measure graphically one channel

B. GRAPHING AND MEASUREMENT OF CHANNELS USING A PC/LAPTOP Procedure information to follow in next revision of the service manual.

Contact Tigercat service department for more information

at a time. In figure 3 highlight a channel and tap the graph button. This will take you to Figure 5. The scaling of the Y-axis is shown next to the axis. Tap the start button to start measure. After having measured, the total log time is displayed after channel name. The SMZ buttons allow you to manipulate the graph. With the S you can use your stylus pent to position a cursor on the graph and read out the corresponding value and time of the cursor at the bottomright corner. With the M you can move the graph and with the Z you can zoom in the graph. This is done by dragging your stylus pen on the screen. The drop down menu at the top right corner has five graph slot that are available to you for measurement.

Select an empty slot, unless you want to overwrite your current graph. The info button allows you to add a comment to

graph. The comment can hold 255 characters. The time is automatically captured when measurement starts.

Notice: Due to limited power of the processor of Palm, the measurement is not performed at full speed with respect to the 6.61

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GET ERROR/EVENT LOG A. GET ERROR/ EVENT LOG USING A PDA The following procedure instructs how to get an error/event log with a PDA (Personal Digital Assistant) device from the MDM (Master Display Module).

1. Get application from the MDM. Refer to IQAN SOFTWARE~GET APPLICATION procedure in THIS SECTION. 2. The error log is retrieved automatically when you get the application.

8. If you tap on one of the errors/events you will get the description and the time at the bottom of the screen.

PDA MAIN IQAN WINDOW 3. Tap the error log icon.

4. The error and event log will be retrieved automatically when you get the application.

5. Switch between viewing the error and event log with the two buttons in the topright corner.

6. If you tap on the Module/Name button you will alternate between showing “module:module name” and “module name” alone or “channel:channel name” and “channel name” alone.

7. If you tap on the Description/Time button you will alternate between showing the date/time and the error/event description.

The time format depends on your PDA formats settings.

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B. GET ERROR/ EVENT LOG USING A PC/LAPTOP The following procedure instructs how to get an error/event log using a PC/Laptop 1. Get application from the MDM. Refer to IQAN SOFTWARE~GET APPLICATION procedure in THIS SECTION.

2. Using the drop-down menus select System then Get error/event log.

4. When the transmission is complete the Events or Errors/alarms can be viewed by selecting one of the tabs at the top of the display.

5. Error/event logs can be copied or saved.

3. The receiving channels pop up box will appear.

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Tigercat 1045/1055 Forwarder

Engine Start & Stop

SECTION 7 - ENGINE START & STOP AUGUST, 2006

CONTENTS - SECTION 7 ADM2 ADAPTION MODULE ........................................................................... 7.3 CIRCUIT DESCRIPTION .................................................................................. 7.2 ELECTRICAL CIRCUIT SCHEMATIC .............................................................. 7.4 ENGINE CONTROL MODULES ...................................................................... 7.3 ENGINE ELECTRONIC CONTROLS LOCATIONS .......................................... 7.5 ENGINE START CIRCUIT ............................................................................... 7.2 MERCEDES ENGINE ..................................................................................... 7.2 PLD-MR ENGINE CONTROL MODULE .......................................................... 7.3

7.1

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Engine Start & Stop

MERCEDES ENGINE ENGINE START CIRCUIT

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

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. Once the engine has started no functions will operate until both cab doors are closed and the PILOT RESET SWITCH is pressed to turn on the computer, allowing machine functions to operate. Refer to PILOT RESET SWITCH and PILOT SYSTEM SHUT OFF in SECTION 2 of the OPERATOR’S MANUAL for more information.

PILOT OFF INDICATOR LIGHT

1065-001

FUSE AND RELAY POWER DISTRIBUTION Power for the ignition switch is supplied from a 20 amp fuse in the fuse and relay power distribution box. Power from the 20 amp fuse is supplied through circuit 10A to the emergency shut off switch. When the switch is turned ON power flows through the switch circuit 10C to the ignition switch.

PILOT RESET SWITCH

••

ADM2 ADAPTION MODULE

•• ••

1014-138

1014-001

R.H. JOYSTICK & CONTROL SWITCHES 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.

ENGINE HOOD

•

ON OFF

• BATTERY DISCONNECT SWITCH

1014-D001

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

7.2

FUSE & RELAY COMPARTMENT IN CAB When the ignition switch is turned to the START position, voltage is supplied through the ignition switch start terminal to wires 178 and 178B. Wire 178B is the engine start signal for the ADM2 Engine Adaption Control Module located in the fuse and relay compartment in the cab.

Tigercat 1045/1055 FORWARDER

The data is evaluated together with the data from the sensors on the engine such as oil pressure, fuel temperature, coolant temperature, air intake temperature, fuel charge pressure, crankshaft speed etc is compared to the data stored in the PLD-MR control module.

••

XT2-A0 MODULE

Engine Start & Stop

From this data, commencement and duration of fuel injection is calculated and the unit pumps are actuated accordingly via solenoid valves.

PLD-MR MODULE

L.H. SIDE ENGINE COMPARTMENT Wire 178 is the engine start signal for the PLD-MR Engine Control Module that supplies voltage to the starter solenoid to close the starter solenoid contacts and supply battery power to the starter motor to start the engine.

1055-060

ADM2 ADAPTION MODULE

•

STARTER SOLENOID STARTER MOTOR

••

1014-138

FUSE & RELAY COMPARTMENT IN CAB

••

ADM2 ADAPTION MODULE

1055-058

R.H. SIDE OF ENGINE COMPARTMENT

ENGINE CONTROL MODULES Communication between the MDM Control and Display Module, the XS-A0 System Interface, and the XT2-A0 Engine Module to the engine is conducted via a CAN-Bus link to the ADM2 Engine Adaption Module and the PLD-MR Engine Control Module.

ENGINE WIRING HARNESS PLUG CONNECTOR

PLD-MR MODULE

••

APPLIANCE WIRING HARNESS PLUG CONNECTOR

•• ••

1014-145

L.H. SIDE ENGINE COMPARTMENT

PLD-MR ENGINE CONTROL MODULE The PLD-MR control module processes the data received from the ADM2 control module such as the throttle pedal position, engine speed control, and engine start/stop etc.

7.3

The ADM2 Adaption Module is used to adapt the engine to the machine application-specific requirements. The control module is programmed with diverse sets of data for specific applications such as idle speed, maximum working speed or speed limitation.

The ADM2 Module receives data from the operator via the throttle pedal potentiometer, engine speed control, engine start/stop etc, and the PLD-MR control module (e.g. oil pressure and coolant temperature).

From this data, instructions are computed for the engine control and are transmitted to the PLD-MR control module via the CAN-Bus link.

Refer to the engine manufacturers manuals for more detailed service, troubleshooting procedures and operational information on the ADM2 and PLD-MR control modules.

Tigercat 1045/1055 FORWARDER

1055-002C

Engine Start & Stop

ENGINE ELECTRICAL CIRCUIT SCHEMATIC 7.4

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Engine Start & Stop

ENGINE ELECTRONIC CONTROLS LOCATIONS

XT2-A0 ENGINE MODULE PLD-MR MODULE

XS-A0 CAB MODULE

• ••

•• MDM DISPLAY MODULE

FRONT DRIVE PEDAL

••

••

L.H. JOYSTICK MODULE

• •• ADM2 ADAPTION MODULE

• REAR DRIVE PEDAL

1014-062.DWG

7.5

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Engine Start & Stop

7.6

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DRIVE

SECTION 8 - DRIVE AUGUST, 2006

CONTENTS - SECTION 8 AUXILIARY FUNCTION VALVE ...................................................................... 8.8 AXLES .......................................................................................................... 8.16 AXLE LUBRICATION ................................................................................. 8.17 DIFFERENTIAL AND DIFFERENTIAL LOCKS ........................................... 8.16 DRAINING AND REFILLING DIFFERENTIAL:(1 PER AXLE) ..................... 8.17 WHEEL INSTALLATION ............................................................................ 8.20 CENTRE JOINT ............................................................................................ 8.19 CHARGE PUMP ............................................................................................. 8.5 DRAINING AND REFILLING BOGIE HOUSING ............................................. 8.18 DRIVE MOTOR ............................................................................................... 8.7 DRIVE MOTOR CONTROLLER SOLENOID .................................................... 8.4 DRIVE MOTOR SCHEMATIC .......................................................................... 8.7 DRIVE PUMP ................................................................................................. 8.3 DRIVE PUMP CONTROLLER SOLENOIDS .................................................... 8.4 HYDRAULIC OIL HEATING PROCEDURE ...................................................... 8.9 HYDROSTATIC DRIVE SYSTEM ................................................................... 8.2 MOTOR BEGIN OF REGULATION ............................................................... 8.13 PUMP BEGIN OF REGULATION .................................................................. 8.11 PUMP SCHEMATIC ................................................................................ 8.3, 8.5 REAR (BOGIE) AXLE PLANETARY DRIVES (4 FILLING POINTS) .............................................. 8.17 SLEW BEARING LUBRICATION .................................................................. 8.19 SLEW BEARING LUBRICATION BOGIE AXLES .......................................................................................... 8.19 TEST PORTS AND RELIEF VALVE LOCATIONS ........................................... 8.6 TRANSMISSION ........................................................................................... 8.16

8.1

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DRIVE

HYDROSTATIC DRIVE SYSTEM The primary components of the hydrostatic drive system are a hydraulic pump and hydraulic motor connected together by hoses. The pump converts the mechanical power of the diesel engine into hydraulic power. This hydraulic power is then provided as high pressure flow of hydraulic oil and is then transmitted to the hydraulic motor through a supply 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 return 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.

LOW PRESSURE RETURN

AXIAL PISTON PUMP

DRIVE MOTOR TRANSMISSION

Return

B

A Flow

1055-059

BOTTOM VIEW

HIGH PRESSURE SUPPLY

DRIVE MOTOR AXIAL PISTON PUMP

B

SIDE VIEW

1055-060

CLOSED LOOP HYDRAULIC CIRCUIT 8.2

TRANSMISSION

Tigercat 1045/1055 FORWARDER

DRIVE

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

DRIVE PUMP

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 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.

MAIN PUMP

SWASHPLATE CONTROL CYLINDER

DRIVESHAFT

SOLENOID CONTROL ‘POR’ VALVE

•

•

••

•

FRONT

•

•

PUMPS The hydrostatic drive 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.

1075-029

SWASHPLATE PISTON

1055-063

SWASHPLATE CONTROL VALVE

•

•

DRIVE PUMP PRESSURE OVERRIDE VALVE

CONTROL CYLINDER

CHARGE PRESSURE FILTER

REV (CCW)

HIGH PRESSURE RELIEF VALVES FWD (CW) CHARGE PRESSURE RELIEF VALVE

HYDRAULIC RESERVOIR 1055-063

DRIVE PUMP SCHEMATIC 8.3

Tigercat 1045/1055 FORWARDER

DRIVE

When the throttle pedal is activated the XT2-AO Engine Module sends an electrical current output to the proportional solenoids installed on the drive pump controller and the drive motor controller.

XT2-AO ENGINE MODULE

The angle and direction that the swashplate moves is directly proportional to the current being sent from the XT2-AO Module. When no current is supplied, pilot oil is not supplied to the drive pump swashplate. The swashplate therefore remains in the neutral position and no oil is pumped by the piston pump.

DRIVE MOTOR CONTROLLER SOLENOID

•

DRIVE MOTOR CONTROLLER SOLENOID

1055-033

DRIVE MOTOR CONTROLLER SOLENOID The motor proportional solenoid shifts the actuation piston. The actuation piston in turn shifts the swashplate control cylinder, which is directly connected to the swashplate of the drive motors.

The angle that the swashplate moves determines the motor speed. Increasing throttle speed decreases swashplate angle which increases motor speed.

DRIVE PUMP FWD/REV CONTROLLER SOLENOIDS 1014-054

DRIVE PUMP CONTROLLER CIRCUITS To propel the machine forward, a proportional current is sent from terminal 19 on the XT2-AO Module, through wire 371A to the forward solenoid on the pump. To propel the machine in reverse, a proportional current is sent from terminal 33 on the XT2-AO, through wire 371B to the reverse solenoid on the pump.

‘A’ PORT FWD

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.

‘B’ PORT REV

•

“Y1” FORWARD SOLENOID

•• 1075-029

REVERSE RELIEF VALVE

•

•

FORWARD RELIEF VALVE

“Y2” REVERSE SOLENOID

030

••

DRIVE PUMP CONTROLLER SOLENOIDS The controller 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.

8.4

• R.H. SIDE OF MACHINE 1055-031

L.H. SIDE OF MACHINE

DRIVE PUMP RELIEF VALVES

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

Tigercat 1045/1055 FORWARDER

DRIVE

CHARGE PUMP

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.

CHARGE PUMP

Excess charge pump oil is relieved by the charge pressure relief valve into the case of the drive pump.

Charge pressure is set at 25 BAR (360 psi).

• CHARGE PUMP FILTER

•• 1055-063

•

DRIVE PUMP

HYDRAULIC RESERVOIR

The charge pump is an integral part of the drive pump. The charge pump is located inside the back of the drive pump.

The charge pump is a fixed displacement 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

1014-D015

HYDRAULIC RESERVOIR AND FILTER LOCATION

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.

CHARGE PRESSURE FILTER

CHARGE PUMP

REV (CCW)

FWD (CW) CHARGE PRESSURE RELIEF VALVE

1055-063

DRIVE PUMP SCHEMATIC 8.5

HYDRAULIC RESERVOIR

Tigercat 1045/1055 FORWARDER

DRIVE

DRIVE PUMP TEST PORTS AND RELIEF VALVE LOCATIONS The following illustrations show the various pressure test ports and relief valve locations on the drive pump.

‘POR’ VALVE

HIGH PRESSURE RELIEF VALVE

CHARGE PRESSURE RELIEF VALVE 1055-065

HIGH PRESSURE RELIEF VALVE

1055-062

DRIVE PUMP RELIEF VALVES DRIVE PUMP

ENGINE

COOLING PUMP

MAIN PUMP

••

•• ‘X1’ TEST PORT

••

••

•

•• • ••

‘X2’ TEST PORT

•• ‘MB’ TEST PORT

‘MA’ TEST PORT

CHARGE PRESSURE TEST PORT

1055-065A

8.6

Tigercat 1045/1055 FORWARDER

DRIVE

HYDROSTATIC DRIVE MOTOR DISPLACEMENT CONTROL CYLINDER

A variable displacement, axial piston 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.

DISPLACEMENT CONTROL SPOOL

FLUSHING VALVE

DRIVE MOTOR

•• 1055-064

1055-033

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.

