Tigercat 220 Loader Service Manual – PDF DOWNLOAD

SERVICE MANUAL Tigercat 220 Loader TABLE OF CONTENTS

ISSUE 1.0, JANUARY, 2006

SECTION INTRODUCTION ............................................................................................................... ii NON-APPROVED FIELD PRODUCT CHANGES ............................................................ iv SAFETY ............................................................................................................................ 1 CONTROLS AND OPERATION ............................. See separate OPERATOR'S MANUAL LUBRICATION AND MAINTENANCE ............................................................................... 3 PILOT SYSTEM ................................................................................................................ 5 ELECTRICAL, GAUGES AND ALARMS ........................................................................... 6 ENGINE START AND STOP ............................................................................................. 7 OIL COOLER, RADIATOR AND FAN ............................................................................. 10 BOOM FUNCTIONS ....................................................................................................... 12 SWING ............................................................................................................................ 15 STABILIZERS ................................................................................................................. 16 GRAPPLE ....................................................................................................................... 17 DELIMBER/SLASHER .................................................................................................... 18 CIRCLE SAW .................................................................................................................. 19

220-OM00

220 Available Literature Operator's Manual ............................................. Part No. 21318A Service Manual (this manual) ............................ Part No. 21319A Parts Catalog ..................................................... Part No. 21317A

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

®

Tigercat 220 Loader

General Specifications

ii

Tigercat 220 Loader

Introduction

Tigercat 220 Loader

INTRODUCTION An Operator's manual, Service manual and a Parts catalog are provided by Tigercat to assist the dealer, customer and operator in becoming familiar with the features of the Tigercat 220 Loader, serial number 2200111 and up.

The operator's manual will assist the operator with the techniques of proper and safe operation of the Loader. The service manual contains safety guidelines, a preventive maintenance schedule and servicing procedures to ensure optimum machine performance.

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

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

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

The 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.

220-D01

iii

Tigercat 220 Loader

General Specifications

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 220 Loader

SECTION 1 - SAFETY JANUARY, 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 BATTERY DISCONNECT SWITCH .............................................................. 1.6 COOLING SYSTEM ....................................................................................... 1.8 EXHAUST FUMES ......................................................................................... 1.9 FIRE PREVENTION ..................................................................................... 1.10 FIRE PREVENTION GUIDELINES .......................................................... 1.10 WHAT ELSE TO DO BEFORE YOU EXPERIENCE A FIRE ................... 1.11 WHAT TO DO AFTER A FIRE ................................................................. 1.12 WHAT TO DO IN CASE OF A MACHINE FIRE ....................................... 1.11 FIRST AID ...................................................................................................... 1.4 FLUID LEAKS ................................................................................................ 1.7 LOOSE CLOTHING HAZARD ....................................................................... 1.9 PROTECTIVE CLOTHING ............................................................................. 1.3 SAFE REMOVAL OF COUNTERBALANCE AND CHECK CARTRIDGE ...... 1.8 SAFETY INTERLOCK SWITCH ON LEFT ARMREST .................................. 1.8 SAFETY PRECAUTIONS, OPERATING ....................................................... 1.5 SAFETY PRECAUTIONS, SERVICING ......................................................... 1.7 SAFETY SYMBOLS ....................................................................................... 1.2 WELDING, PRIOR TO ................................................................................... 1.7

Tigercat 220 Loader

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 220 Loader

Safety 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.

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.

KEEP CLEAR When approaching an operating machine on foot, stay a safe distance away from the machine and all related attachments including the grapple, delimber, topping saw and ground saws until the operator recognizes your presence. Make sure that all equipment is shut down with grapple resting securely on stable ground before advancing to the machine.

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

Follow all instructions from safety inspector and supervisors.

Always avoid the discharge path of all saws.

Operators of this equipment must be fully trained by a qualified person in safety and operating procedures. The operator must be fully aware of the capabilities and limitations of the equipment and must at no time exceed them. The machine is to be used only for its intended purpose. Learn the most efficient operating techniques.

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

Prolonged exposure to loud noise can cause impairment or loss of hearing.

Do not let an untrained person operate the machine.

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 use the seat armrest or joystick as handle when entering or leaving the cab.

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

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

Fellow workers and other bystanders around the machine must also be provided with the appropriate safety devices mentioned above.

These safety rules highlight both general and specific measures that the operator should be 1.3

Tigercat 220 Loader

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

GENERAL SAFETY PRECAUTIONS CONTINUED

Approach with extreme caution, 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 minimum distance of 10 ft. (3m) between the machine or boom and any power line carrying up to 50,000 volts or less.

Avoid mounting or dismounting the machine in areas with slippery surfaces.

Powerlines carrying more than 50,000 volts require a minimum safety distance of 10 ft. (3m) plus 1/2 inch (10mm) for each addition 1,000 volts above the 50,000 volt level. If State/Provincial, local or job site regulations require even greater safety distances than stated above, adhere strictly to these regulations for your own protection.

If this is not possible clean up or cover slippery surfaces with a non-slip material.

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

Machine should be washed completely at every major service.

When the machine is transported, make sure that it is adequately secured to the transporting vehicle.

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 grapple, delimber and saw manufacturers.

WARNING

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

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.

Do not operate the equipment with anyone in the cab, on platforms, or anywhere else, unless they are within a safe distance of the machine or related equipment. The machine is provided and approved with seating for the operator only.

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

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

Inspect the machine daily for signs of damage, unusual wear, fluid leaks, or faulty operation.

Repair or replace malfunctioning parts and systems immediately.

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

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

1.4

Tigercat 220 Loader

Safety

OPERATING SAFETY PRECAUTIONS

Start the engine according to the instructions in this manual.

Never use a liquid starting aid to start an engine with a pre-heat device.

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

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

Ensure that the windshield guard is installed and properly secured.

During refuelling do not leave the filler nozzle unattended.

Avoid over filling and immediately clean up spilled fuel.

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

Keep the cab door closed when operating the machine to prevent accidental entry of branches and debris into the cab.

Always rest the grapple on solid ground or trailer when not operating, regardless if the engine is running or shut off.

Make sure that all of the controls are positioned as specified in the starting instructions in the operator's manual.

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

Sound the machine horn before starting the machine.

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

Maintain a safe operating distance between the machine and other personnel. Never swing the boom with or without trees, over the heads of bystanders.

Use only prearranged and approved signalling practices.

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

1.5

Tigercat 220 Loader

Safety

OPERATING SAFETY PRECAUTIONS CONTINUED

WARNING Always lower the boom to the ground and shut down the engine before leaving the cab.

Do not allow other people either in the cab or anywhere else on the machine.

WARNING Safe mounting of this loader onto a trailer or truck is the responsibility of the owner.

WARNING An unstable loader can cause serious injury or death or equipment damage. Do not operate the loader without lowering the stabilizers onto firm ground and with the loader level.

Before leaving operator's cab, lower the grapple onto solid ground or the trailer.