When the throttle pedal is activated the XT2-AO Engine Module sends an electrical current output to the proportional solenoids on the drive pump controller and the drive motor controller.

DRIVE MOTOR SCHEMATIC

The drive motor controller directs pressure from the charge pump to the displacement control spool.

When sufficient pressure from the pump is directed to the spool, the spool shifts against a spring and direct oil to the displacement control cylinder thus decreasing the displacement of the motor increasing the motor speed.

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 decreasing motor speed.

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.

‘G’ PORT

••

1055-010

‘M1’ PORT

•

DRIVE MOTOR AND TRANSMISSION 8.7

1055-009

Tigercat 1045/1055 FORWARDER

DRIVE

AUXILIARY FUNCTION VALVES

HIGH PRESSURE MANIFOLD

BRAKE VALVE MANIFOLD

•• RP3

••

C6

••

•• 1014-150

C5 PU

HYDRAULIC VALVE COMPARTMENT

PR3

The Brake Valve Manifold and High Pressure Manifold provide reduced pressure for the operation of service brake, parking brake release, front and rear differential locks, accumulator and ladder cylinder circuits. These manifolds are located in the hydraulic valve compartment and contain the following components: SV

PR1

• P1

RV

PR2

• • ••

C3 C4

C1

BRAKE VALVE MANIFOLD BRAKE VALVE MANIFOLD COMPONENTS 1014-059

C1 ...................................... Solenoid 1 ~ Service Brakes C3 .......................................... Solenoid 2 ~ Park Brakes C4 ..................................... Solenoid 3 ~ Front Diff Locks C5 ........................................ Solenoid 4 ~ Rear Diff Lock C6 .................................................. Solenoid 5 ~ Ladder PR3 ... Pressure Reducer – Diff Lock/Brake/Ladder 44 BAR PU .................... Overpressure Pressure Shut-Off 55 BAR RP3 ............. Pressure Test (Diff Locks/Park Brake/Ladder

SW2

••

STEERING

••

• ••

•• SW1

•• •• •• •• •• •

•

••

RP2 BRAKE

1014-D006B

ACC1 1014-057

Auxilary Steering and Secondary Brake system are operated via an auxilary steering valve and a secondary brake valve located in the cab.

HIGH PRESSURE MANIFOLD

HIGH PRESSURE MANIFOLD COMPONENTS ACC1 ............................ Accumulator Pressure Test P1 .................................. Pump Outlet Pressure Test PR1 ........................ Pressure Reducer 1 (*138 BAR) PR2 .................... Pressure Reducer Brakes 70 BAR RP2 ........................... Pressure Test Service Brakes RV ............................................. Relief Valve 75 BAR SW1 .... Low Pressure Switch 70 BAR (Start Charge) SW2 . High Pressure Switch 124 BAR (Stop Charge) SV ................................ To LS Signal on Main Pump

8.8

Gear Shift and Rear Drive Disconnect solenoid control valves are located in a manifold block mounted on the front chassis beside the transmission

Tigercat 1045/1055 FORWARDER

DRIVE

HYDRAULIC OIL HEATING PROCEDURE

DRIVE SYSTEM SET UP

This procedure is used to heat up the hydraulic oil in the machine in preparation for setting up hydraulic pressures.

1. Pump Begin of Regulation and Max Displacement adjustment and control pressure.

These tests will verify the following:

1. Park machine on level ground, 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. Start the engine, rotate the seat to face the rear, depress the PILOT RESET switch, place the WORKING RPM switch in the ON position, and set engine to max throttle using the L.H. joystick thumb switch.

2. Motor Begin of Regulation and Min Displacement adjustment and control pressure.

3. Steering check; slow and fast.

4. Front and rear differential lock functions.

5. Service braking check.

“X1” TEST PORT

••

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

••

2. Operate the TELESCOPE IN/OUT function, while at the same time operating the GRAPPLE ROTATE function with cooling fan in AUTO. Release after 5 seconds, wait 5 seconds, then repeat. This will cause oil to pass over the telescope IN/OUT port relief, which will generate heat. Monitor ENGINE COOLANT TEMPERATURE and HYDRAULIC OIL TEMPERATURE on the display module.

WARNING

••

“X2” TEST PORT “MB” TEST PORT 1055-065A

•• ••

“MA” TEST PORT CHARGE PRESSURE TEST PORT

INSTALL PRESSURE TEST GAUGES Install two 0-10,000 psi gauges on ‘MA’, ‘MB’ and two 0-500 psi gauges on the pump controller ‘X1’ and ‘X2’ test ports on the DRIVE PUMP. and a 0500 psi gauge on ‘CHARGE PRESSURE’ test port on the DRIVE PUMP. NOTE: Fasten the gauges so they can be easily viewed from the operator’s seat and will not be damaged during the test.

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.

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

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

8.9

Tigercat 1045/1055 FORWARDER

DRIVE

CONNECT A PDA (PERSONAL DIGITAL ASSISTANT) The following procedure instructs how to connect a PDA (Personal Digital Assistant) device to the MDM module. The PDA will be used as a second display unit required when performing test procedures outlined later in this section.

To perform this procedure you will require: • • •

PDA IQAN data cable for PDA PDA serial port adapter cable (for the PDA being used).

A. Ensure the Ignition key switch is OFF. Remove the lower cover on the L.H. joystick pod.

B. Locate the ‘round’ RS232 port connection on the back of the MDM. Do not disconnect the rectangular 6-pin connector.

1014-191

C. Remove the rubber dust seal from the RS232 port and connect IQAN data cable for PDA.

G. Select the ‘CHANNELS’ icon from the bottom right corner of the PDA screen.

This will display a drop down menu showing channels to chose from.

WARNING

NOTE: In this instance we will be selecting Frequency In then motor speed rpm.

Damage may occur to the PDA if the wrong data cable is used. Ensure the appropriate cable is selected when using a PDA; DO NOT USE AN ADAPTER TO MATCH UP SERIAL PORTS. IQAN DATA CABLE FOR PDA

PDA MAIN IQAN WINDOW

0 selected Voltage In Digital In Frequency In J1939 analog In Current Out Digital Out Conditional Message Alarm

PDA SERIAL PORT ADAPTER CABLE

IQAN - MDM PALM OS PDA

CONNECTING MDM TO PDA D. Connect the other end of the cable to the serial port adapter cable for the PDA being used.

E. Turn on power to the PDA. F. Turn the key switch to ‘RUN’. START THE MACHINE. Turn on computers.

1014-192

PDA DROP DOWN MENU DISPLAY H. Select frequency in, and select motor speed then select measure menu.

8.10

Tigercat 1045/1055 FORWARDER

DRIVE

DRIVE PUMP BEGIN OF REGULATION & MAX DISPLACEMENT ELECTRICAL ADJUSTMENT The pump begin of regulation is the point at which an electrical signal to the pump control solenoid will result in rotary motion of the wheels.

NOTE: Prior to performing this adjustment the drive motor begin of regulation Min Current and Max Current must be set to 0.0 mA. See MOTOR BEGIN OF REGULATION & MIN DISPLACEMENT ADJUSTMENT for setting Motor Min Current/Max Current and adjust the values to 0.0 mA. Heat up the hydraulic oil to operating temperature, see procedure in this section.

Connect a PDA (Personal Digital Assistant) device to the MDM module, see procedure in this section.

7. Using the UP or DOWN arrow buttons, scroll through the 5 different menus until the “Properties” menu is found.

8. Press the F2 button to enter the output property menu.

1. With machine on flat level ground and clear path to travel on, start the engine and depress the pilot reset switch to activate the computer.

2. Reset the pilot.

3. Use the switch to the left of the display to select the Iqan display screen. Must be in operator mode 1, see Mode Menu in section 6 of this manual.

9. Use the UP or DOWN arrow buttons if necessary to locate the “Current Out” menu.

4. Turn Maximum Travel speed switch OFF.

10. Press the F1 button to enter the function selection menu.

5. select 1st gear and turn all wheel drive ON.

•

TRAVEL SPEED SWITCH

1055-001

R.H. JOYSTICK & CONTROL SWITCHES 11. Press the F3 button to activate manual function selection.

6. Press the ESCAPE button to display the menu selection screen.

8.11

Tigercat 1045/1055 FORWARDER

DRIVE 19. When the forward begin of regulation has been established release the drive pedal and press F1 “OK”.

12. Using the UP or DOWN arrow buttons, scroll through the adjustable functions until “Drive Pump COUT” is displayed.

13. Press F1 “SELECT (+)” to enter the forward begin of regulation adjustment menu.

20. Using the UP or DOWN arrow buttons, scroll through the adjustable values until “MAX CURRENT” is displayed.

21. Press F1 to start adjusting the pump maximum displacement.

22. Depress the drive pedal to max.

14. Using the UP or DOWN arrow buttons, scroll through the adjustable values until “MIN CURRENT” is displayed.

15. Press F1 and select FWD travel direction to start adjusting the pump begin of regulation.

16. Engage the front differential locks and depress the drive pedal to max.

23. Using the UP/DOWN arrow buttons, adjust the “MAX CURRENT” to the point at which the motor speed (on PDA) stops increasing.

Round this value up to the nearest 5mA and add 20mA to this value 24. Observe the current and pressure, should be 550 - 560mA @ 14.5 - 15 BAR (210 - 218 psi).

25. When the forward max displacement has been established release the drive pedal and press F1 “OK”.

17. Using the UP/DOWN arrow buttons, adjust the “MIN CURRENT” to the point at which the wheels just begin rotating or until drive pressure is sensed on the appropriate work port. Round this value down 20mA.

26. Press the escape button once to return to step 13 and repeat steps 14-25 for the reverse direction by pressing F2 “SELECT (-)” and selecting REV travel direction.

NOTE: If the FWD (+ve) and REV (-ve) currents differ more than 30 mA , then perform the Pump Hydraulic Neutral Procedure, see procedure in this section.

18. Observe the current and pressure, should be 220 - 230mA @ 3.75 - 4 BAR (54.4 - 58 psi). (if the values are out of range, refer to HYDROSTATIC DRIVE PUMP HYDRAULIC NEUTRAL procedure in this section for adjustment) 8.12

Tigercat 1045/1055 FORWARDER

DRIVE

MOTOR BEGIN OF REGULATION & MIN DISPLACEMENT ELECTRIC ADJUSTMENT The motor begin of regulation is the point at which an electrical signal to the motor control solenoid will result in an increase in wheel speed.

9. Observe the current and pressure readings, should be 220 - 225mA @ 9.5-10 BAR (138-145 psi).

Note: The motor max current is to be set-up at 1800 engine rpm.

Note: You can’t adjust the minimum current to be 10. Set travel direction to neutral, turn on limited larger than the maximum so you must first increase drive function (turtle) and then adjust drive the maximum current prior to adjusting the minimum. speed to 100% and adjust engine speed to Set this to a value of 400mA to start.

1800rpm (use Murphy display).

1. Follow steps 1-11 as in pump begin of regulation.

11. Select a travel direction.

2. Use the UP or DOWN arrow buttons, scroll through the adjustable functions until “Drive Motor COUT” is displayed.

3. Press F1 “SELECT (+)” to enter the motor begin of regulation adjustment menu.

NOTE: Perform steps 10 -13 and adjust Max Current to 400mA before adjusting MIN CURRENT.

12. Using the UP or DOWN arrow buttons, scroll through the adjustable values until “MAX CURRENT” is displayed.

13. Press F1 to start adjusting the motor end of regulation.

14. Depress the drive pedal to max.

4. Using the UP or DOWN arrow buttons, scroll through the adjustable values until “MIN CURRENT” is displayed.

5. Press F1 to start adjusting the motor begin of regulation.

6. Depress the drive pedal to max.

7. Using the UP/DOWN arrow buttons, adjust the “MIN CURRENT” to the point at which the wheel speed increases. Round this value down 20mA.

15. Using the UP/DOWN arrow buttons, adjust the “MAX CURRENT” until a motor speed of 4000rpm ± 50 is achieved. Round this value to the nearest 5mA. 16. When the motor end of regulation has been established release the drive pedal and press F1 “OK”.

17. Observe the current and pressure readings, should be 570 - 580mA @ 15.5 - 16 BAR (225 232 psi).

8. When the motor begin of regulation has been established release the drive pedal and press F1 “OK”.

8.13

Tigercat 1045/1055 FORWARDER

DRIVE

STEERING OPERATION

STEERING CURRENT OUTPUT ADJUSTMENTS

TRAVEL DIRECTION SWITCH

1. With the seat facing forward, start the engine and depress the pilot reset switch to activate the computer.

••

2. Reset the pilot.

3. Use the switch to the left of the display to select the Iqan display screen. Must be in operator mode 1, see Mode Menu in section 6 of this manual.

R.H. JOYSTICK & CONTROL SWITCHES

1014-001

A. Set the TRAVEL DIRECTION 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 JOYSTICK slightly in one direction until it hits the stop.

4. Disable the limited travel speed function.

STEERING JOYSTICK

5. Press the ESCAPE button to display the menu selection screen.

•

1014-002

L.H. JOYSTICKS &CONTROLS B. Operate the STEERING JOYSTICK 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 JOYSTICK 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.

6. Using the UP or DOWN arrow buttons, scroll through the 5 different menus until the “Properties” menu is found.

7. Press the F2 button to enter the output property menu.

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

For additional information on the steering system refer to SECTION 11 of THIS MANUAL. 8. Use the UP or DOWN arrow buttons if necessary to locate the “Current Out” menu.

8.14

Tigercat 1045/1055 FORWARDER

DRIVE 2 1 6 5 7

9. Press the F1 button to enter the function selection menu.

CRANE/BLADE SWITCH

4

•• •

3

8

• •• •• ••

9

TRAVEL SPEED SWITCH

1014-001

R.H. JOYSTICK & CONTROL SWITCHES NOTE: The CRANE/BLADE switch is a three position switch. Selecting the OFF position enables the R.H. Joystick (1) to ENGAGE or DISENGAGE the differential locks as follows:

10. Press the F3 button to activate manual function selection.

11. Using the UP or DOWN arrow buttons, scroll through the adjustable functions until “Steer COUT” is displayed.

Joystick Left (2) - Rear Differential Lock OFF Joystick Right (3) - Rear Differential Lock ON Joystick Forward (4) - Front Differential Lock ON Joystick Back (5) - Front Differential Lock OFF

The differential locks will remain in the selected condition regardless of how the CRANE/BLADE switch is operated afterwards. The differential locks are only controllable when the CRANE/ BLADE switch is in the OFF position.

B. Release the drive pedal 12. Press F1 “SELECT (+)” to enter the Steering Forward adjustment menu.

C. Use joystick to set FRONT DIFF. LOCK ON. Press the drive pedal slightly to disengage the parking brake. While steering the machine and driving slowly, engage and disengage the front differential locks. There should be a noticable difference in the turn radius of the machine and the rotation speed of the LH and RH wheels on the front bogie when the differential locks turn off and on.