When leaving the operator's cab for an extended period shut the engine off.

DANGER

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

A moving stabilizer can cause serious injury or death. Before lowering the stabilizers make sure the area is clear of personnel.

DANGER A falling or swinging load or boom can cause serious injury or death. Do not operate the loader when personnel are in the area of the machines operating reach or load movement. Do not move the boom or load over the heads of people.

EARLIER MACHINES

WARNING Do not allow the driver to remain in the truck cab during loading operations and do not move loads over the top of the truck cab.

Serious injury or death or property damage may result.

240B-003

LATER MACHINES

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

Before transporting the machine: •

Secure the grapple to the trailer and raise the stabilizers.

•

Shut down the engine and turn the master disconnect switch off.

•

Check to ensure that all doors, panels and access covers are installed and properly secured.

1.6

Tigercat 220 Loader

Safety

SERVICING SAFETY PRECAUTIONS

•

••

220-D06

Conduct maintenance inspections at least as frequently as recommended in section 3 of the operator's manual.

DISCONNECT THE TWO MULTI-PIN PLUGS FROM THE ENGINE CPU

This machine is equipped with sensitive electronic control equipment, prior to welding:Disconnect the engine CPU (Central Processing Unit) by unplugging the two multi-pin connectors from the left side of the engine.

When servicing or repairing equipment, shut the engine down. Turn Master Disconnect switch OFF. Install a “DO NOT START ENGINE” sign on the operator’s cab door when making repairs to the machine.

Never use your bare hand to check for fluid leaks.

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.

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 inspected daily and cleaned as necessary 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 swing bearing.

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

1.7

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.

Tigercat 220 Loader

Safety the housing, or cylinder base end on earlier machines; Raise the stabilizer until it is in the "overcenter" position and stop the engine. In this position, the weight of the stabilizer will not influence pressures in either end of the cylinder.

SERVICING SAFETY PRECAUTIONS CONTINUED Explosive release of fluids from the pressurized cooling system can cause serious burns.

If a stabilizer cannot be moved to the vertical position due to a malfunction, move the other stabilizers in conjunction with the boom so that the stabilizer pad is clear of the ground. In this position the pilot operated check valve may be removed followed by the counterbalance valve.

SAFETY INTERLOCK SWITCH ON LEFT ARMREST: The left arm rest is equipped with a safety interlock switch to prevent the machine from being operated while the armrest is in the raised position (pilot system is shut off).

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.

NOTE: The engine can be started but the machine functions cannot be operated with the left arm rest up.

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

PILOT SYSTEM SHUT OFF SWITCH

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

SAFE REMOVAL OF STABILIZER COUNTERBALANCE AND CHECK CARTRIDGES

••

WARNING When the stabilizers are on the ground, Hydraulic oil in the cylinders can be under very high pressure. Never remove the check valve or the counterbalance cartridges when the stabilizers are on the ground.

LEFT ARM REST IN "UP" POSITION AND LIMIT SWITCH "OFF"

377-17A

If it becomes necessary to remove either the stabilizer counterbalance or check cartridge from VERTICAL CENTERLINE

LOWER FRAME

•

COUNTERBALANCE VALVE

•

STABILIZER UP IN VERTICAL POSITION

• •

377-18A

•

LEFT ARM REST IN "DOWN" POSITION AND LIMIT SWITCH "ON"

To operate: With the engine running and the left arm rest DOWN, push the pilot reset switch.

CYLINDER

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.

STABILIZER COUNTERBALANCE/CHECK VALVE CARTRIDGE REMOVAL

230-06A

1.8

Tigercat 220 Loader

Safety

The left arm rest safety interlock switch (pilot system shut off limit switch) and the pilot reset switch are a safety feature and their function must not be defeated in any way.

Dispose of all fluids properly according to all applicable laws and regulations for the region.

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

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.

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

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

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

Before performing work on the grapple or boom, ensure they are firmly supported.

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.

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

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

1.9

Tigercat 220 Loader

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.

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

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

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

1.10

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

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

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

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

Tigercat 220 Loader FIRE PREVENTION continued

Safety •

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.

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

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

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

WHAT TO DO IN CASE OF A MACHINE FIRE •

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

•

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

•

Shut the engine off.

•

Activate the fire suppression system*

•

Radio or call for help (as appropriate).

•

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

•

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

•

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

•

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

•

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

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

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

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

EQUIPMENT FIRES ADVERSELY EFFECT YOUR ABILITY TO LOG, MAY INCREASE YOUR INSURANCE PREMIUMS DRAMATICALLY OR PREVENT YOU FROM OBTAINING INSURANCE COVERAGE AT ALL. WHAT ELSE TO DO BEFORE YOU EXPERIENCE A FIRE •

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

•

Ensure that your fire suppression system* is charged and functional.

•

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

1.11

Tigercat 220 Loader FIRE PREVENTION continued •

Safety •

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

**NOTE: Water mixing with dry chemical

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.

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

1.12

Tigercat 220 Loader

SECTION 3 - LUBRICATION & MAINTENANCE CONTENTS - SECTION 3 AIR CLEANER ...................................................................................... 3.14, 3.15 AIR CLEANER MAINTENANCE ..................................................................... 3.15 AIR CONDITIONING SYSTEM A/C SYSTEM TOTAL CAPACITIES ........................................................... 3.16 CHECKING SYSTEM .................................................................................. 3.16 AIR INTAKE MAINTENANCE INTAKE TUBING AND JOINTS ................................................................... 3.15 ELECTRICAL SCHEMATIC DIAGRAMS ................. 3.22, 3.30, 3.31, 3.32, 3.33 FILTERS ENGINE AIR FILTER .................................................................................. 3.14 ENGINE FILTERS ....................................................................................... 3.10 FUEL FILTER/WATER SEPARATOR ......................................................... 3.10 HYDRAULIC RETURN ................................................................................ 3.10 PILOT RETURN PRESSURE FILTER ....................................................... 3.12 FIRE PREVENTION .......................................................................................... 3.3 GENERAL MAINTENANCE .............................................................................. 3.3 HYDRAULIC OIL OPERATING TEMPERATURE RANGE ............................... 3.8 HYDRAULIC OILS ............................................................................................ 3.8 LUBRICATING CYLINDER PINS AND BOOM JOINTS .................................. 3.4 LUBRICATION POINTS ............................................................................ 3.6, 3.7 NEW MACHINE MAINTENANCE ..................................................................... 3.2 FIRST 50-100 HOUR INSPECTION AND SERVICE REPORT .................... 3.2 INITIAL PRE-DELIVERY INSPECTION ........................................................ 3.2 TIGHTENING POINTS .................................................................................. 3.2 OIL LOST FROM LEAKAGE CHART ............................................................... 3.2 PILOT RETURN PRESSURE FILTER ............................................................ 3.12 PRESSURE SETTING PROCEDURES. SEE SERVICE MANUAL PRESSURE SETTINGS ....................................................................... 3.20, 3.21 PREVENTIVE MAINTENANCE SCHEDULE .................................................... 3.2 SCHEDULED MAINTENANCE EVERY 8 HOURS: ......................................................................................... 3.4 EVERY 24 HOURS: ....................................................................................... 3.4 EVERY 125 HOURS ...................................................................................... 3.4 EVERY 250 HOURS ...................................................................................... 3.5 EVERY 500 HOURS: ..................................................................................... 3.5 EVERY 1000 HOURS .................................................................................... 3.5 EVERY 2000 HOURS .................................................................................... 3.5 SERVICE AND LUBRICATION POINTS .......................................................... 3.7 SWING DRIVE COMPONENTS LUBRICATION .............................................. 3.9 TIGHTENING POINTS...................................................................................... 3.2 TORQUE CHART, GENERAL ........................................................................ 3.19 TORQUE, FLUID CONNECTIONS ............................................. 3.34, 3.35, 3.36 TORQUE SETTINGS, RECOMMENDED ....................................................... 3.18