13. Using the UP or DOWN arrow buttons, scroll through the adjustable values until “MIN CURRENT” is displayed.

14. Press F1 to start adjusting the output.

15. Engage steering joystick and use the UP or DOWN arrow buttons to adjust the “MIN CURRENT” to obtain desired steering response.

D. Release the drive pedal.

16. When desired steering response is achieved release joystick and press F1 “OK”.

DIFFERENTIAL LOCKS OPERATIONAL TEST A. Bring the machine to a full stop, ensure that both front and rear differential locks are turned OFF. Set the TRAVEL DIRECTION 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). Steer the machine.

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

E. Use joystick to set REAR DIFF.LOCK ON. Press the drive pedal slightly to disengage the parking brake. While steering the machine and driving slowly, engage and disengage the rear differential locks. There should be a noticable difference in the turn radius of the machine and the rotation speed of the LH and RH wheels on the rear bogie when the differential locks turn off and on.

F.

8.15

Release the drive pedal.

Tigercat 1045/1055 FORWARDER

DRIVE AXLES

TRANSMISSION

1055-015

DRIVE TRAIN

TRANSMISSION & DRIVE MOTOR The transmission transmits power to both the front and rear axles unless pilot pressure is supplied to the rear drive disconnect 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 with pilot pressure from the gear select manifold valve. When a gear is engaged, a feed back signal from the shifting sensor is sent back to the XT2. If the XT2 sends an electrical signal to the solenoid on the gear change valve and does not receive the proper feedback, a “Transmission Gear Not Engaged” warning will display on the MDM to alert the operator of the condition. When this alarm is activated, change gear selection to engage another drive gear and disable alarm.

Each axle assembly consists of an input yoke, differential with hydraulic differential lock, Inboard multiple wet disk brakes, slew bearings bogie housings and gear sets, axle housings and shafts.

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

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.

1055-012

DRIVE MOTOR

DIPSTICK

•• ••

1055-033

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.

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

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

By using the R.H. joystick, one or both of the axles can have the differential lock activated. This function energizes the differential lock control valve solenoids (C4 & C5, 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 8.16

Tigercat 1045/1055 FORWARDER

DRIVE

AXLE LUBRICATION

6. Clean any filings from the magnetic drain plug.

Each bogie axle has seven separate oil reservoirs that require individual draining/filling, there are nine drain points and nine fill points. The axle must be level when draining/filling lubricant. Perform scheduled oil change in the axles when doing the seasonal hydraulic oil change. Refill the axle differentials and bogie housings with SAE 90/APIGL-5 gear oil.

7. Replace the differential housing drain plug.

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.

10. Position the wheel hub for draining the planetary, with the drain plug in the lowest possible position as shown.

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 located opposite the input yoke on the differential housing.

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

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

9. Replace the differential fill/level plug.

PLANETARY DRIVES (4 FILLING POINTS)

11. Remove the PLANETARY FILL PLUG. 12. Remove the PLANETARY DRAIN/LEVEL PLUG and drain the oil into a suitable container for disposal.

13. Reposition the wheel hub for filling the planetary, with the PLANETARY DRAIN/LEVEL PLUG at 9 o’clock and the fill plug at 1 o’clock as shown.

14. Refill the planetary with new oil until the level reaches the bottom of the PLANETARY DRAIN/LEVEL PLUG. (Note: To get a correct filling level the wheel hub must be in the planetary fill position as shown.)

15. Repeat steps 10 to 14 for each of the four planetary drives.

BREATHER

BOGIE HOUSING FILL & LEVEL PLUG (4 PLACES)

DIFFERENTIAL FILL PLUG (1 PLACE) DIFFERENTIAL DRAIN PLUG (1 PLACE)

•

••

• ••

•

(DIPSTICK 1 PLACE) BOGIE HOUSING DRAIN PLUG (4 PLACES)

PLANETARY FILL PLUG (4 PLACES)

BOGIE HOUSING CONTAMINATED DRAIN PLUG (4 PLACES - LOWER)

1055-016

WHEEL HUB IN PLANETARY FILL POSITION

BOGIE AXLE FILL, DRAIN AND LEVEL PLUGS 8.17

WHEEL HUB IN PLANETARY DRAIN POSITION

PLANETARY LEVEL/DRAIN PLUG (4 PLACES)

• •

•

Tigercat 1045/1055 FORWARDER

DRIVE BREATHER

BOGIE HOUSING FILL & LEVEL PLUG (4 PLACES)

DIFFERENTIAL FILL PLUG (1 PLACE) DIFFERENTIAL DRAIN PLUG (1 PLACE)

•

••

• ••

•

(DIPSTICK 1 PLACE) BOGIE HOUSING DRAIN PLUG (4 PLACES)

PLANETARY FILL PLUG (4 PLACES)

BOGIE HOUSING CONTAMINATED DRAIN PLUG (4 PLACES - LOWER)

1055-016

WHEEL HUB IN PLANETARY DRAIN POSITION

PLANETARY LEVEL/DRAIN PLUG (4 PLACES)

• •

•

WHEEL HUB IN PLANETARY FILL POSITION

BOGIE AXLE FILL, DRAIN AND LEVEL PLUGS

DRAINING AND REFILLING BOGIE HOUSING: (2 PER AXLE) 16. Remove the bogie housing fill plugs located on the top of the bogie housing.

17. Remove the bogie housing level plugs located on the inside of the housing.

Note: There are two bogie housing level plugs to be removed per axle.

18. Remove the bogie housing drain plugs 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.

19. Clean any filings from the magnetic drain plugs.

20. Replace the bogie housing drain plugs in all locations.

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

21. Refill the bogie housings by pumping oil into the fill plug on the bogie housings. Stop adding oil when the oil level reaches the bottom of the bogie housing level plug. Note, each of the bogie housings must be filled separately.

22. Replace the bogie housing level plugs.

23. Replace the bogie housing fill plugs.

Note: There are 9 drain points and 9 fill points CAPACITIES For front and rear axle oil fill capacities, refer to the table: SERVICE AND LUBRICATION in SECTION 3 of THIS MANUAL.

8.18

Tigercat 1045/1055 FORWARDER

DRIVE

SLEW BEARING LUBRICATION BOGIE AXLES The slew bearing has a lifetime lubrication in the raceway grease chamber and needs no service.

The only service work is the replacement of soiled grease in pre-chamber (buffer chamber).

BOGIE 2

Then open the opposite outlet plug (also pos. 92 covered with white plastic cap).

Grease with a hand grease gun, at both grease nipples per side, until grease squeezes out thumb wide from the outlet opening (pos. 92). Then close this outlet hole with plug and cap.

BOGIE 1

Clean the area around the grease nipples and outlet plugs (pos. 90/92).

When grease squeezes out from the gap, the gap has sealed itself with grease all the way around the circumference. Leave the excess grease built up to protect against dirt.

Cover the grease nipples with plastic caps.

BOGIE 3

Open outlet plug, first the one on side A (pos. 92; covered with white plastic cap).

Fill at both grease nipples per side (pos. 90; covered with white plastic caps) standard grease.

Lubricate with hand grease gun until grease squeezes out with thumb wide from the outlet opening (pos. 92). Then close this outlet hole with plug and cap.

8.19

Tigercat 1045/1055 FORWARDER

DRIVE

WHEEL INSTALLATION 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 (1) in the axle flange, as well as the nuts and washers (2). When cleaning studs in the axle flange, double check and be sure to use the proper size die for the threads (M22x1.5).

WARNING 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.

•

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

•

Torque the M22x1.5 wheel nuts to 800Nm (600 lbf/ft).

1

2

8.20

••

Tigercat 1045/1055 FORWARDER

DRIVE

1045 PRESSURE AND SPEED SETTINGS (at 48 - 60 deg. C.) Engine RPM (Full Throttle)

2200 rpm

Engine RPM (Low Idle)

825 - 875 rpm

Hydrostatics Charge Pressure Integral to Drive Pump

24.5-25.2 bar @ 1100 rpm 355-365 psi @ 1100 rpm

Main Reliefs Forward

462 +/- 3.5 bar @ full throttle 6700 +/- 50psi @ full throttle 462 +/- 3.5 bar @ full throttle 6700 +/- 50psi @ full throttle

Reverse

Pressure Override

432 +/- 3.5 bar @ full throttle 6260 +/- 50 psi @ full throttle

Overload Protection Functions Correctly

after 5 secs.

Drive Motor Min Displacement Control

4100 - 4200 rpm

1055 PRESSURE AND SPEED SETTINGS (at 48 - 60 deg. C.) Engine RPM (Full Throttle)

2200 rpm

Engine RPM (Low Idle)

825 - 875 rpm

Hydrostatics Charge Pressure Integral to Drive Pump

24.5-25.2 bar @ 1100 rpm 355-365 psi @ 1100 rpm

Main Reliefs Forward

400 +/- 3.5 bar @ full throttle 5800 +/- 50psi @ full throttle 400 +/- 3.5 bar @ full throttle 5800 +/- 50psi @ full throttle

Reverse

Pressure Override

370 +/- 3.5 bar @ full throttle 5360 +/- 50 psi @ full throttle

Overload Protection Functions Correctly

after 5 secs.

Drive Motor Min Displacement Control

4100 - 4200 rpm

8.21

Tigercat 1045/1055 FORWARDER

DRIVE

8.22

Tigercat 1045/1055 Forwarder SECTION 9 - BRAKES AUGUST, 2006

CONTENTS - SECTION 9 ACCUMULATOR ............................................................................................ 9.6 CHARGING AND TESTING DEVICE ......................................................... 9.6 CHARGING THE ACCUMULATOR ............................................................ 9.6 CHECKING THE GAS PRE-CHARGE PRESSURE ................................... 9.6 ACCUMULATOR CHARGE VALVE ............................................................... 9.2 AXLES SERVICE/PARKING BRAKES .................................................................... 9.8 BRAKE ADJUSTMENT ............................................................ 9.10, 9.12, 9.13 BRAKE BLEEDING ...................................................................................... 9.10 BRAKE PEDAL CONTROL ............................................................................ 9.2 EMERGENCY BRAKE VALVE ....................................................................... 9.9 TEST DRIVE SERVICE BRAKE OPERATION ............................................................... 9.12

Tigercat 1045/1055 Forwarder

Brakes

BRAKE PEDAL CONTROL 1

••

1014-D007

2

1

•

•

FRONT FOOT PEDAL CONTROLS

ACCUMULATOR CHARGE The main pump supplies oil directly to the boom valve. From the boom valve, pilot oil is directed to the high pressure manifold when the low pressure switch detects pressure below 70 Bar (1015 psi) and is turned off at 124 Bar (1798 psi). These switches regulate the pressure in the accumulator and braking systems. 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 up in the accumulator. When flow and pressure are required by the accumulator charge circuit, 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 12 of THIS MANUAL for more information on load sense systems.

2

•• •

1014-D008

REAR FOOT PEDAL CONTROLS

The brake pedal (1) is manually operated and communicates with the MDM Display and Control Module electronically. The pedal has a precision potentiometer (2) built into it, and will vary the voltage signal (0 to 3.2 volts) to the brake control valve proportionally as it is depressed. The brakes are spring applied and hydraulicly released.

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 and the brakes will no longer release.

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

BRAKE CYLINDER COVERS

•

1014-D090

••

REAR CHASSIS BRAKE CYLINDERS 1014-D202

1055-046

REAR CHASSIS ~ ACCUMULATOR

BRAKE VALVE AND HIGH PRESSURE MANIFOLDS 9.2

Tigercat 1045/1055 Forwarder

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 70bar (1015 psi) in the first 5 minutes.

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

HIGH PRESSURE MANIFOLD

BRAKE VALVE MANIFOLD

•• 1014-203

Brakes

••

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 70bar (1015 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 109-124bar (1450-1800psi).

HYDRAULIC VALVE COMPARTMENT

CHECKING ACCUMULATOR CHARGE CYCLE 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.

8. Remove the gauge.

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.

SV

PR1

RP1

P1

• ••

RV

PR2

• •• •• SW2

• • •

• SW1

1014-057

••

RP2 ACC1

HIGH PRESSURE MANIFOLD 3. Connect a 0-5000 psi gauge to the ACC1 test port on the high pressure 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 100-124bar (1450-1800 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.

9.3

Tigercat 1045/1055 Forwarder

1055-046

Brakes

BRAKE VALVE AND HIGH PRESSURE MANIFOLDS

BRAKE / AUXILLARY CIRCUIT SET-UP:

SV

PR1

PR2

RV

RP1

The brake/auxiliary circuit is comprised of two manifolds. The high pressure manifold contains two reduced pressure circuits. The first reduction activates and charges the accumulator, the second supplies the low pressure manifold. The low pressure manifold controls the service brake with its inlet pressure and reduces pressure for park brake, ladder and differential lock functions.

The low pressure manifold incorporates a pressure shut off circuit which will relieve pressure from the park brake, ladder and differential lock functions if it becomes too high.

••

• • •

•

P1

SW2

•• •• ••

•• •

SW1

1. Ensure that the hydraulic oil is at operating temperature (refer to hydraulic oil heat up procedure).

RP2 ACC1

1014-057

HIGH PRESSURE MANIFOLD - FIGURE 1

2. Connect a 5000psi (345bar) gauge to ‘ACC1’ and 'RP1' test portS (figure 1).

C6

3. Disconnect the 2 pin Deutsch connector from ‘SV’ (force main pump to stand by) and the spade connectors from ‘SW1’ & ‘SW2’ (figure 1). Disconnect the 2 pin Deutsch connectors from ‘SV1’, ‘SV’, ‘SV3’, ‘SV4’ and ‘SV5’ (figure 2)

ii)

•• •

C1 C3

• ••

•• RP3

4. Adjust ‘PR1’ valve to minimum (turn adjustment screw counter clockwise until it stops). The reading at ‘RP1’ is the pressure directly affected by ‘PR1’ and can be adjusted as follows: i)

C4

C5

••

••

SV5 SV4 PU

•• •• •• •• •• • PR3

Use an 11/16” wrench to loosen the locknut on the 'PR1' pressure reducing valve adjustment screw (figure 1).

Turn the adjusting screw using a 3/16” allen key. Turning the adjusting screw IN (clockwise) will increase the pressure, turning the screw OUT (counterclockwise) will decrease the pressure.

SV2 SV3

SV1

1014-059

BRAKE VALVE MANIFOLD - FIGURE 2

9.4

Tigercat 1045/1055 Forwarder 5. Start the engine, and depress the pilot reset switch twice, once to activate the IQAN computer system and once more to enable the controls.