JANUARY, 2006

Tigercat 220 Loader

Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE FOR 220 LOADER NEW MACHINE MAINTENANCE

*INITIAL PRE-DELIVERY INSPECTION:PERFORM THE INITIAL PRE-DELIVERY INSPECTION USING Tigercat FORM NUMBERS 5281 AND 5282; "PDI AND 50-100 HOUR INSPECTION REPORT"

*FIRST 50-100 HOUR INSPECTION AND SERVICE REPORT:WITH THE OWNER'S MECHANIC PRESENT, PERFORM AN INSPECTION AND SERVICE ACCORDING TO THE Tigercat FORM NUMBERS 5281 AND 5282; "PDI AND 50-100 HOUR INSPECTION REPORT" THIS MUST BE COMPLETED WITHIN THE FIRST 50-100 HOUR TIME FRAME.

*IMPORTANT: TO QUALIFY FOR CONTINUED WARRANTY, THIS REPORT MUST BE COMPLETED AND RETURNED TO Tigercat Industries Inc. WARRANTY DEPARTMENT.

Tightening points:~

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

All hydraulic connections Hose clamps Pin retainers Check torque on swing bearing retaining bolts

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

Engine mounting bolts Pump mounting bolts Pilot pump mounting bolts Swing gearbox mounting bolts

OIL LOST FROM LEAKAGE

Swing motor mounting bolts Cab securing bolts

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

Boom pin nuts Trailer mounting studs Any other loose nut, bolt or fitting

3.2

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

Tigercat 220 Loader

Lubrication and Maintenance

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

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

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

CAUTION

Clean around filler caps before checking or adding fluids.

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

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

Clean up spills as soon as possible.

Always use clean oil and containers.

Drain dirty oil while still warm.

Do not exceed recommended fluid levels.

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

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

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

Before welding on machine be sure the negative battery terminal is disconnected and the two engine CPU multi-pin plugs from the left side of the engine are unplugged.

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

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

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

3. In case of fire lower the boom system to the ground and shut off the engine before discharging any fire extinguishers.

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

Clean away all branches, bark and chips.

Clean up all traces of oil to avoid fires.

Always have a fire extinguisher at hand.

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

3.3

Tigercat 220 Loader

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 8 HOURS:~

• Condition and tension of fan belts.

• Check engine coolant level

• Conduct an overall visual inspection.

• Check engine oil level

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

• Drain fuel/water separator • Check swing gearbox oil level. Fill reservoir to half way mark.

• Clean air cleaner unloader valve. Refer to AIR CLEANER in SECTION 2 of the OPERATOR'S MANUAL.

EVERY 24 HOURS:~ • Perform 8 hour maintenance

• Check hydraulic oil level

And in addition:~ • Lubricate stabilizer arm pins; 8-fittings - purge

Lubricate:~ • Swing bearing; 1-fitting - 4 shots while swinging

• Lubricate stabilizer cylinders; 8-fittings - purge

• Swing pinion; 1-fitting - 10 shots while swinging

• Lubricate grapple rotate bearing; 1-fitting - 4 shots, rotate 90° after each shot

• * Boom joint; 2-fittings - purge • * Stick joint; 2-fittings - purge

EVERY 125 HOURS:~ • Perform 8 hour maintenance

• * Cylinder pins; boom, stick & tilt; 4-fittings - purge

• Perform 24 hour maintenance

*Lubricating cylinder pins and boom joints:-

And in addition:~ • Check air cleaner filter restriction indicator at full engine RPM

1. Ensure machine is on level ground

• Check hydraulic oil return filter restriction indicator on filter return manifold with engine running at high idle and oil flow

2. Fully extend stick boom cylinder 3. Lower main boom and rest grapple firmly on ground or stable trailer

• Carry out A/C system inspection; Refer to CHECKING THE AIR CONDITIONING SYSTEM in THIS SECTION

4. While in this position lubricate all cylinder retaining pins and boom joints • Yoke pins; 2-fittings - purge

Check:~ • Fluid level in batteries unless maintenance free

• Grapple rotate pinion; 1-fitting - 4 shots, rotate 90° after each shot • Grapple arm pins; 6-fittings - purge

• Engine RPM

• Grapple cylinder pins; 4-fittings - purge

• Hydraulic pumps and motor securing bolts

• All hydraulic pressures • Torque tightening points as per new machine maintenance

Clean:~ • Oil cooler, engine radiator and a/c condenser

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

• Remove potentially damaging limbs or sticks and all debris

• Lower frame, stabilizer arms and cylinders • Swing bearing area

Check:~ • For leakage around hydraulic components and flexible hoses

• Attachment Make repairs immediately

• For loose nuts, bolts and fittings 3.4

Tigercat 220 Loader

Lubrication and Maintenance

SCHEDULED MAINTENANCE Visually inspect for:~ • Frayed electrical wiring and hydraulic hoses

EVERY 1000 HOURS:~ • Perform 8 hour maintenance

• Wear in any other components

• Perform 24 hour maintenance

Clean/replace:~ • Air conditioner re-circulation filter

• Perform 125 hour maintenance

• Cab fresh air filter

• Perform 250 hour maintenance

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

• Perform 500 hour maintenance And in addition:~ • Check intank fuel strainer. Drain tank, clean or replace as necessary.

• Replace air cleaner unloader valve.

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

EVERY 2000 HOURS:~ • Perform 8 hour maintenance

• Perform 125 hour maintenance And in addition:~ • Replace engine oil and filter

• Perform 24 hour maintenance

• Replace engine fuel filter

• Perform 250 hour maintenance

• Replace fuel/water separator filter

• Perform 500 hour maintenance

• Replace air cleaner primary element

• Perform 1000 hour maintenance

• Perform 125 hour maintenance

• Check fire extinguisher and turn it to mix contents And in addition:~ • Replace turbocharger rubber intake elbow • Check torque on trailer mounting studs.