6. Discharge the accumulator by setting the park brake switch to off and operating the park brake lever in the cab until ‘ACC1’ reads 400psi (28bar) or less.

7. Disconnect the 2 pin Deutsch connector from ‘SV2’ (figure 2).

8. Reconnect the 2 pin Deutsch connector to ‘SV’ (allow main pump to stroke).

9. Connect a Multi-meter to ‘SW1’, set to measure continuity.

10. Slowly increase the pressure by adjusting valve ‘PR1’ as in step 4.

11. Once the pressure at ‘ACC1’ has reached 1015psi (70bar) ±30psi (2bar) the reading across ‘SW1’ should switch from open to closed.

•

Adjustment to the pressure switch can be made by turning the small flat-head screw between the blade terminals clockwise to increase and counter-clockwise to decrease.

12. Connect a Multi-meter to ‘SW2’, set to measure continuity.

13. Continue adjusting the pressure at valve ‘PR1’ to 1800psi (124bar) ±30psi (2bar). The reading across ‘SW2’ should switch from open to closed.

If required, ‘SW2’ can be adjusted as in step 11.

14. Adjust the pressure at ‘RP1’ to 2000psi (138bar) ±30psi (2bar), by adjusting valve ‘PR1’, then tighten the locknut.

15. Connect a 3000psi (205bar) gauge to ‘RP2’ test port (figure 1).

16. Using a ¼” allen key, remove the end cover of ‘PR2’.

Brakes 18. Adjust valve ‘RV’ if required (Use a ¼” allen key to remove the end cover. Turn the adjusting screw using a 1/4” allen key. Turning the adjusting screw IN (clockwise) will increase the pressure, turning the screw OUT (counterclockwise) will decrease the pressure.) as required to achieve 1088psi (75bar) ±30psi (2bar) at ‘RP2’.

19. Reset valve ‘PR2’ to 1015psi (70bar) ±30psi (2bar) and re-install end cover. Valve 'PR2' should be set at 73 to 87psi (5 to 6bar) below 'RV'.

20. Connect a 1000psi (69bar) gauge to ‘RP3’ test port (figure 2). The pressure ar 'RP3' should read 638psi +0 -15psi (44bar +0 -1bar).

21. Use a ¼” allen key to remove the end cover of valve ‘PU’. Turn the adjusting screw of valve ‘PU’ 2 turns clockwise using a 1/4” allen key.

22. Adjust valve ‘PR3’ until the reading at ‘RP3’ is 798psi (55bar) +15psi (1bar) (Use a ¼” allen key to remove the end cover. Turn the adjusting screw using a 1/4” allen key. Turning the adjusting screw IN (clockwise) will increase the pressure, turning the screw OUT (counterclockwise) will decrease the pressure.) (figure 2).

23. Slowly adjust valve ‘PU’ counter-clockwise using a ¼” allen key until the pressure at ‘RP3’ drops.

24. Reduce the setting of valve 'PR3' until the pressure at 'RP3' increases from zero to some new value. This resets the prssure shut off valve 'PU'.

25. Slowly adjust valve 'PR3' to increase the pressure at 'RP3' to 798psi (55bar). At 798psi (55bar) the pressure at 'RP3 should suddenly drop to zero. If valve 'PU' does not operate to shut off the prssure at 798psi (55bar), adjust 'PU' up or down a small amount and retest starting at step 23A. 26. Reduce ‘PR3’ until a reading at ‘RP3’ is obtained and increase to 638psi (44bar) -15psi (1bar) and re-install end cover.

17. The pressure at 'RP2' should read 1015psi (70bar) ±30psi (2bar). Slowly increase the 25. Reconnect the 2 pin Deutsch connectors from setting of valve ‘PR2’ (Use a ¼” allen key to ‘SV1’, ‘SV2’, ‘SV3’, ‘SV4’ and ‘SV5’ (figure 2) remove the end cover. Turn the adjusting and the spade terminals for ‘SW1’ & ‘SW2’ screw using a 1/4” allen key. Turning the (figure 1). adjusting screw IN (clockwise) will increase the pressure, turning the screw OUT (counterclockwise) will decrease the pressure.). The reading at ‘RP2’ should increase to 1088psi (75bar) ±30psi (2bar), at which point RV will open to relieve the excess pressure. RV should relieve 73 to 87psi (5 to 6bar) higher than the original pressure read at 'RP2'.

9.5

Tigercat 1045/1055 Forwarder

Brakes CHECKING THE GAS PRE-CHARGE PRESSURE Bleed off the system pressure as stated earlier.

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

•

•

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

VALVE GUARD

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

GAS VALVE

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

WARNING •

USE ONLY NITROGEN for charging accumulators, NEVER USE OXYGEN OR AIR, due to the risk of explosion.

HYDRAULIC CONNECTION AX205

ACCUMULATOR (PISTON TYPE)

CHARGING THE ACCUMULATOR

The gas pressure should be checked if the pilot system exhibits repeated and frequent charging cycles.

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

NITROGEN BOTTLE

WARNING

HOSE*

Hydraulic circuits with accumulators store hydraulic oil under pressure, therefore the system may remain pressurized after the engine is turned off.

PRESSURE GAUGE*

ADAPTER* ADAPTER* ACCUMULATOR

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.

ASSEMBLY PART NO. 90254 INCLUDES PARTS SHOWN * ACCU-2

A low pressure switch is installed in the hydraulic circuit, which will signal the Iqan display module when the accumulator has less than 40bar (580psi) of pressure. This will trigger an “Low Brake Pressure” alarm on the display terminal in the cab. This alarm warns the operator that the machine’s service brake capabilities will NOT be sufficient.

9.6

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.

Tigercat 1045/1055 Forwarder •

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

•

Remove the valve guard and cap.

•

Screw the charging and testing device onto the gas valve.

•

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.

9.7

Tigercat 1045/1055 Forwarder

Brakes

SERVICE/PARKING BRAKES

cylinder to move the piston and push on the operating disk lugs applying pressure to the steel and friction disks engaging the brakes. For information on the hydraulic brake circuit refer to SECTION 9 of THIS MANUAL.

The disk type brake assembly consists of a operating disk, a series of steel and friction disks and a brake cylinder. One brake assembly is located on each side of the differential case inside the slew bearings.

The brake cylinder 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 THIS SECTION for brake bleeding procedure.

The disk brake assembly (5) is mounted on the differential housing with locking dowels (6) that prevent rotation of the steel disks. The friction disks are splined to the gear shaft which connects the differential to the centre gear in the bogie housing.

Brake operation is accomplished by the use of a brake cylinder (1) applying force against the operating disk lugs (2) forcing the operating disk to spread apart and apply pressure against the friction disks (3) and steel disks (4).

2

•

6

3

• •

6

•

•

The brake cylinder (1) is activated in three ways: 1. Spring applied for Parking Brakes.

5

2. Hydraulic applied Service Brakes.

3. Hydraulic applied Secondary Parking Brakes

•

• 6

1014-002.TIF

DISK BRAKE ASSEMBLY

5

•

•

2

•

1

1014-001.PDF

•

6

When the brake pedal control in the cab is depressed, an electronic signal is sent to the computer. The computer 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 on the brake

1

4

•

•

BRAKE INSTALLATION CROSS SECTION 9.8

1014-002.PDF

Tigercat 1045/1055 Forwarder

1014-077.DWG

Brakes

BRAKE VALVE MANIFOLD

PARKING BRAKE VALVE

Push the lever forward 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.

The parking brake valve is located on the instrument panel in the cab. This control is a proportional 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.

STEERING

The parking 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 MDM Control when the parking brakes are applied (ie: brake release circuit has less than 40bar (580psi) 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 display in the cab. This alarm warns the operator that the parking brake is ENGAGED while attempting to drive.

•• ••

BRAKE 1014-D006B

Pull the lever back to engage the 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 cylinder to push on the operating disk lugs applying pressure to the steel and friction disks applying the brakes.

9.9

Tigercat 1045/1055 Forwarder

Brakes

BRAKE BLEEDING 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.

SERVICE BRAKE BLEED SCREW

PROCEDURE 1. Remove the cover plates to gain access to the brake cylinders.

1

2. Install a hose on bleed fittings and use a container to collect bleed oil.

2 PARK BRAKE RELEASE BLEED SCREW

3. Start engine and run at IDLE, press the PILOT RESET switch. Release park brake switch/ladder up.

4. Turn park brake switch off and ensure park brake release lever is in the park brake off position.

5. Set Travel Direction switch to neutral.

1014-001.PDF

1

BLEED SCREW ORIENTATION

BRAKE ADJUSTMENT

••

2

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.

••

BRAKE CYLINDERS 1014-D090

PROCEDURE:

REAR CHASSIS BRAKE CYLINDERS

1. Park the machine on level ground, place the crane in the park position, and lower the blade to the ground (if equipped) and engine off. Block all wheels to prevent machine rolling while brakes are off.

6. Loosen service brake bleed screw (1).

7. Close bleed screw when oil is free of air.

8. Repeat above procedure for each service brake bleed screw (2 per axle).

SOLENOID 'SV1'

9. Loosen parking brake release bleed screw (2).

1

••

10. Close bleed screw when oil is free of air.

•

11. Repeat above procedure for each parking brake bleed screw (2 per axle).

2. Open valve compartment and disconnect wire connector (1) from service brake solenoid (SV1).

9.10

Tigercat 1045/1055 Forwarder

Brakes 7. With brake OFF, use a feeler gauge to measure gap between operating disks.

Record this value (X1).

WARNING Hydraulic circuits with accumulators store hydraulic oil under pressure, therefore the system may remain pressurized after the engine is turned off.

OPERATING DISK AIR GAP

BRAKE CYLINDERS

••

OPERATING DISK PLATES

BRAKE DISK PLATES

•

•

••• ••••••• ••

1014-D090 REAR CHASSIS BRAKE CYLINDERS 3. Remove the cover plates to gain access to the brake cylinders and top of the bogie axle brake inspection plug.

REMOVE COVERS

••

•• ••

1014-204

CHECKING DISK AIR GAP 8. Turn the park brake switch on to engage the park brakes. Use a feeler gauge to measure gap between operating disks. Record this value (X2).

1014-207.PDF

REMOVE PLUG

• 1014-205

9. Subtract value X1 from value X2 to calculate the operating disk plate travel.

REMOVE DISK INSPECTION PLUG

10. The operating disk plate travel should be 2.2 to 3mm Max. If travel measures greater then 3mm disk plates require replacement.

4. Remove inspection plug on top of axle to gain access to brake disk assembly.

5. Start the engine and operate the pilot reset to turn on the computer.

6. Turn the park brake switch off and operate the park brake release lever to release the park brakes.

9.11

11. If brake operating disk plate travel is within the 2.2 to 3mm dimension, proceed to checking brake cylinder stroke adjustment.

Tigercat 1045/1055 Forwarder

Brakes

CHECKING BRAKE CYLINDER STROKE BRAKE CYLINDER THREADED HOLE BRAKE CYLINDER COVERS

••

1014-D090

•

••

REAR CHASSIS BRAKE CYLINDERS

•

1. Remove brake cylinder covers and brake locking bolt found inside the cover.

1

2. With the engine running and the computers on, turn on the park brake switch to release the park brakes. Ensure the wire to the service brake solenoid coil (SV1) is still removed turning off the service brakes.

3. Insert a depth gauge through threaded hole in the piston. Measure dimension "B".

4. Turn the park brake switch on.

5. Insert a depth gauge through threaded hole in the piston. Measure dimension "A".

1014-208.PDF

CHECKING BRAKE CYLINDER STROKE

6. The difference between "A" and "B" dimension should be 5-6mm. RECORD THIS DIMENSION it is required for BRAKE STROKE ADJUSTING BOLT PROCEDURE. If the dimension is not between 5-6mm the bolt (1) can be adjusted to obtain this dimension, See BRAKE STROKE ADJUSTING BOLT ADJUSTMENT in this section.

SERVICE BRAKE OPERATION 1. Set the Travel speed to LOW range and Travel Direction switch to either the FWD. or REV. position. Drive the machine and allow it to accelerate fully.

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

7. If the brake disk air gap and the cylinder stroke dimension are correct install the covers and plugs.

3. Set the Travel Direction switch to either the FWD. or REV. position. Drive the machine and allow it to accelerate fully.

8. Reconnect the wire for the service brake solenoid coil SV1. Close the valve compartment.

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

9. Test brakes for proper operation.

9.12

Tigercat 1045/1055 Forwarder

Brakes

BRAKE CYLINDER STROKE ADJUSTING BOLT ADJUSTMENT The following procedure outlines adjustment of the brake stroke adjustment bolt. Both front and rear axles should be adjusted at the same time.

Each axle has two brakes which require adjustment.

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).

WARNING Hydraulic circuits with accumulators store hydraulic oil under pressure, therefore the system may remain pressurized after the engine is turned off.

2. Stop the engine and release pilot system pressure by performing the following steps: a. Close both doors. Turn key switch to the ON position. Do not start the engine.

Press pilot reset switch. b. Fully engage and then disengage the front or rear diff locks 50 times or more. c. Pressure may remain in the system after completing the above steps. Use caution when loosening hydraulic connections.

3. Remove the brake hoses from the brake cylinder.

4. Loosen and remove 4 allen bolts (28) and remove spring loaded cylinder (cylinder upper part). Do not loosen the remaining two allen bolts (8).

9.13

Item

Part Description

Qty.

1 2 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 28 29 30

Screw Plug Protective cap Hex bolt O-ring Housing Plate spring Piston Allen screw Locking ring Allen screw Hex nut Guide ring Cylinder (upper part) Gasket Piston seal Breather valve with dust hood Guide ring O-ring Cylinder (lower part) Piston seal Stud O-ring Pressure piston

1 1 1 1 1 26 1 2 2 1 1 1 1 1 1 2 1 1 1 2 1 1 1

Ring Piston seal Piston seal Allen screw Locking clip Wedge

1 2 1 4 4 1

Tigercat 1045/1055 Forwarder

Brakes

5. Loosen locking nut (11) and and remove adjusting allen bolt (10). Clean threads of the adjusting allen bolt (10) and locking nut (11) of oil and adhesive residue.

10 ADJUSTING BOLT

•• ••

11 LOCK NUT

7. Screw the locking nut (11) up to the head of the adjusting allen bolt (10).

CYLINDER LOWER PART

8. Coat entire diameter and length of thread of adjusting allen bolt (10) with Loctite 242.

••

9. Screw the adjusting allen bolt (10) into the pressure piston (23), until the bolt requires a turning torque of 8 to 15 Nm. The brake disks should be fully activated.

10. Screw the bolt out 3 1/2 turns. The brake disk air gap should now be 2.4 mm, and the adjusting bolt length should be 5.25 mm.

Tighten lock nut against pressure piston(23).

1014-209.PDF

MEASURE BOLT LENGTH

11. Insert a new o-ring (18) into the groove of the cylinder-bottom part (19) and install the spring loaded cylinder onto the brake cylinder (19) and tighten the four allen bolts (28).

NOTE: Recheck the brake cylinder stroke as outlined earlier in this section.

9.14

5.25 mm

Tigercat 1045/1055 Forwarder SECTION 10 - OIL COOLER/RADIATOR, FAN AND HYDRAULIC TANK AUGUST, 2006

CONTENTS - SECTION 10 BELT - ENGINE SERPENTINE ....................................................................... 10.8 CHARGE & COOLING PUMP CIRCUITS ....................................................... 10.2 CHARGE PRESSURE FILTER-DRIVE PUMP .............................................. 10.12 ENGINE SERPENTINE BELT ......................................................................... 10.8 FAN DRIVE ..................................................................................................... 10.3 FAN DRIVE MOTOR ....................................................................................... 10.4 FILTERS CHARGE PRESSURE ............................................................................... 10.12 HYDRAULIC OIL ....................................................................................... 10.11 SERVICING GUIDELINES FOR OIL FILTERS .......................................... 10.12 HYDRAULIC FILTERS ...................................................................................................... 10.9 OIL FILL PUMP .......................................................................................... 10.10 OIL RESERVOIR ......................................................................................... 10.9 OIL VACUUM PUMP ................................................................................. 10.10 OIL COOLER .................................................................................................. 10.2 SCHEMATIC XP2-A0 FRONT FRAME MODULE ............................................................. 10.6

Tigercat 1045/1055 Forwarder

Oil Cooler/Radiator, Fan and Hydraulic Tank Clean charge air cooler, radiator, oil cooler and A/C condenser.

OIL COOLER OIL COOLER

CLEAN THE INSIDE OF HOOD SCREENS

••

• CLEAN AROUND FAN AREA

• • 1055-041

The hydraulic oil cooler is part of the side by side by side oil cooler / radiator / charge air cooler / A/C condenser package. The cooler package is mounted in front of the engine and cooling fan. The fan draws air from the front of the machine through the hood screen and cooler package and then blows it out either side of the engine compartment.

A/C CONDENSER

CHARGE AIR COOLER

ENGINE COMPARTMENT

Remove debris from hood screens on both sides and from around the fan.

1055-034

COOLER PACKAGE

••

Refer to CLEANING A/C CONDENSER, OIL COOLER, RADIATOR AND CHARGE AIR COOLER in SECTION 2 of the OPERATOR’S MANUAL.

•• •• • •

RADIATOR

•

OIL COOLER

1055-040

COOLER PACKAGE

The cooling assembly should be checked daily and cleaned as required.

10.2

1055-055

COOLING PUMP CIRCUIT

Tigercat 1045/1055 Forwarder

Oil Cooler/Radiator, Fan and Hydraulic Tank

HYDRAULIC FAN DRIVE

OIL COOLER

The charge air cooler, hydraulic oil cooler, engine radiator and A/C condenser core are mounted beside each other as a cooler assembly. The assembly is mounted in the front chassis in front of the engine.

RADIATOR

CHARGE AIR COOLER

•

• • ••

The cooling fan is mounted behind the cooler assembly and draws air through the front. The air passes through the charge air cooler/oil cooler/ radiator and A/C condensor core, through the engine compartment and out through the engine cover screens.

The fan is hydraulically driven. The fan drive system is reversible to facilitate cleaning by blowing air in the opposite direction through the cooler assembly.

COOLER ASSEMBLY

1055-034

8 BLADE 30" FAN

••

FAN MOTOR

•

FAN VALVE A

•

B

•• RETURN LINE TO COOLER

FAN DRIVE PUMP

•

1055-042

A/C CONDENSER

HYDRAULIC FAN DRIVE SYSTEM 10.3

Tigercat 1045/1055 Forwarder

Oil Cooler/Radiator, Fan and Hydraulic Tank FAN MOTOR

TO FAN MOTOR

PILOT OPERATED DIRECTIONAL VALVE (PD1)

The fan drive motor is a fixed displacement piston type motor. The fan drive motor is driven by hydraulic pressure from the fan pump via the fan manifold and in turn directly drives the fan.

••

DIRECTIONAL SOLENOID VALVE (SV1)

•

PROPORTIONAL RELIEF VALVE (SV2)

TO TANK

1055-055

T

• FROM FAN PUMP

FAN CONTROL VALVE SCHEMATIC

FROM FAN MANIFOLD A (REV)

1055-055

1055-058

FROM FAN MANIFOLD B (FWD)

FAN MOTOR HYDRAULIC SCHEMATIC

FAN COOLING CIRCUIT DESCRIPTION

FAN CONTROL VALVE ELECTRICAL SCHEMATIC

The fan "cooling" circuit is an open loop hydraulic system consisting of a gear pump, a fixed displacement motor and a control valve and manifold block .

The Iqan computer receives signals from the fan switch, engine coolant temperature sensor, engine intake air temperature sensor and hydraulic oil temperature sensor.

8 BLADE 30" FAN

• •• FAN MOTOR

FAN VALVE

••

1055-038 1055-034

COOLING FAN DRIVE COMPONENTS 1055-057

FAN ELECTRONIC CONTROLS 10.4

Tigercat 1045/1055 Forwarder

Oil Cooler/Radiator, Fan and Hydraulic Tank

With the fan switch in the AUTO position, the Iqan computer has full control over the operation of the cooling fan.

1065-007 32163B.AI

FULL ON (OVERRIDE) POSITION - When the switch is in the FULL ON (OVERRIDE) position, the fan control system is overridden and the fan will run at FULL speed for cooling regardless of charge air, coolant or oil temperatures. Normally the fan control switch is placed in the AUTO position for optimal cooling. The FULL ON (OVERRIDE) position is intended for use in the event of a temporary failure of the fan control.

FAN SWITCH

The three position fan switch is labelled FULL ON/AUTO/CLEAN. This switch along with the Iqan computer, controls the operation of the hydraulic cooling fan.

AUTO POSITION - AUTO is the normal operating position for the fan control switch. When the switch is in the AUTO position, the fan will operate completely in an automatic mode.

It will start, speed up, or slow down all based on the temperature of the charge air, engine coolant and/or the temperature of the hydraulic oil. The Iqan computer automatically adjusts fan speed to the minimum required level to maintain optimal operating conditions, provide auto reversing and default to fan at full speed if an error in the controller exists.

Automatic control of fan speed to match operating conditions can lower fuel consumption and reduce operating costs. In high temperature operating conditions the fan speed is increased to improve cooling ability and efficient operation of the charge air cooler, oil cooler, radiator and air conditioning systems.

In low temperature operating conditions fan speed is reduced, as less cooling is required.

When the switch is in the AUTO position, the fan will operate at low speed when charge air, engine coolant or hydraulic oil temperatures are low, turning ON the A/C will cause the fan control to immediately turn the cooling fan On. This is to ensure that sufficient air flow is available for the cab A/C even while the machine is still warming up.

10.5

CLEAN POSITION - This is a momentary position of the switch. When the switch is depressed the direction of rotation is reversed for 15 seconds and automatically returns to forward rotation.

Reverse rotation is used to clean the charge air cooler, radiator, oil cooler, A/C condenser and air intake door screens. By "reversing" the flow of the fan, air flow is propelled in the opposite direction, thereby forcing dust and debris off of the radiator screen.

The Iqan computer will also turn the A/C system OFF for as long as the fan is in the CLEAN mode.

Tigercat 1045/1055 Forwarder

Oil Cooler/Radiator, Fan and Hydraulic Tank

COOLING FAN DRIVE ELECTRICAL CIRCUIT

FAN DRIVE CONTROL VALVE

1055-056A

10.6

Tigercat 1045/1055 Forwarder

Oil Cooler/Radiator, Fan and Hydraulic Tank

CHARGE AIR COOLER The charge air cooler provides cooling of the engine intake air. Air flows from the air cleaner to the engine turbocharger through the turbo charger where the air pressure is boosted to 27.56 psi (1.9 bar).

Intake air then passes through the charge air cooler where it is cooled by the cooling fan and then flows to the intake manifold on the engine.

= AIR FLOW DIRECTION

1055-036A

CHARGE AIR COOLER: AIR FLOW DURING OPERATION 10.7

Tigercat 1045/1055 Forwarder

Oil Cooler/Radiator, Fan and Hydraulic Tank

REPLACING THE ENGINE SERPENTINE BELT Replace the engine serpentine belt as follows:.

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

SERPENTINE BELT

• •• 1

1075-012

SERPINTINE BELT

2. Install a 1/2" Johnson bar with a 15mm socket on the hex head bolt (1) of the belt tensioner.

3. Rotate the tensioner away from the belt to release belt tension. This will provide enough clearance to replace the serpentine belt.

1014-071

SERPENTINE BELT INSTALLATION

4. Reverse removal procedure to replace the belt.

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

10.8

Tigercat 1045/1055 Forwarder

Oil Cooler/Radiator, Fan and Hydraulic Tank HYDRAULIC FILTERS

HYDRAULIC OIL TANK Located above the articulation joint on the front chassis, the hydraulic tank has a capacity of 185 liters (50 US gallons).

BLUE ELEMENT CHARGE PUMP FILTER

•

SIGHT GAUGE

FULL FLOW FILTER ELEMENTS

•

• •• • ••

FULL FLOW FILTER ELEMENT

• HYDRAULIC TANK

•

HYDRAULIC TANK

1014-D057

1014-D015

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. It is recommended that all machines use the following different filter elements:

HYDRAULIC OIL SIGHT GAUGE

A sight gauge visible through the right side panel indicates the HIGH and LOW level of the hydraulic oil.

3 white, Tigercat high performance, full flow hydraulic oil filter elements

LEVEL SENDER

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

HYDRAULIC TANK

TEMPERATURE SENDER 1014-D015

HYDRAULIC TANK AND FILTER LOCATION

•• ••• HYDRAULIC TANK ACCESS L.H. SIDE

A level sending unit and temperature sending unit signal the MDM to display a “Low Hydraulic Oil” or “High Oil Temperature” alarm in the cab when the oil level is low or the temperature is high.

Always keep the hydraulic oil level between the HIGH and LOW calibrations. A low hydraulic oil level can result in severe damage to pumps.

WARNING 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 SECTION 3 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.

10.9

The drive pump charge circuit contains a single element, full flow, Tigercat hydraulic filter with a restriction indicator sending unit and a third port bypass valve.

For additional information on these filters, refer to HYD. FILTER BYPASS LIGHT in THIS SECTION. Also refer to FILTERS and SERVICE AND LUBRICATION POINTS in SECTION 3.

Tigercat 1045/1055 Forwarder

Oil Cooler/Radiator, Fan and Hydraulic Tank

HYDRAULIC OIL FILL PUMP

HYDRAULIC OIL VACUUM PUMP

HYDRAULIC OIL FILL PUMP

•

FILL PUMP ON/OFF SWITCH

VACUUM PUMP

••••

QUICK COUPLER

VACUUM GAUGE

••

VACUUM PUMP ON/OFF SWITCH

•

1014-D057 1014-D059

TOP OF HYDRAULIC TANK

The hydraulic oil fill pump, located on the top of the hydraulic tank is used to add oil to the hydraulic oil reservoir.

To add oil to the reservoir: Park the machine on level ground, with the crane in the “parked” position. Remove suction hose from storage compartment. Clean the suction hose, and remove cap. Open the right hand side access door on the hydraulic tank. Install hose into quick coupler on fill pump. Insert the end of suction tube into the supply drum and operate the pump by turning the fill pump switch ON. The oil is pumped into the reservoir through the return filters. When the oil level in the tank is satisfactory, switch the fill pump OFF.

IMPORTANT Replace the cap on the suction tube, disconnect from the fill pump, wipe dry and store in rear chassis compartment. Close the hydraulic tank doors.

10.10

•• R.H. SIDE OF HYDRAULIC TANK

With the IGNITION KEY SWITCH in the OFF position, place the vacuum switch in the ON position to energize the vacuum pump and open the air space in the top of the hydraulic tank to the vacuum created by the vacuum pump. This will greatly reduce oil leakage from the machine while hydraulic system repairs are underway. The pump should remain ON during the time the repairs are in progress. A gauge incorporated in the system will indicate the level of vacuum being held. Turn the switch to the OFF position when the work is complete Turning the vacuum switch OFF will stop the vacuum pump and open the tank to the atmosphere via a vent fitting.

Note: If the ignition key is turned ON while there is a vacuum in the tank, a valve will release the vacuum from the tank automatically.

Tigercat 1045/1055 Forwarder

Oil Cooler/Radiator, Fan and Hydraulic Tank

HYDRAULIC OIL FILTERS

Changing the filters: BLUE ELEMENT

CHARGE PUMP FILTER

• FULL FLOW FILTER ELEMENTS

1. Park machine on level ground, install articulation lock bar, lower the 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.

FULL FLOW FILTER ELEMENT

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

1014-D015

HYDRAULIC RESERVOIR AND FILTER LOCATION

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

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 valve 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 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 SECTION 3.

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

Discard the square section gasket.

FILTER HEAD

• • 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.

WARNING

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.

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

•

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

•

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

•

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

10.11

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 1045/1055 Forwarder

Oil Cooler/Radiator, Fan and Hydraulic Tank

CHARGE PRESSURE FILTER-DRIVE PUMP

HYDRAULIC FILTER SERVICING GUIDELINES

CHARGE PUMP FILTER

IMPORTANT

••

NEVER PRE-FILL ANY HYDRAULIC FILTERS

•• HYDRAULIC RESERVOIR

HYDRAULIC RESERVOIR AND FILTER LOCATION 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.

1014-D015

Tigercat generally does not recommend the prefilling of spin-on filters due to the risk of damage to the hydraulic system caused by unfiltered oil.

Unfiltered oil used to pre-fill filters enters directly into the hydraulic circuit. Contaminants in unfiltered oil can cause significant and costly damage to hydraulic valves, pumps and motors.

The cleanliness of hydraulic oil cannot be guaranteed unless it is always prefiltered before use.

Changing a pressure filter:

IMPORTANT

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.

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.

10.12

Direct contact with oil implies a risk of skin complaints. Oil on skin should be washed off immediately with soap and water. Refer also to WORKING WITH OIL in SECTION 1 of THIS MANUAL.