High temperatures in this area can cause the rubber to harden. See AIR INTAKE MAINTENANCE in THIS SECTION

EVERY 500 HOURS:~

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

• Perform 8 hour maintenance • Perform 24 hour maintenance

• Drain and refill hydraulic oil tank with recommended hydraulic oil. See APPROVED HYDRAULIC OILS in THIS SECTION

• Perform 125 hour maintenance • Perform 250 hour maintenance And in addition:~ • Replace air cleaner safety element

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

• Replace hydraulic oil return filters † • Replace hydraulic oil pilot pressure filter † • Replace oil in swing gearbox. Fill reservoir to half way mark • Lubricate door and cover hinges; 8 fittings - 1 shot

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

Check:~ • Torque on swing bearing and swing gearbox retaining bolts • Refer to diesel engine service manual and attachment manual for additional required maintenance at this scheduled time period.

3.5

Tigercat 220 Loader

Lubrication and Maintenance

20325B.AI R1

3.6

SERVICE AND LUBRICATION POINTS

Tigercat 220 Loader

Lubrication and Maintenance

20325B.AI R1

3.7

Tigercat 220 Loader

Lubrication and Maintenance

APPROVED HYDRAULIC OILS Use only one of the following oils to fill or replenish the hydraulic system.

Chevron

Mechanism LPS 68 (summer)

Citgo

Mystik HVI-68 (summer)

Imperial/ESSO Univis N68 (summer) Univis N22 (winter) Shell

Tellus T68 (summer) Tellus T22 (winter)

Texaco

Rando HDZ 68 (summer)

®

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

HYDRAULIC OIL OPERATING TEMPERATURE RANGE 5168AR03

3.8

Tigercat 220 Loader

Lubrication and Maintenance

LUBRICATION OF SWING BEARING, SWING PINION AND GEARBOX

HALF FILL RESERVOIR WITH RECOMMENDED OIL AS SPECIFIED IN SECTION 3 OF THIS MANUAL

BEARING AND PINION LUBE FITTINGS

•

•• CONNECTING HOSE TO GEARBOX

•

220-D32

SWING BEARING AND PINION LUBRICATION

•

206-16A

SWING DRIVE GEARBOX OIL RESERVOIR GEARBOX UPPER GEARING LUBRICATION The swing gearbox upper gearing is lubricated by SAE 75W90 EP oil. The oil is stored in an oil reservoir attached to the side of the swing drive

SWING BEARING AND PINION The swing bearing and swing pinion must be lubricated every 8 hours. To assist with dispursing the grease evenly around the gear teeth, rotate the upper frame as the grease is being applied. The grease fittings are located inside the operator's cab on the foot pedal base.

CONNECTING HOSE FROM OIL RESERVOIR

GEARBOX LOWER BEARING LUBRICATION The cavity in the lower portion of the gearbox where the two lower bearings are housed is completely filled with grease at the factory.

Scheduled greasing is not required for this particular application therefore a grease fitting is not installed.

••

••

SWING DRIVE MOTOR

•• OIL FILL TUBE SWING DRIVE GEARBOX

206-15A

• SWING DRIVE GEARBOX

cover. A hose connects the reservoir to the gearbox oil fill tube. Keep the reservoir HALF FILLED with oil at all times.

Follow the lubricating procedure on the label(s) located beside the grease fittings and also refer to SCHEDULED MAINTENANCE in THIS SECTION.

3.9

Tigercat 220 Loader FILTERS - REMOVE AND REPLACE

Lubrication and Maintenance HYDRAULIC RETURN FILTERS

ENGINE FILTERS

The majority of return oil entering the hydraulic tank passes through 3 spin-on hydraulic oil filters. One of the filters is a water absorbing filter (color blue) which is in place to assist with the removal of unwanted moisture from the hydraulic oil (the filters are rated 10m abs).

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

FROM FROM RETURN MANIFOLD, ("STICK"/ SWING "TILT"/SWING MOTOR 'T' PORTS) VALVE

DOUBLE FILTER HEAD

••

• •

•

FUEL FILTER ELEMENT

• •

TO OIL COOLER "IN" OIL COOLER BYPASS CHECK VALVE (50 PSI)

WATER/SEDIMENT DRAIN VALVE

WATER-IN-FUEL SENSOR CONNECTION

••

••

••

1-WATER ABSORBING RETURN FILTER (COLOUR BLUE)

•

220-D17

220-D33

•• 2-HYDRAULIC RETURN FILTERS

HYDRAULIC RETURN FILTERS

ENGINE FUELFILTER/WATER SEPARATOR

•

••

•• FROM OIL COOLER "OUT" AND HAND FILL PUMP 220-D18

220-D34

OIL COOLER BYPASS CHECK VALVE (50 PSI)

FILTER RESTRICTION INDICATOR

HYDRAULIC RETURN FILTERS

Each filter head has a bypass valve with a 25 psi. cracking pressure so that oil can bypass the filters if they become restricted. The "in" side of the filter heads are connected to a return manifold which receives oil from the 'T' ports of the "Hoist" and "Stick" valves, the "Swing" valve via the oil cooler and the return port of the rotary manifold. A filter restriction indicator is mounted onto the "Double" filter head.

ENGINE OIL FILTER

3.10

To check the condition of the filter elements; With the hydraulic oil at normal operating temperature, place engine throttle control to FULL and without any machine functions operating, the filter restriction indicator should be in the GREEN zone. If the pointer is in the RED zone replace both filter elements.

Tigercat 220 Loader

Lubrication and Maintenance

Changing the filters:

•

1. Ensure Loader is on level ground with stabilizers down. Lower grapple to ground, stop engine, put parking brake ON.

• GASKET

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 squirt), unscrew the old filter. Dispose of old filter and any oil properly.

FILTER HEAD

FILTER ELEMENT

SQUARE SECTION GASKET INSTALLATION FILTR_SEALS 2

Square Section Gasket Remove used gasket and clean groove in head.

Apply clean oil to new gasket surfaces.

Install new gasket into groove in filter head.

Screw on new filter until gasket makes contact.

Tighten filter an additional 3/4 turn.

6. The new Tigercat filter is supplied with two gaskets enclosed, examine the filter head closely to determine which gasket should be used and follow the instructions to ensure proper installation.

DO NOT use bottom nut for filter installation or damage/leakage may result. Bottom nut is to assist in filter removal only.

FILTER HEAD

• • GASKET

• FILTR_SEALS 2

FILTER ELEMENT

'O' RING GASKET INSTALLATION

z 'O' Ring Gasket Remove used gasket and clean gasket seat in head.

Apply clean oil to new gasket surfaces.

Install new gasket on inside lip of filter.

Screw on new filter until gasket makes contact.

Tighten filter until top edge makes metal to metal contact with filter head. (approximately 1 1/2 additional turns after gasket contact) DO NOT use bottom nut for filter installation or damage/leakage may result. Bottom nut is to assist in filter removal only.