Tigercat 1045/1055 Forwarder SECTION 11- CENTER JOINT, STEERING, GATE AND SNOW BLADE AUGUST, 2006

CONTENTS - SECTION 11 ARTICULATION LOCK .................................................................. 11.19, 11.20 CENTER JOINT ........................................................................................... 11.2 ARTICULATION JOINT DIAGRAM ................................................ 11.5, 11.7 ARTICULATION JOINT PRELOAD ADJUSTMENT ................................. 11.4 CHECKING ARTICULATION JOINT PRELOAD ...................................... 11.3 CHECKING/ADJUSTING THE OSCILLATION JOINT PRELOAD .. 11.6, 11.8 DRIVESHAFT INSTALLATION ................................................................. 11.8 GREASE SEALS ...................................................................................... 11.4 LUBRICATION .......................................................................................... 11.2 MAINTENANCE OF ARTICULATION JOINT ........................................... 11.2 MAINTENANCE OF OSCILLATION JOINT .............................................. 11.2 ELECTRONIC SYSTEM ............................................................................ 11.14 GATE VALVE TESTING PORT RELIEF PRESSURE ................................................... 11.20 LOAD GATE ............................................................................................... 11.20 OSCILLATION LOCK CIRCUIT SET-UP OIL FILL AND PURGE AIR ..................................................................... 11.11 PRESSURE SETTINGS - RELIEF VALVES ........................................... 11.12 STEER VALVE ........................................................................................... 11.15 ADJUSTING STEER VALVE FEED REDUCTION VALVE SETTING ..... 11.19 REPLACING MAIN PRESSURE RELIEF VALVE ................................... 11.18 REPLACING PORT RELIEFS ................................................................ 11.18 STEERING AND BLADE FUNCTIONS ELECTRONIC SYSTEM ......................................................................... 11.14 STEERING AND BLADE FUNCTIONS ...................................................... 11.14

Tigercat 1045/1055 Forwarder

Center Joint, Steering, Gate and Snow Blade REAR CHASSIS

FRONT CHASSIS

REAR CHASSIS

FRONT CHASSIS

CENTER JOINT

CENTER JOINT

••

1055-027

CHECK FOR MOVEMENT IN THIS JOINT AREA

••

CENTER JOINT 1055-027

CENTER JOINT

CENTER JOINT

MAINTENANCE OF ARTICULATION JOINT

MAINTENANCE OF OSCILLATION JOINT

Maintenance in this area is usually limited to:

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.

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 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.

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 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.

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/ 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.

11.2

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 1045/1055 Forwarder

Center Joint, Steering, Gate and Snow Blade

CHECKING ARTICULATION JOINT PRELOAD 1. Park the machine on level ground. Set the Travel Direction switch in the OFF position, place the crane in the park position, and lower the blade to the ground (if equipped). Shut off engine.

•

•

B

A

PLACE BLOCKS OR SAFETY STANDS UNDER FRONT AND REAR CHASSIS AS SHOWN 1014-095A 1055-038

2. Place blocks or safety stands under front and rear chassis as shown to prevent any movement of the chassis during this procedure.

CENTER JOINT RIGHT SIDE

5. Fully loosen only the top pin retainer bolts. DO NOT REMOVE BOLTS. 6. The dial indicator should now show a change of 0.012" to 0.013" between pin lugs ‘A’ and ‘B’.

FRONT CHASSIS REAR CHASSIS

•

This is the proper bearing preload setting.

If the reading is within this range re-torque the top retainer bolts to 400Nm (300 lb. ft.).

‘B’

••

‘A’

A change of less than 0.012" 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.

CENTER JOINT

• 1055-027

CENTER JOINT LEFT SIDE

3. Place the magnetic base of a dial indicator on the top surface of the center joint bottom lug ‘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.

4. Partially depress the plunger end of the dial indicator against the bottom surface of the top center joint lug ‘B’ as close to center pin as possible.

11.3

Tigercat 1045/1055 Forwarder

Center Joint, Steering, Gate and Snow Blade

ARTICULATION JOINT PRELOAD ADJUSTMENT

ORIENTATION OF GREASE SEALS

Before making any adjustments to the articulation joint, please follow CHECKING THE ARTICULATION JOINT PRELOAD procedure in THIS SECTION.

The articulation pivot bearings (10) 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.

With dial indicator still in place;

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;

1. Remove the bottom pin retainer bolts (item 1), the bottom pin retainer plate (item 3) and all of the shims in the shim pack (items 4).

NOTE: Keep upward pressure on the bottom pin (2) and do not allow pin to fall out from the bearing. These pivot pins are very heavy, block the pin in place if necessary.

1

TOP PIVOT BEARING

•

2. Remove the thinnest shim from the pack.

••

3. Reinstall the remaining shims, the retainer plate and the bolts. Leave the bolts loose.

2

2

4. Zero the dial indicator and torque the bottom bolts in sequence to 400Nm (300 lbf-ft).

••

5. A change of 0.012" to 0.013" should register on the dial indicator.

This is the proper articulation bearing preload setting. If the reading is within this range no further action is required. a) If change in dial indicator reading is greater than 0.013", the shim removed (in step 2) may not have been the thinnest shim in the pack. Repeat steps 1 through 4, replacing this shim and removing only the thinnest shim from the shim pack (item 4). b) If the change in the dial indicator reading is less than 0.012", another shim will have to be removed. Repeat steps 1 through 4, removing additional shims but only the thinnest shim each time, until the change in the reading on dial indicator is within the proper range. 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.

11.4

•

BOTTOM PIVOT BEARING 1055-080 1055-081

1

CENTRE JOINT PIVOT BEARING SEALS

• The seals (1 AND 2) installed on either side of the top and bottom bearings must be installed with the seal lips facing as shown above.

Apply blue 243 Loctite (removable) and torque the bolts (item 8) for the bearing retainer plate (item 9) to 270Nm (200 lbf-ft).

Tigercat 1045/1055 Forwarder

Center Joint, Steering, Gate and Snow Blade

9

• •

8

10

•• •

6

7

• • • 5

1

•

3

•

•

2 4

• 3

•

1

•

1

3

6

5 4

1055-025

ARTICULATION JOINT 11.5

2

BOLT TIGHTENING SEQUENCE

Tigercat 1045/1055 Forwarder

Center Joint, Steering, Gate and Snow Blade

CHECKING/ADJUSTING THE OSCILLATION JOINT PRELOAD

OSCILLATION END CAP

1. Park the machine on level ground. Set the Travel Direction switch in the OFF position, place the crane in the park position, and lower 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.

VERNIER CALIPER

• •

1018-D114

OSCILLATION JOINT PRELOAD

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:

4. Remove the shim pack (item 5a & 5b).

Measured distance (step 6): 1.127” Measured thickness (step 8): 0.998” Total thickness of shims required: 0.129”

5. With the shim pack removed, install the oscillation end cap (item 2) using six washers and M16 bolts (item 4). Evenly torque to 275Nm (200 lbf-ft). Be careful not to damage Polypak Seal (item 6) while installing the oscillation end cap (item 2).

10. Select an arrangement of shims (item 5) that add up to the thickness of shims required calculated in step 9.

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).

11.6

11. Install selected shims (item 5), and oscillation end cap (item 2) using washers and bolts (item 4). Torque these fasteners to 275Nm (200 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.

Tigercat 1045/1055 Forwarder

Center Joint, Steering, Gate and Snow Blade

1

3

6

BOLT TIGHTENING SEQUENCE

5 2

4

••

1

•• 3

4

2

• ••

•

••

•• 5a 5b 6

1055-026

OSCILLATION JOINT 11.7

Tigercat 1045/1055 Forwarder

Center Joint, Steering, Gate and Snow Blade

CENTRE JOINT DRIVESHAFT INSTALLATION 1. Sling Centre Joint such that it hangs mostly horizontal. (See figure 1).

6. Spray Loctite 7649 primer around the rear face of the centre joint where it mates with the shaft seal housing cover once and allow to dry.

2. Remove paint and grease from bores and machined surfaces used in DRIVESHAFT installation area, using a paint scraper, reducer and rag ONLY. DO NOT use a die grinder or a flap wheel.

7. Use the output sleeve (6) to install the 2 seals into the smaller (rear) shaft seal housing cover so that the spring sides face the exterior of the centre joint when mounted. The double lip oil seal (4) will be installed first. Lightly tap in the seals until they bottom out on the shoulders using a rubber mallet or ballpeen hammer.

Tap all around the sleeve to ensure that the seals are fully seated. Grease seals to hold the spring in place.

3. Inspect bores for imperfections. Repair any problems.

4. Heat bearing cones in oil until the oil temperature has stabilized at 149°C (300°F) (approximately 15 minutes).

5. Install heated bearing cones on to each end of drive shaft. The cones should slide on quite easily. Cones must be FIRMLY seated on the shaft up against the shoulder and ROTATED while pressing firmly, until cones no longer move.

NOTE: Never tap the bearing cage directly or anywhere that would put the cage at the risk of being struck.

8. Use the output sleeve to install the 2 seals into the larger (front) shaft seal housing cover. With (front) shaft seal housing cover on bench, first install double lip oil seal (4), spring side down.

The single lip (5), Teflon rotary seal is installed into the (front) housing cover second, spring side up. The different types of seals should be back-to-back when installed. Lightly tap on the seals until they bottom out on the shoulders using a rubber mallet or ballpeen hammer.

Tap all around the sleeve to ensure that the seals are fully seated. Grease seals to hold the spring in place.

1

••

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

Center Joint Assembly Yoke Housing Seal, Double Lip Seal, Rotary Sleeve, Output Washer Bolt Bearing Cup Bearing Cone Bolt and Washer Shim .005” Shim .007” Shim .020” O-ring

0000-000

DETAIL ‘A’

DETAIL ‘B’

CENTRE JOINT DRIVESHAFT INSTALLATION 11.8

Tigercat 1045/1055 Forwarder

Center Joint, Steering, Gate and Snow Blade 5

4

9

10

7 2

8

3

15 1

6 11 12 13

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

Center Joint Assembly Yoke Housing Seal, Double Lip Seal, Rotary Sleeve, Output Washer Bolt Bearing Cup Bearing Cone Bolt and Washer Shim .005” Shim .007” Shim .020” O-ring

7

14

8

15

10

9

4

5

6

3

2

11

1055-027

9. Pack the front and rear driveshaft BEARING CONES (10) with clean grease using a Grease Gun Needle Attachment.

10. Place driveshaft bearing cups (9) in liquid nitrogen container to cool and shrink them.

11. Install cooled bearing cups into the seal housing covers using gloves. Fully install the bearing cups up to the shoulder, keep inward pressure on it while turning until it no longer moves by hand (cup expands to fit tight in seal housing).

12. Apply a small steady bead of Loctite 518 to the rear face of the centre joint that mates with the seal cover in a ring just inside the bolt holes then apply a ring around each bolthole.

13. Apply a small amount of Loctite 567 to the 6 M12X1.75 bolts (8) that fasten the seal cover to the centre joint. Install seal cover by finger tightening 6 bolts until snug. Tighten to 80 lbfft in a star pattern. The Loctite applied in Step 11 should just barely be visible at the edges of the seal cover.

11.9

14. Install o-rings (15) on both sides of drive shaft.

Slide drive shaft through the centre joint being careful not to damage the bearing cones and rear seals. Installing a bolt in the rear of shaft can aid in pulling the shaft through the rear bearing housing.

15. Put 3 x 20 thousandth of an inch (thou.) shim (yellow) on the front side of the centre joint.

16. Fasten seal cover to the centre joint using the 6 bolts. While turning the shaft, slowly tighten the bolts in a star fashion until the shaft no longer turns. Loosen the bolts until the shaft turns and then retighten to 65 lbf-ft in a star pattern while turning the shaft. This ensures the bearings have properly seated themselves.

NOTE: Do NOT use any sealing product on this seal cover; the shims will provide sealing.

17. Let the assembly sit in this “pre-load” state for 1hr to allow the rear bearing Loctite to set.

18. Remove the front seal cap and bearing cup.

19. Add 1 or 2 more 20 thou. shims and reinstall the front seal housing as above, tightening to a torque of 65 lbf-ft.

Tigercat 1045/1055 Forwarder

Center Joint, Steering, Gate and Snow Blade 5

4

9

10

7 2

8

3

15 1

6 11 12 13

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

Center Joint Assembly Yoke Housing Seal, Double Lip Seal, Rotary Sleeve, Output Washer Bolt Bearing Cup Bearing Cone Bolt and Washer Shim .005” Shim .007” Shim .020” O-ring

7

14

8

15

10

9

4

5

6

3

2

11

1055-027

20. Check the resistance to turning the shaft.

Repeat the above step, adding more shims as required until the shaft turns freely. Do not proceed until the shaft is set correctly.

25. Record this value of endplay. Remove or add SHIMS so that an endplay of 4 - 6 thou.

(0.004” - 0.006”) is achieved.

NOTE: Shim colour code: 3 thou. = green, 5 thou. = blue, 7 thou. = silver, and 20 thou. = yellow.

21. Pry on the front of the shaft with a pry bar (pushing the shaft towards the rear) and spin the shaft until the bearings are seated.

Continue holding pressure on the shaft using the pry bar.

NOTE: Sample calculation: 20 thou. shim present. Reading is 10 thou. endplay.

Remove 20 thou. shim and add 15 thou. worth of shims (one green, one blue, one silver) to achieve 5 thou. endplay.

22. Position a DIAL INDICATOR stand on either the front or rear face of the Centre Joint so that it measures on the end of the shaft. Spin the drive shaft to settle it in the bearing race.

Setup the DIAL INDICATOR to give a zero (0) reading on a machined face of the driveshaft.

26. Apply Loctite 567 to the 6 bolts that are used to fasten the shaft seal housing to the front face. Finger-tighten the bolts then tighten to 80 lbf-ft using a star pattern.

23. Repositon the pry bar on the rear of the drive shaft. Spin the shaft and pry on the shaft from the rear (pushing the shaft towards the front).

Read the value on the dial indicator.

24. Repeat the above 3 Steps until the same value in step above is noted 3 consecutive times.

27. Verify the endplay with the dial indicator.

28. Insert the front output sleeve into place.

Assemble front driveshaft yoke. Torque M16x2.0 bolt to 200 lbf-ft.

29. Insert the rear output sleeve into place. Install rear driveshaft yoke. Ensure that front and rear driveshaft yokes are aligned in phase.

Torque M16x2.0 bolt to 200 lbf-ft.

11.10

Tigercat 1045/1055 Forwarder

Center Joint, Steering, Gate and Snow Blade

OSCILLATION LOCK CIRCUIT SET-UP

BASE END

INSTALLING NEW CYLINDERS - OIL FILL & PURGE AIR

• ••

1. Prior to installing Oscillation Lock Cylinders on the rear chassis, retract the cylinders fully and fill rod end with oil and cap.

••

BASE END

•••

• •••

••

CYLINDER

BASE END HOSES

••

HOSES

•• ••

ROD END

1055-053

L.H. OSCILLATION LOCK CYLINDER

•

ROD END NOT ATTACHED

••

••

1055-055 OSCILLATION LOCK CYLINDERS 1055-056 2. Install base end of cylinders on the rear chassis. Do not install rod end at this time.

Clear the area around the cylinder to allow it to extend fully without interference.

BASE END

•• CYLINDER

HOSES

•• ••

3. Place a drip pan below the Oscillation Lock Cylinders.

4. Attach all hydraulic connections. Be careful to prevent oil from leaking out of the rod end of the cylinder.

5. Start the engine and allow cylinders to fully extend.

6. While engine is running, bleed the air from the base end of the cylinders by carefully cracking open the hose connection feeding the base end of each cylinder (use rags to cover the connection to prevent oil from spraying). Allow oil/air mixture to purge out and retighten hose connection once all air has been removed.

••

ROD END

1055-053

R.H. OSCILLATION LOCK CYLINDER 8. Complete installation of cylinders, pinning rod end to Center Joint. This can be accomplished by cracking the fitting at the base end and using a pry bar or dead blow hammer to retract cylinder.

7. Stop engine and allow system to rest for a few minutes, then crack the base end hoses once again (take precautions as listed in step 5 since the accumulator will keep pressure on the circuit). Retighten hose connection. If air is still present in the system, repeats steps 5 & 6 until all air has been purged.

11.11

Tigercat 1045/1055 Forwarder

Center Joint, Steering, Gate and Snow Blade

OSCILLATION LOCK CIRCUIT SET-UP PRESSURE SETTINGS – RELIEF VALVES

SV

PR1

PR2

RV

RP1

1. Connect Minimess hose from ‘P1’ test port on High Pressure Manifold to test port ‘L1’ on Oscillation Lock Manifold.

• ••

P1

2. Connect a 0-5000psi gauge to test fitting ‘R1’ on Oscillation Lock manifold.

SW2

•

3. Engage manual override on ‘SV’ solenoid valve of the Oscillation Lock manifold. Push stem, twist counterclockwise and release stem to engage override.

4. Loosen locknuts on both relief valves ‘RV1’ and ‘RV2’ of the Oscillation Lock Manifold and turn both adjustment screws CW all the way in to the maximum setting.

• •• ••

• •

•• ••

SW1

RP2 ACC1

1014-057

HIGH PRESSURE MANIFOLD - FIGURE 1

5. Disconnect red wire from both pressure switches SW1 & SW2 on the high pressure manifold.

‘R1’ TEST PORT

MANUAL OVERIDE CONTROL

6. Start the machine. The gauge should reach the setting of the main pump pressure.

•

7. Adjust ‘RV2’, turning screw CCW to lower its setting. Adjust until gauge reads 172-178bar (2495-2580psi).

•• •• •• ••

OSCILLATION LOCK HYDRAULIC VALVE MANIFOLD ‘L1’ TEST PORT

‘RV2’ ‘RV1’

8. Adjust ‘RV1’, turning screw CCW to lower its setting. Adjust until gauge reads 62-68bar (900-985psi).

1055-006

HYDRAULIC VALVE COMPARTMENT

9. Stop the machine.

10. Reconnect red wire from both pressure switches SW1 & SW2 on the high pressure manifold.

11. Disconnect Minimess line and pressure gauge.

12. Disengage the manual override on ‘SV’. Push in stem, twist clockwise and release.

11.12

Tigercat 1045/1055 Forwarder

Center Joint, Steering, Gate and Snow Blade

1055-053

OSCILLATION LOCK HYDRAULIC CIRCUIT

1055-067

OSCILLATION LOCK HYDRAULIC SCHEMATIC 11.13

Tigercat 1045/1055 Forwarder

Center Joint, Steering, Gate and Snow Blade

STEERING AND BLADE FUNCTIONS The steering and blade functions are proportional valve functions. Each of them is controlled electro-hydraulically from a valve assembly located in the rear 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 steering 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”.

1014-D018

ELECTRONIC SYSTEM The steer and blade functions are all controlled by the MDM Controller. The CON TROLLER monitors and analyzes inputs, then produces outputs (as defined in its program) to control the machine functions. The operator may adjust settings for all functions controlled by the MDM Controller. Refer to SECTION 2 of the OPERATOR’S MANUAL for details:

The blade function operates proportionally with respect to function “speed” in the same manner as the steering function.

11.14

Tigercat 1045/1055 Forwarder

Center Joint, Steering, Gate and Snow Blade

STEER VALVE DESCRIPTION

‘B’ SIDE

‘A’ SIDE

A B A B A B A B A B

1014-083

The steer valve, located in the rear chassis, is a load sensing and pressure compensated proportional valve and consists of spool sections, an inlet section and an end section.

A

B

GATE

A

B

STEER

A

B

BLADE

A

B

BLADE

A

B

VALVE SECTIONS (FIVE VALVE SECTION SHOWN)

Pressure Relief Valve

INLET SECTION The inlet section is equipped with connection ports to the main pump via the boom valve, tank, load sense signal (‘LS’) to the main pump, 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) port relief. This pressure relief valve is intended to protect the steer 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. PRESSURE RELIEF VALVE

INLET (FROM MAIN PUMP)

• •

1014-091

WINCH

•

INLET SECTION 11.15

OUTLET (RETURN TO MANIFOLD)

Tigercat 1045/1055 Forwarder “B” SIDE FEED REDUCTION VALVE “A” SIDE FEED REDUCTION VALVE

•

Center Joint, Steering, Gate and Snow Blade 24V PROPORTIONAL ELECTRO-HYDRAULIC SPOOL ACTUATORS

PORT RELIEF ‘A’ SIDE

PORT RELIEF ‘B’ SIDE

• •

•

•

•

• • PRESSURE COMPENSATOR 1014-007.PDF

SPOOL

SPOOL SECTION

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.

TANK CONNECTION

•

COUNTERBALANCE VALVE

••

PILOT PRESSURE CONNECTION

• ••

PILOT FILTER

••

Counterpressure Valve The counterpressure valve, housed in the outlet 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).

LS CONNECTION 1014-006.PDF

END SECTION

END SECTION 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.

11.16

Tigercat 1045/1055 Forwarder “B” SIDE FEED REDUCTION VALVE “A” SIDE FEED REDUCTION VALVE

•

Center Joint, Steering, Gate and Snow Blade PORT RELIEF ‘A’ SIDE

PORT RELIEF ‘B’ SIDE

24V PROPORTIONAL ELECTRO-HYDRAULIC SPOOL ACTUATORS

• •

•

•

•

• • PRESSURE COMPENSATOR 1014-007.PDF

SPOOL

SPOOL SECTION

SPOOL SECTIONS

Pressure Compensation

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 Iqan XP2 module) 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.

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.

Feed Reducers All feed reducers are turned IN all the way.

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.

11.17

Tigercat 1045/1055 Forwarder

Center Joint, Steering, Gate and Snow Blade

Port Reliefs

MAIN RELIEF

‘A’ SIDE

‘B’ SIDE

•

PORT RELIEF VALVES A B A B

• WINCH

A

B

GATE

A

B

A

B

BLADE

A

B

BLADE

A

B

•••AB •• STEER •• • A

B A

FEED REDUCERS

B

INLET SECTION 1014-083

PORT RELIEF

FEED REDUCER

VALVE SECTIONS (FIVE VALVE SECTION SHOWN)

••

SPOOL SECTION

REPLACING PORT RELIEFS:

NOTE: Be sure to replace port relief cartridges The steer valve is equipped with port reliefs on each with the appropriate replacement, as indicated in the PARTS CATALOG. side of all spool sections. The function of the port 1. Park the machine on level ground, place the relief is to protect the steer valve and the function crane in the park position, and lower all cylinder or motor from pressure peaks in the attachments to the ground. Shut off the system. The port reliefs also act as anti-cavitation engine. valves, which means they allow oil to flow from the tank gallery in the valve to the service ports in the 2. Switch the vacuum pump ON (refer to event of underpressure. Port reliefs cannot be HYDRAULIC OIL VACUUM PUMP in adjusted. Port reliefs installed in each section are SECTION 2 of the OPERATOR’S MANUAL). specifically designed for use in that section and 3. Remove the plastic cap from the relief to be should not be interchanged with port reliefs from changed. other valve sections . Refer to REPLACING PORT 4. Remove the retaining cap from the valve body RELIEF in THIS SECTION. using a 1 1/16” wrench or socket.

REPLACING MAIN PRESSURE RELIEF VALVE: 5. Remove the existing relief, and install the replacement relief cartridge.

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 all attachments to the ground. Shut off the engine.

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.

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 relief cartridge using a ½” Allen key.

5. Install the replacement relief cartridge, and tighten to 60 Nm (45ftlb).

6. Install the plastic cap.

7. Switch the vacuum pump OFF.

11.18

Tigercat 1045/1055 Forwarder

Center Joint, Steering, Gate and Snow Blade

ADJUSTING STEER VALVE FEED REDUCTION VALVE SETTINGS: 1. Park the machine on level ground, place the crane in a secure position, and lower all attachments to the ground. Shut off the engine.

••

DRIVE PUMP

ENGINE

MAIN PUMP

9. The reading on the 0-5000 psi gauge installed on the ‘LS’ test port should be 230 bar (3335 psi) for both A and B side. Release the function.

‘B’ SIDE

‘A’ SIDE

COOLING PUMP A

•

••

•

B A B

1 CHARGE PRESSURE

• •

••

2

1055-066

•• •

•••AB •

PUMP CONTROLLER VALVE “LS” TEST PORT

A B

A B

2. Connect a 0-5000 psi gauge to the ‘LS’ test port on the main pump.

1014-083

4. Ensure that the hydraulic oil is at operating temperature. See HYDRAULIC OIL HEATING PROCEDURE in SECTION 8 of THIS MANUAL.

GATE

A

B

STEER

A

B

BLADE

A

B

BLADE

A

B

7. The reading on the 0-5000 psi gauge installed on the ‘LS’ test port should be 215 bar (3118 psi) for both A and B side.

VALVE SECTIONS (FIVE VALVE SECTION SHOWN)

Note: The port relief valves are not adjustable and the feed reducers are turned in fully at the factory. If the pressure readings are not to specifications the port relief valves must be replaced.

6. Have an assistant operate the steer function in one direction, to its full extent. Continue to hold the function at this position.

••

B

10. Operate the same function in the opposite direction and repeat step 9.

5. Start the engine (and run at idle). Depress the pilot reset switch.

MAIN PUMP

A

FEED REDUCERS

3. Install the chassis articulation lock bar between the chassis and center joint.

DRIVE PUMP

WINCH

11. Loosen the lock nut and turn adjustment screw on main pump pressure cut-off valve (2) out until the gauge reads 215 bar (3118 psi) and tighten lock nut.

12. Shut off the engine.

13. Remove gauge and wipe up any spilled oil.

•

14. Close valve compartment.

15. Remove chassis articulation lock bar and return it to the storage location.

1

• • 2 1055-066

•

“LS” TEST PORT

8. Loosen the lock nut on main pump pressure cut-off valve (2) and turn adjustment screw in 1/2 turn and tighten the lock nut.

Note: This will increase pressure cut-off from 215 bar to 261 bar (one screw revolution is equal to 92 bar, 1/2 screw revolution is equal to 46 bar).

11.19

Tigercat 1045/1055 Forwarder

Center Joint, Steering, Gate and Snow Blade

LOAD GATE

5. Start the engine (and run at idle). Depress the pilot reset switch.

The load gate can be moved UP or DOWN to accommodate various load sizes, and crane movements.

6. Have an assistant operate the GATE UP/ DOWN function to its full extent. Continue to hold the function at this position.

GATE UP/DOWN SWITCH

••

••

7. The reading on the 0-5000 psi gauge installed on the ‘LS’ test port should be 50 bar (725 psi) for both A and B side.

PILOT RESET SWITCH

DRIVE PUMP

MAIN PUMP

•• •

1014-001

R.H. JOYSTICK & CONTROL SWITCHES

1

• •

The GATE switch is momentary and must be held in either the UP or DOWN position for the gate to move. 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 section.

“LS” TEST PORT

2

•

1055-066

‘B’ SIDE

‘A’ SIDE

Two gate valve port relief cartridges control the pressure made available to the cylinder for extension. The other controls the pressure available for the cylinder to retract.

A B A B

TESTING PORT RELIEF PRESSURE IN GATE VALVE

A B A

1. Park the machine on level ground, place the crane in a secure position, and lower all attachments to the ground. Shut off the engine.

B A B

WINCH

A

B

GATE

A

B

STEER

A

B

BLADE

A

B

BLADE

A

B

2. Remove the cover on the valve compartment of the rear frame to expose the gate valve.

••

DRIVE PUMP

ENGINE

••

MAIN PUMP

•

CHARGE PRESSURE 1055-066

••

2

•• •

PUMP CONTROLLER VALVE “LS” TEST PORT

VALVE SECTIONS (FIVE VALVE SECTION SHOWN)

NOTE: Relief valves are not adjustable, if pressure dose not meet specifications the relief valves must be replaced. See previous page, REPLACING PORT RELIEFS for replacement procedure.

••

1

• •

1014-083

COOLING PUMP

8. Operate the GATE functions again, and verify that the pressure being read is correct.

3. Connect a 0-5000 psi gauge to the “LS” test port on the main pump.

9. Shut off the engine.

3. Install the chassis articulation lock bar between the chassis and center joint.

11. Close valve compartment.

4. Ensure that the hydraulic oil is at operating temperature. See HYDRAULIC OIL HEATING PROCEDURE in SECTION 8 of THIS MANUAL.

10. Remove gauge and wipe up any spilled oil.

12. Remove chassis articulation lock bar and return it to the storage location.

11.20

Tigercat 1045/1055 Forwarder

Center Joint, Steering, Gate and Snow Blade

•• STEER, GATE, WINCH, AND BLADE CONTROL VALVE

1014-086

HYDRAULIC VALVE COMPARTMENT - REAR CHASSIS

11.21

Tigercat 1045/1055 Forwarder

Center Joint, Steering, Gate and Snow Blade

11.22

Tigercat 1045/1055 Forwarder SECTION 12 - CRANE, GRAPPLE AND MAIN PUMP AUGUST, 2006

CONTENTS - SECTION 12 BOOM VALVE .............................................................................................. 12.6 ADJUSTING BOOM VALVE FEED REDUCTION VALVE SETTING ..... 12.10 REPLACING MAIN PRESSURE RELIEF VALVE CARTRIDGE ............... 12.9 REPLACING PORT RELIEFS ................................................................ 12.10 SCHEMATIC ............................................................................................. 12.7 CIRCUIT DIAGRAM ......................................................................... 12.3, 12.11 CRANE AND GRAPPLE .............................................................................. 12.2 CRANE AND GRAPPLE FUNCTIONS ELECTRONIC SYSTEM ........................................................................... 12.2 HYDRAULIC SYSTEM .............................................................................. 12.2 ELECTRONIC SYSTEM ............................................................................... 12.2 GRAPPLE ROTATOR .................................................................................. 12.2 HYDRAULIC SYSTEM DESCRIPTION ........................................................ 12.4 LOAD SENSING HYDRAULIC SYSTEM .............................................................................. 12.4 LOAD SENSING BASIC DESCRIPTION .................................................. 12.4 LOAD SENSING BASIC PRINCIPALS ..................................................... 12.4 LOAD SENSING OPERATING TIPS ........................................................ 12.5 MAIN PUMP ............................................................................................... 12.12 MARGIN PRESSURE ................................................................................ 12.14

Tigercat 1045/1055 Forwarder

Crane, Grapple and Main Pump

CRANE AND 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 faster.