10. Start the engine and check for leaks.

3.11

Tigercat 220 Loader

Lubrication and Maintenance

LOCATED LOWER LEFT SIDE OF ENGINE COMPARTMENT

IMPORTANT Filters that are an integral part of the engine (fuel and lubricating oil) should be serviced and replaced according to the engine manufacturer's operation and maintenance manual.

• 220-D35

PILOT FILTER ELEMENT

HYDRAULIC PILOT FILTER

PILOT RETURN PRESSURE FILTER A single element filter head filters all pilot oil prior to entering the pilot system. The filter head has a built-in bypass valve with a 50 psi cracking pressure so that oil can bypass the filter if the element becomes restricted.

Changing the filter: 1. Ensure Loader is on level ground with stabilizers down. Lower grapple to ground and stop engine.

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 squirt), 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. Turn filter an additional 1/2 turn by hand to tighten.

DO NOT use bottom nut for filter installation or damage/leakage may result. Bottom nut is to assist in filter removal only.

9. Start the engine and check for leaks.

The return filters and the pilot filter should be checked and replaced as per the maintenance schedule in SECTION 3 of THIS MANUAL.

3.12

Tigercat 220 Loader

Lubrication and Maintenance IMPORTANT

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

3.13

Tigercat 220 Loader

Lubrication and Maintenance

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

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

AIR CLEANER

INDICATOR 1/4" HOSE CONNECTION

•

AIR CLEANER UNLOADER VALVE

••

AIR INTAKE TUBE

•

•

AIR CLEANER

205-18A

AIR CLEANER PRIMARY ELEMENT

220-D20

•• AIR CLEANER SAFETY ELEMENT

FILTER RESTRICTION INDICATOR

••

•

RESET BUTTON

• • •

INDICATOR

1/4" HOSE CONNECTION

220-D41

AIR CLEANER

Remove the unloader valve from the tube of the air cleaner housing.

FILTER RESTRICTION INDICATOR FILTER RESTRICTION INDICATOR

220-D19

A filter restriction indicator is located in the engine enclosure beside the air intake grill. The indicator is remote mounted and is connected to the outlet side of the air filter with a 1/4" diameter hose. Service to the filter is required when the indicator shows RED. This indicator provides a continuous reading whether the engine is running or is shut down. After servicing the filter, reset the indicator by pressing down on the reset button.

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 unloader valve should be replaced every 1000 hours.

3.14

Check and clean the valve. A good valve should be soft and flexible. If it is plugged, then check the filter elements, they may need replacing. Re-attach the valve to the tube.

The valve should suck closed at about 1/3 of full throttle.

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

In addition to the LUBRICATION AND MAINTENANCE SCHEDULE, the following instructions should also be noted.

Tigercat 220 Loader AIR CLEANER MAINTENANCE The most common and most damaging air intake servicing problems are: OVER SERVICING Filter elements increase in dust cleaning efficiency as dust builds up on the media.

Looks can be deceiving. A filter that is 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 the engine manufacturer’s guidelines, should be replaced.

Lubrication and Maintenance INTAKE TUBING AND JOINTS Replace turbocharger rubber inlet elbow and coupling - High temperatures in this area can cause the rubber to harden.

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

RUBBER ELBOW AND JOINTS

•

IMPROPER SERVICING Engine exposure to dust during servicing is the largest single factor contributing to engine damage due to dust. Abrasive dust can easily enter the intake system once the air cleaner element has been removed for replacement.

The safety element reduces the risk, however it must also be replaced at every third primary element change.

220-D31

IMPORTANT STEPS TO FOLLOW 1. Release the seal gently to reduce the amount of dust dislodged.

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

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

4. Always clean the inside of the outlet tube.

5. Check the old filter, it can help you detect foreign material on the sealing surface that may be causing leakage.

6. Inspect the new filter for damage.

7. Insert the new filter properly. Apply pressure to the outer rim of the filter, not the flexible center.

8. Check connection and ducts for air tight fit. Ensure that all clamps, bolts and connections are tight. Leaks here send dust directly to the engine.

3.15

•

INTAKE TUBING AND JOINTS

••

Tigercat 220 Loader CHECKING THE AIR CONDITIONING SYSTEM

Lubrication and Maintenance either underneath the engine compartment or through the engine compartment door.

Perform following inspection along with 125 HOURS inspection outlined in SCHEDULED MAINTENANCE in THIS SECTION.

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

a. Check re-circulating and fresh air filters in operator's cab. Refer to SECTION 2 of the OPERATOR'S MANUAL.

A/C SYSTEM TOTAL CAPACITIES PAG OIL R134a REFRIGERANT (polyalkylene glycol) 2 LBS. 12 OZ.

HINGE OUT A/C CONDENSER

RADIATOR

•

2 OZ.

•

LEFT SIDE OF ENGINE

• A/C COMPRESSOR OIL COOLER 220-D39

••

CHECK A/C CONDENSER CORE

CAUTION

CHARGE VALVES

If using water or compressed air for cleaning, use at 30 psi. or less. Always use personal protective equipment to guard against flying debris.

•• 220-D36

•

b. Check the condenser core for dirt and debris.

Clean as required. Refer to CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR in SECTION 2 of the OPERATOR'S MANUAL.

A/C COMPRESSOR

The compressor and charge valves are accessed on the LEFT side of the engine. The receiver dryer is located in the lower engine compartment beside the front left engine mount and accessible from

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

•• RECEIVER DRYER LOWER FRAME RIGHT SIDE

220-D37

••

Run air conditioning system for 3 - 5 minutes.

g. Check air temperature exiting vents in cab. h. Listen to compressor and blower motor for abnormal noises.* i.

Check to see that compressor clutch will engage.*

j.

Inspect sight glass on receiver dryer with A/C ON. A constant stream of bubbles indicates system requires charging.*

A/C RECEIVER DRYER 3.16

Tigercat 220 Loader

Lubrication and Maintenance

SIGHT GLASS INDICATES CONDITION OF CHARGE

• •• ••

BINARY SWITCH, SYSTEM PROTECTION (ORIENTATION MAY VARY)

MOISTURE INDICATOR BLUE - OK. PINK - REPLACE DRYER, RECHARGE SYSTEM

•• •

A/C RECEIVER/DRYER

870-D43

LOWER FRAME RIGHT SIDE

A/C RECEIVER/DRYER

Check colour in moisture indicator; BLUE is OK. PINK indicates desiccant material in dryer is saturated with moisture. In this situation replace receiver/dryer, evacuate system and recharge system with both refrigerant and PAG oil.* * Indicates that these repairs must only be carried out by a certified A/C technician.

IMPORTANT It is recommended that during cold weather, when the A/C system is not in use, the system be run for a period of 5 minutes every two weeks. This will circulate oil to all components of the A/C system.