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.

1014-D018

ELECTRONIC SYSTEM All of the boom valve functions are controlled by the MDM Controller. The Controller monitors and analyzes inputs and produces outputs (as defined in its program) to control the machine. The operator may interface with the controller program using the MDM Display Terminal. Refer to SECTION 2 of the OPERATOR’S MANUAL for ionformation regarding the following: • GAUGE MENUS • MODE MENU • INFORMATION MENU • SETTINGS MENU

CRANE & GRAPPLE

• MEASURE MENU

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.

• PROPERTIES MENU

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 rotation of the grapple.

Inputs: The computer monitors signals from the STEERING JOYSTICK and the LEFT and RIGHT MINI JOYSTICKS. The Controller also reacts to digital signals from the CRANE/BLADE switch, the TRANSMISSION GEAR SELECT switch, TRAVEL DIRECTION switch, TRAVEL SPEED switch, SEAT ROTATE POSITION switch, LADDER UP/ DOWN switch, BRAKE and THROTTLE FOOT PEDALS. Outputs: The computer directs an output (24 Volt proportional electrical current) to the boom valve solenoids to operate the various functions.

HYDRAULIC SYSTEM The proportional valve functions depend on a load sense hydraulic system composed of the following major components; 1.

2.

3.

4.

12.2

Main pump Steer Valve Boom Valve Working Components

Tigercat 1045/1055 Forwarder

1014-087

Crane, Grapple and Main Pump

CIRCUIT DIAGRAM

12.3

Tigercat 1045/1055 Forwarder

Crane, Grapple and Main Pump

HYDRAULIC SYSTEM DESCRIPTION

LOAD SENSING BASIC DESCRIPTION

The proportional valve functions depend on a load sense hydraulic system composed of the following major components;

Load sensing systems use variable flow pumps and only flow the volume of oil that is 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.

LOAD SENSING BASIC PRINCIPALS 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.

In an attempt to recover some of the wasted energy, variable volume pumps evolved. These pumps are pressure regulated to limit the maximum output and since they reduce the pumps output to maintain a constant system pressure, oil flow over the relief valve is eliminated, therefore reducing the wasted power losses and heat generation.

However, the power wasted in the pressure control system is still considerable and still requires constant “throttling” by the operator if he wants the speeds to remain as selected, when the function pressure changes.

The load control system was developed to address the problems outlined above.

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

WASTED FLOW

Main pump.

Steer/Blade/Gate/Winch Valve Boom Valve Working Components

853SM18

W USED

FIG. 1

FIXED DISPLACEMENT PUMP

W FIG. 3

853SM19

PRESSURE REGULATED

HP =C ON ST AN

FLOW

T

∆p LS W

PRESSURE

1018-26

LOAD SENSING (FLOW ON DEMAND) 12.4

WASTED

USED

USED

FIG.5

PRESSURE FIG. 2 853SM16

FLOW

1.

2.

3.

4.

FIG.6

853SM16

PRESSURE FIG. 4 853SM16

Tigercat 1045/1055 Forwarder

Crane, Grapple and Main Pump regardless of load. It is important to remember the pump is really responding to the pressure differential resulting from flow through the valve, not the actual load pressure level.

The key component in the simplified system described is the spring in the control cylinder. The pump’s output pressure must be 24.5 to 25.5bar (355-370 psi) higher than the load pressure to compress the spring and reduce the flow of the pump. This 24.5 to 25.5bar (355-370 psi) is the differential or margin pressure.

1014-081.dwg

1014-081.dwg 1355-1370 PSI

In the figure above the control valve is closed blocking the pump from the load. With the load at zero the pump will maintain 24.5 to 25.5bar (355370 psi) of standby pressure and pump flow is zero.

0 PSI

1014-081.dwg

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.

1014-081.dwg

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 24.5 to 25.5bar (355-370 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 24.5 to 25.5bar (355-370 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 24.5 to 25.5bar (355-370 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

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 flow 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 MDM Controller 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.

12.5

Tigercat 1045/1055 Forwarder

Crane, Grapple and Main Pump

AT203.AI

1014-008.AI

BOOM VALVE DESCRIPTION The boom valve is located in the rear chassis. It can easily be accessed by opening the valve compartment enclosure door on the right side of the frame below the crane swing cylinders.

INLET SECTION

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.

12.6

The inlet section is equipped with connection ports to the main pump, tank, internal pilot filter, a load sense signal (‘LSP’) to the steer and 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.

Tigercat 1045/1055 Forwarder

1055-082

Crane, Grapple and Main Pump

BOOM VALVE SCHEMATIC 12.7

Tigercat 1045/1055 Forwarder

Crane, Grapple and Main Pump OUTLET (TO RETURN MANIFOLD)

INLET (FROM MAIN PUMP)

•

•

PRESSURE RELIEF VALVE

•

COUNTERPRESSURE VALVE

• LOAD SIGNAL COPY VALVE

• •

•

•

•

‘PS’ PORT (FROM PILOT SYSTEM FILTER)

‘PL’ TEST PORT (NOT COPIED) ‘LS’ TEST PORT (COPIED)

‘PX’ TEST PORT (PUMP PRESSURE) 1018-I03X

INLET SECTION

Pilot pressure supply Pilot pressure supply is provided as an internal function of the Boom Valve. Pressure is regulated internally to 35 bar (508 psi).

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.

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.

Load sensing 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 from the LS port in the boom valve to LSPB port on the steer valve, where it is compared to the needs of the steer valve functions.

SEPARATE TANK CONNECTION FOR PILOT SYSTEM

••

1018-I04

12.8

END SECTION

Tigercat 1045/1055 Forwarder

Crane, Grapple and Main Pump

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 MDM 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 maximum pressure for those functions flowing oil over relief.

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’

•

•

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 each section are specifically designed for use in that section should not be interchanged with port reliefs from other valve sections .

REPLACING MAIN PRESSURE RELIEF VALVE CARTRIDGE 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 all attachments to the ground. Shut off the engine.

FEED REDUCTION SIDE ‘A’

PORT RELIEF ‘A’ SIDE

24V PROPORTIONAL ELECTRO-HYDRAULIC SPOOL ACTUATORS

•

•

•

•

•

• SPOOL 1014-089.PLT

SPOOL SECTION 12.9

PRESSURE COMPENSATOR

Tigercat 1045/1055 Forwarder

Crane, Grapple and Main Pump

2. Switch the vacuum pump ON (refer to HYDRAULIC OIL VACUUM PUMP in SECTION 2 of the OPERATOR’S MANUAL).

‘B’ SIDE PORT RELIEF

3. Remove the plastic cap from the relief to be changed.

4. Remove the relief cartridge using a ½” Allen key.

5. Install the replacement relief cartridge, and tighten to 60 Nm (45ftlb).

6. Install the plastic cap.

7. Switch the vacuum pump OFF. ADJUSTING BOOM VALVE FEED REDUCTION VALVE SETTINGS: 1. Park the machine on level ground, place the crane in the park position, and lower all attachments to the ground. Shut off the engine.

••

DRIVE PUMP

ENGINE

MAIN PUMP

• • ‘B’ SIDE FEED REDUCTION

COOLING PUMP 1014-008 CV

•

••

•

1

1055-066

•

CHARGE PRESSURE

••

• • 2

•• •

‘A’ SIDE FEED REDUCTION

FEED REDUCTION ADJUSTMENTS 7. Operate the Grapple Open function again, and verify that the pressure being read on ‘LS’ is correct.

PUMP CONTROL VALVE “LS” TEST

8. Repeat steps 5 – 7 for the Grapple Close function in the opposite direction.

2. Connect a 0-5000 psi gauge to the ‘LS’ test port on the main pump.

REPLACING PORT RELIEFS:

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 Grapple Open 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 the ‘LS’ test port should be 200 bar (2900 psi). Release the function.

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 OUT (counterclockwise) to decrease the pressure. Once the adjustment has been made, tighten the locknut, and install the cover nut.

NOTE: Be sure to replace port relief cartridges 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 all attachments to the ground. 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.

12.10

Tigercat 1045/1055 Forwarder

1014-088

Crane, Grapple and Main Pump

BOOM VALVE CIRCUIT DIAGRAM 12.11

Tigercat 1045/1055 Forwarder

Crane, Grapple and Main Pump

MAIN PUMP All proportional valve hydraulic functions are powered by the main pump. The main pump is mounted in tandem with the drive pump.

DRIVE PUMP MAIN PUMP

•

• MAIN PUMP SCHEMATIC

1055-028

CONTROL

••

FRONT 1075-029

SWASHPLATE

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 .

•

DRIVE SHAFT

PISTON ASEMBLY KV3LPUMP1.AI

••

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 never 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 215 bar (3118 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.

12.12

Tigercat 1045/1055 Forwarder

Crane, Grapple and Main Pump

MAIN PUMP / LOAD SENSE SET-UP

HIGH PRESSURE MANIFOLD

SET COMPENSATOR PRESSURE: COMPENSATOR PRESSURE is the pressure at which the main pump will begin to automatically destroke to limit the maximum pressure from the pump to the valves and other components in the circuit. The compensator pressure setting should be 215-220 bar (3118-3190 psi).

••

1. Ensure that the hydraulic oil is at operating temperature (refer to hydraulic oil heat up procedure).

1014-203

HYDRAULIC VALVE COMPARTMENT SV

PR1

2. Connect a 0-5000 psi gauge to the ‘P1’ test port of the High Pressure Manifold, located in rear chassis valve compartment.

•

3. Start the engine, and depress the pilot reset switch.

•

5. Set CRANE/BLADE switch to WORKING RPM and rotate seat to face REAR. Maneuver the crane to a position where it is safe to operate the stick boom. The compensator pressure is to be determined by reading the gauge while operating the stick boom in function. Apply and hold the stick boom in function, and read the gauge installed at ‘P1’.

••

DRIVE PUMP

ENGINE

•

MAIN PUMP

••

CHARGE PRESSURE 1055-066

••

• • 2

COOLING PUMP

••

1

•• •

PR2

• • ••

P1

4. Using the MDM controller, adjust the engine working speed to 1400 rpm.

••

RV

PUMP CONTROL VALVE “LS” TEST

SW1

SW2

• •• •

RP2 ACC1

HIGH PRESSURE MANIFOLD HIGH PRESSURE MANIFOLD COMPONENTS ACC1 ............................ Accumulator Pressure Test P1 .................................. Pump Outlet Pressure Test PR1 ....................... Pressure Reducer 1 (*138 BAR) PR2 ................... Pressure Reducer Brakes 70 BAR RP2 .......................... Pressure Test Service Brakes RV ............................................ Relief Valve 75 BAR SW1 .. Low Pressure Switch 70 BAR (Start Charge) SW2 High Pressure Switch 124 BAR (Stop Charge) SV ............................... To LS Signal on Main Pump 1014-057

PUMP ARRANGEMENT

If the compensator pressure requires adjustment: Use a 13mm wrench to loosen the locknut on the compensator pressure adjusting screw (2) (located on the main pump controller).

Turn the adjusting screw (2) using a 6mm wrench until the reading on the gauge is be 215-220 bar (3118-3190 psi). Turning the adjusting screw IN (clockwise) will increase the compensator pressure, turning the screw OUT (counterclockwise) will decrease the compensator pressure.

When the compensator pressure is correct, tighten the locknut on the adjusting screw. Repeat above procedure to verify the compensator pressure setting is still correct.

12.13

Tigercat 1045/1055 Forwarder

Crane, Grapple and Main Pump

SET MARGIN PRESSURE: MARGIN PRESSURE is the difference between the LOAD SENSE (LS) pressure and the PUMP OUTPUT (P) pressure while a function (crane, blade, steer or cab rotate) is being operated. For the load sensing system to operate correctly the differential pressure between ‘P’ and ‘LS’ should be 24.5-25.5bar (355-370 psi). ‘P’ being higher than ‘LS’.

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

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

The pressure gauge connections are the ‘P1’ test port on the High Pressure Manifold and the ‘LS’ test port on the Main Pump.

••

DRIVE PUMP

ENGINE

•

MAIN PUMP

••

1055-066

••

• • 2

•

•• •

R.H. JOYSTICK & CONTROL SWITCHES 4. Start the engine, and depress the pilot reset switch.

5. Set CRANE/BLADE switch to WORKING RPMand maneuver the crane to a position where it is safe to rotate the grapple. Rotate the grapple in either direction, adjust the rotate speed with the joystick until a pump output reading of 90-110bar (1305-1595 psi) is achieved and maintained, the margin pressure will be the reading on the differential gauge.

••

PUMP CONTROL VALVE “LS” TEST

MAIN PUMP

•

1 CHARGE PRESSURE 1055-066

COOLING PUMP

••

PUMP ARRANGEMENT

1. Use a differential pressure gauge with ten psi increments.

••

• • 2

•• •

PUMP CONTROL VALVE “LS” TEST

PUMP ARRANGEMENT

If the margin pressure requires adjustment: With test gauge on LS test connection, reset margin adjustment screw (1)as follows: Use a 13mm wrench to loosen the locknut on margin pressure adjusting screw (1) (located on the main pump controller).

P1

•

1014-057

DRIVE PUMP

ENGINE

••

2. With the hydraulic oil at operating temperature (refer to hydraulic oil heat up procedure), connect the “low” side of the differential pressure gauge to the ‘LS’ test port.

PILOT RESET SWITCH

1014-001

•

1 CHARGE PRESSURE

COOLING PUMP

PILOT OFF INDICATOR LIGHT

••

6. Turn the adjusting screw using a 6mm wrench until the differential reading on the gauge 24.525.5bar (355-370 psi). Turning the adjusting screw IN (clockwise) will increase margin pressure, turning the screw OUT (counterclockwise) will decrease the margin pressure.

NOTE: This is a sensitive adjustment, a small movement of the adjusting screw will produce a significant change in pressure.

HIGH PRESSURE MANIFOLD

3) Connect the “high” side of the gauge and a 05000 psi gauge to the ‘P1’ test port .

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

12.14