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

3.17

Tigercat 220 Loader

Lubrication and Maintenance

TORQUE CHART LOCATION

THREAD DIAMETER

Cylinders Piston nut, stabilizer cylinders 2"-12 UNF (GC) Piston nut, main boom cylinder 2"-12 UNF (GC) Piston nut, stick cylinder 2"-12 UNF (GC) Gland, stabilizer cylinder 5 1/2" I/D CYLINDER Keeper plate bolts, Main boom cylinder 3/4"-16 UNF (G8) Keeper plate bolts, Stick boom cylinder 3/4"-16 UNF (G8)

TORQUE (LUBRICATED) lbf-ft Nm

2100 2500 2500 450 250 250

2835 3390 3390 610 340 340

3/4"-10 UNC (G8)

282-310

393-420

Main and Stick boom pin retaining nut

2"-12 UNF (GC)

400

540

Cab securing bolts Trailer mounting studs

7/8"-9 UNC (G8) 1 "-8 UNC (G5)

450-500 400

610-680 540

7/8"-9 UNC (G8) 5/8"-11 UNC (G8) M14-2 (10.9)

400-450 160-175 130

540-610 215-235 175

M22-2.5 (10.9) M12-1.75 (10.9) M10-1.5 (12.9)

540 75 63 40

725 100 83 54

3/8"-16 UNC (G8) M10-1.5 (10.5)

40 45

54 60

Boom joint and cylinder pin retaining bolts

*

Swing bearing bolts Swing gearbox mounting bolts Swing motor mounting bolts Engine mounting Bolts, bracket/mount to chassis Bolts, bracket to engine Flex drive coupling hub setscrew Engine cooling fan mounting bolts Pump drive Drive plate to flywheel Bell housing to engine

Torque values for the engine and attachment are provided in the appropriate manuals.

*

Refer to LOADER MOUNTING/INSTALLATION in SECTION 2 of the OPERATOR'S MANUAL for additional precautionary information.

3.18

Tigercat 220 Loader

Lubrication and Maintenance The torque values listed below are for general use only.

GENERAL TORQUE SPECIFICATIONS

IMPERIAL

DO NOT use these values if a different torque value or tightening procedure is shown for a specific application.

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

DRY lbf-ft Nm 11 - 12 15 - 16 20 - 28 27 - 38 44 -48 60 - 65 70 - 77 95 - 104 106 - 117 144 - 158 153 - 168 208 - 228 212 - 233 288 - 316 376 - 414 510 - 561 606 - 667 822 - 904 909 - 1000 1233 - 1355 1288 - 1417 1746 - 1921 1817 - 1999 2464 - 2710 DRY lbf-ft Nm 13 - 14 18 - 19 23 - 28 31 - 38 49 - 54 67 - 73 78 - 86 106 - 116 120 - 132 163 - 179 171 - 188 232 - 255 240 - 264 326 - 358 420 - 462 570 - 626 668 - 735 906 - 996 995 - 1096 1359 - 1486 1445 - 1590 1960 - 2155 2012 - 2213 2728 - 2997

LUBRICATED lbf-ft Nm 8 - 10 11 - 13 26 - 30 35 - 40 33 - 36 45 - 49 52 - 57 71 - 77 80 - 88 109 - 119 115 - 127 156 - 172 159 - 175 216 - 237 282 - 310 393 - 420 455 - 501 617 - 679 682 - 750 925 - 1016 966 - 1062 1310 - 1441 1360 - 1496 1844 - 2027 LUBRICATED lbf-ft Nm 10 - 13 14 - 17 18 - 25 25 - 33 37 - 41 50 - 55 58 - 64 79 - 86 90 - 99 122 - 134 128 - 141 174 - 191 180 - 198 244 - 268 315 - 347 427 - 470 501 - 550 679 - 745 746 - 821 1012 - 1113 1083 - 1191 1469 - 1613 1509 - 1660 2046 - 2250

DRY LUBRICATED COARSE lbf-ft Nm lbf-ft Nm THREAD 1/4" - 20 7- 8 10 - 11 8 - 10 11 - 13 5/16" - 18 14 - 18 19 - 24 38275 13 - 20 3/8" - 16 31 - 34 42 - 46 23 - 25 31 - 34 7/16" - 14 49 - 54 66 - 73 37 - 41 50 - 55 1/2" - 13 75 - 83 102 - 112 57 - 63 77 - 85 9/16" - 12 109 - 120 148 - 162 82 - 90 111 - 122 5/8" - 11 150 - 165 204 - 223 113 - 124 152 - 168 3/4" - 10 266 - 293 360 - 397 200 - 220 271 - 298 7/8" - 9 394 - 433 535 - 586 296 - 326 402 - 441 1" - 8 591 - 649 802 - 879 443 - 489 601 - 663 1 1/8" - 7 794 - 873 1077 - 1183 596 - 656 808 - 889 1 1/4" - 7 1120 - 1232 1519 - 1670 840 - 924 1139 - 1252 FINE DRY LUBRICATED THREAD lbf-ft Nm lbf-ft Nm 1/4" - 28 9 - 10 12 - 13 9 - 10 12 - 13 5/16" - 24 17 - 22 23 - 29 16 - 20 21 - 27 3/8" - 24 35 - 39 48 - 53 26 - 29 35 - 39 7/16" - 20 55 - 61 75 - 83 41 - 45 56 - 61 1/2" - 20 85 - 94 116 - 127 64 - 70 87 - 95 9/16" - 18 121 - 133 164 - 180 91 - 100 124 - 135 5/8" - 18 170 - 187 231 - 253 128 - 141 174 - 191 3/4" - 16 297 - 327 403 - 443 223 - 245 303 - 332 7/8" - 14 434 - 477 589 - 646 326 - 359 442 - 486 1" - 12 646 - 711 876 - 965 484 - 534 657 - 724 1 1/8" - 12 891 - 980 1208 - 1328 668 - 735 906 - 996 1 1/4" - 12 1240 - 1364 1682 - 1849 931 - 1024 1262 - 1387

METRIC

METRIC BOLT TORQUE SPECIFICATIONS SIZE

CLASS 4.8 LUBRICATED 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 ISSUE 4 604

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

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

3.19

Tigercat 220 Loader

Lubrication and Maintenance

PRESSURE SETTINGS, Effective on machine serial numbers 2200111 and up Engine RPM Cummins 'QSB5.9 155 HP’ ................ 2280 - 2320 rpm ........................................................................................... 2200 rpm ................................................................................... 800 - 900 rpm Pilot Valve Main relief ........................................................................... 450 psi STICK valve Main and Port reliefs: Main relief ........................................................................... 2750 psi Port relief Grapple Rotate CCW ...................................... ¶ 3000 psi Port relief Grapple Rotate CW ........................................ ¶ 3000 psi Port relief Stick OUT .......................................................... 3400 psi Port relief Stick IN ............................................................... 1500 psi Port relief Saw RETRACT (option) ..................................... 1500 psi Port relief Slasher CUT (option) ...................................... § 3000 psi Port relief Drive FWD. (SP option) ..................................... 2500 psi Port relief Drive REV. (SP option) ....................................... 2500 psi Port relief Live Heel IN (option) .......................................... 3000 psi Port relief Live Heel OUT (option) ...................................... 3000 psi

@ Full throttle (no load) @ Rated working @ Idle (no load) @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle

HOIST valve Main and Port reliefs: Main relief ........................................................................... 2750 psi Port relief Grapple OPEN .................................................. †3000 psi Port relief Grapple CLOSE ................................................ †3000 psi Port relief Hoist UP ............................................................. 3400 psi Port relief Hoist DOWN ...................................................... 1500 psi Port relief Slasher CUT (option) ...................................... § 3000 psi Port relief Top Saw CUT (option) ........................................ 3000 psi Port relief Drive FWD. (SP option) ..................................... 2500 psi Port relief Drive REV. (SP option) ....................................... 2500 psi Port relief Butt Board UP(CS option) .................................. 2000 psi Port relief Butt Board DOWN (CS option) .......................... 2000 psi

@ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle

SWING valve Main and Port reliefs: Main relief ...........................................................................

Port relief Swing CCW .......................................................

Port relief Swing CW ..........................................................

Port relief Stabilizer DOWN ................................................

Port relief Stabilizer UP ......................................................

Port relief Delimber OPEN (option) ....................................

Port relief Spare (option) ....................................................

Port relief Steer LEFT (SP option) ......................................

Port relief Steer RIGHT (SP option) ...................................

Port relief Saw CUT (CS option) ........................................

Port relief Saw RETRACT (CS option) ...............................

@ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle

2600 psi 3000 psi 3000 psi 3000 psi 2000 psi 3000 psi 3000 psi 2000 psi 2000 psi 2000 psi 2000 psi

Swing motor Crossline Reliefs ............................................................... **1750 psi

@ Idle

BRAKE valve (SP option) ..................................................... 70 psi

@ Full throttle

CIRCLE valve Main and Port reliefs: Main relief ........................................................................... 2500 psi Port relief ............................................................................ 3000 psi

@ Full throttle @ Full throttle

NOTE: The above values are for reference purposes only, SEE SERVICE MANUAL FOR SETTING PROCEDURE. 20089B-R1.06/09/04

3.20

Tigercat 220 Loader

Lubrication and Maintenance

PRESSURE SETTINGS, Effective on machine serial numbers 2200111 and up IMPORTANT System to be at operating temperature when setting pressures. ** Using the following procedure to set crossline reliefs: a. Install swing locking device or secure boom to keep the machine from swinging. b. Disconnect and cap the pilot hose running to the swing motor crossline relief valves. c. At idle adjust both swing motor crossline relief valves to the value given on the chart. d. Reconnect the pilot hose and purge the air out of the lines. † Tigercat grapple OPEN/CLOSE set to 3500 psi. ¶ Applicable to Hultdins and Rotobec HD grapples only.

Refer to grapple manufacturers specifications for all other models. § SLASHER CUT port relief valve on "HOIST" valve must be turned up above 3100 psi before setting port relief on "STICK" valve. * Do not adjust pressure over 3000 psi or pump may be damaged. *** Factory set at 10 gpm.

20089B-R1.06/09/04

3.21

Tigercat 220 Loader

220-02

Lubrication and Maintenance

ELECTRICAL SCHEMATIC DIAGRAM 23056B (REV. 0 SHEET 1 OF 3) SERIAL NUMBER 2200111 TO 2200260 (EXCLUDING CIRCLE SAW MACHINES) 3.22

Tigercat 220 Loader

220-03

Lubrication and Maintenance

ELECTRICAL SCHEMATIC DIAGRAM 23056B (REV. 0 SHEET 2 OF 3) SERIAL NUMBER 2200111 TO 2200260 (EXCLUDING CIRCLE SAW MACHINES) 3.23

Tigercat 220 Loader

220-04

Lubrication and Maintenance

ELECTRICAL SCHEMATIC DIAGRAM 23056B (REV. 0 SHEET 3 OF 3) SERIAL NUMBER 2200111 TO 2200260 (EXCLUDING CIRCLE SAW MACHINES) 3.24

Tigercat 220 Loader

220-10

Lubrication and Maintenance

ELECTRICAL SCHEMATIC DIAGRAM 26662B (REV. 0 SHEET 1 OF 3) SERIAL NUMBER 2200261 AND UP (EXCLUDING CIRCLE SAW MACHINES) 3.25

Tigercat 220 Loader

220-11

Lubrication and Maintenance

ELECTRICAL SCHEMATIC DIAGRAM 26662B (REV. 0 SHEET 2 OF 3) SERIAL NUMBER 2200261 AND UP (EXCLUDING CIRCLE SAW MACHINES) 3.26

Tigercat 220 Loader

220-12

Lubrication and Maintenance

ELECTRICAL SCHEMATIC DIAGRAM 26662B (REV. 0 SHEET 3 OF 3) SERIAL NUMBER 2200261 AND UP (EXCLUDING CIRCLE SAW MACHINES) 3.27

Tigercat 220 Loader

220-07

Lubrication and Maintenance

ELECTRICAL SCHEMATIC DIAGRAM 25386B (REV. 0 SHEET 1 OF 3) SERIAL NUMBER 2200171 TO 2200260 - CIRCLE SAW MACHINES 3.28

Tigercat 220 Loader

220-08

Lubrication and Maintenance

ELECTRICAL SCHEMATIC DIAGRAM 25386B (REV. 0 SHEET 2 OF 3) SERIAL NUMBER 2200171 TO 2200260 - CIRCLE SAW MACHINES 3.29

Tigercat 220 Loader

220-09

Lubrication and Maintenance

ELECTRICAL SCHEMATIC DIAGRAM 25386B (REV. 0 SHEET 3 OF 3) SERIAL NUMBER 2200171 TO 2200260 - CIRCLE SAW MACHINES 3.30

Tigercat 220 Loader

220-058

Lubrication and Maintenance

ELECTRICAL SCHEMATIC DIAGRAM 31310B (REV. 0 SHEET 1 OF 3) SERIAL NUMBER 2200261 AND UP - CIRCLE SAW MACHINES 3.31

Tigercat 220 Loader

220-059

Lubrication and Maintenance

ELECTRICAL SCHEMATIC DIAGRAM 31310B (REV. 0 SHEET 2 OF 3) SERIAL NUMBER 2200261 AND UP - CIRCLE SAW MACHINES 3.32

Tigercat 220 Loader

220-060

Lubrication and Maintenance

ELECTRICAL SCHEMATIC DIAGRAM 31310B (REV. 0 SHEET 3 OF 3) SERIAL NUMBER 2200261 AND UP - CIRCLE SAW MACHINES 3.33

Tigercat 220 Loader

Lubrication and Maintenance

Par ker ark

Assemb que Assemblly Tor orque

3.34

Tigercat 220 Loader

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

3.35

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 220 Loader

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 Straight Adapter or Locknut Torque lb.-ft.

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

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

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

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

3.36

Tigercat 220 Loader

SECTION 5 - PILOT SYSTEM JANUARY, 2006

CONTENTS - SECTION 5 CIRCUIT DIAGRAM ................................................................. 5.11, 5.12, 5.13 ELECTRICAL CIRCUIT ................................................................................ 5.10 PILOT CIRCUIT COMPONENTS CIRCLE SAW ............................................................................................. 5.8 DELIMBER/SLASHER ................................................................................ 5.7 STANDARD LOADER ................................................................................ 5.6 PILOT SYSTEM CIRCUIT DIAGRAM BASIC LOADER ....................................................................................... 5.11 CIRCLE SAW ........................................................................................... 5.13 DELIMBER SLASHER .............................................................................. 5.12 PILOT SYSTEM COMPONENTS ................................................................... 5.2 JOYSTICKS AND FOOT PEDALS ............................................................. 5.9 PILOT MANIFOLD ...................................................................... 5.3, 5.4, 5.5 PRESSURE SETTINGS ............................................................................... 5.10

Tigercat 220 Loader

Pilot system

PILOT SYSTEM COMPONENTS

A shut-off valve is installed in the pilot suction line at the hydraulic tank connection. Use this valve to isolate the pilot hydraulic system when disconnecting any hoses or fittings. A plastic tie is installed on the shut off valve at the factory to prevent the valve from being accidentally turned to the CLOSED position when the engine is running, this could cause serious damage to the pilot pump. The tie should be replaced whenever it is taken off to operate the shut off valve.

The pilot circuit is supplied with oil from the pilot pump which is driven by the auxiliary drive off the left side of the engine.

Oil is first filtered by an in-line pressure filter before entering the pilot manifold. A pilot relief valve built into the pilot manifold maintains the pilot system pressure at 450 psi. The oil enters pilot manifold (inlet port) at this reduced pressure and is then distributed by the pilot manifold to the various pilot actuated functions of the machine.

Solenoid operated pilot valves within the pilot manifold control the flow of pilot oil to various functions. A second Stabilizer pilot manifold is fed with pilot oil from the first pilot manifold via pressure port PB. This Stabilizer pilot manifold contains four combination solenoid operated pilot valves/directional valves which are used to control the Stabilizer functions. Joysticks and foot pedals are also fed pilot oil which in turn distribute the oil to shift spools in the corresponding control valves.

PRESSURE FILTER This filter is a cartridge filter with a built-in differential pressure relief valve, if the pressure differential at the oil filter exceeds 50 psi this valve will bypass the pilot oil back to the tank.

LOCATED LOWER LEFT SIDE OF ENGINE COMPARTMENT

LEFT SIDE OF ENGINE

•

• •

PILOT PUMP

HYDRAULIC PILOT FILTER This will also result in lower pilot pressure. If a loss of controls or slow response is experienced the filter element may need to be changed.

220-D35

PILOT PUMP NOTE: Low pilot pressure can influence machine controls causing slow or sluggish response times, If this symptom occurs, first check hydraulic oil level in reservoir, if the level is correct, verify that the pilot relief valve setting is 450 psi. Refer to SET PILOT PRESSURE in THIS SECTION. 240B-D23

HYDRAULIC TANK BALL VALVE (SHOWN OPEN)

PLASTIC TIE TO PILOT PUMP

•

•

• ••

240B-D21

PILOT FILTER ELEMENT

PILOT SHUT-OFF BALL VALVE 5.2

Tigercat 220 Loader

Pilot system "PB" POWER BEYOND PORT CONNECTIONS TO JOYSTICKS AND FOOT PEDAL VALVES

PILOT SHUT "IN" CONNECTION OFF VALVE FROM PILOT FILTER

PILOT MANIFOLD

"T" TANK CONNECTION

• ••

•

••

"T" TANK CONNECTION

PILOT MANIFOLD PILOT MANIFOLD 220-D47

••

The pilot manifold is located below the floor plates in the hydraulic valve compartment.

PILOT RELIEF VALVE PILOT MANIFOLD

The pilot manifold on standard loader distributes oil to the following circuits: Joysticks (both) Swing control foot pedal Gauge test port Stabilizers down Stabilizers up

(PB) port (PB) port (G) port (1) solenoid valve (2) solenoid valve

The outlet port ('PB') on the inlet end of the pilot manifold, feed both joysticks and the swing foot pedal valve. A gauge test port (G) has a quick connect fitting installed for connecting a pressure gauge to perform pressure setting procedures.

NOTE: See individual circuit diagrams and pilot manifold descriptions for circle saw and delimber/ slasher pilot functions in this section.

Solenoid operated pilot valves on the manifold, when energized, supply "on demand" pilot oil to the corresponding functions. These valves are activated by controls in the cab.

Pilot oil enters the manifold through the inlet port.

The pilot shut off valve, which is an integral part of the pilot manifold, controls the flow of oil from the INLET port to the three outlet ports labelled (2/ PB and G) and to the eight solenoid operated pilot valves. The pilot shut off valve is activated by pressing the pilot reset switch in cab (with the left armrest down).

STABILIZERS DOWN

GAUGE TEST PORT CONNECTION

PILOT MANIFOLD

220-D48

• • • • •

•• •• • •

Two tank ports ('T') drain return oil to the reservoir.

STABILIZERS UP

•

'PB' TO JOYSTICK AND SWING FOOT PEDAL

PILOT SHUT OFF VALVE

• •

GAUGE TEST PORT INLET PILOT RELIEF VALVE

• •

220-018

PILOT MANIFOLD ASSEMBLY 5.3

• •

•

•

'T' RETURN OIL, JOYSTICK AND SWING FOOT PEDAL TO TANK

Tigercat 220 Loader

Pilot system

PILOT MANIFOLD - DELIMBER/SLASHER

220-D55

PILOT MANIFOLD - DELIMBER/SLASHER The pilot manifold is located below the floor plates in the hydraulic valve compartment.

The pilot manifold distributes oil to the following circuits: • • • • • • • • • • • •

Joysticks (both) Swing control foot pedal Stabilizer pilot manifold Gauge test port Slasher saw, cut Slasher saw, retract Top saw, cut Delimber, open Stabilizers down Stabilizers up Spare *Delimber Open/Dump

(PB) port (PB) port (PB) port (G) port (1) solenoid valve (2) solenoid valve (3) solenoid valve (4) solenoid valve (5) solenoid valve (6) solenoid valve (7) solenoid valve (8) solenoid valve

STABILIZERS STABILIZERS DOWN SPARE UP DELIMBER OPEN DUMP VALVE

• •

•

TOP SAW, CUT

DELIMBER OPEN

•

•

• •

•

'PB' TO JOYSTICK AND SWING FOOT PEDAL

SLASHER SAW, CUT SLASHER SAW, RETRACT PILOT SHUT OFF VALVE GAUGE TEST PORT

•

INLET

•

PILOT RELIEF VALVE

•

•

•

• • 'T' RETURN OIL, JOYSTICK AND SWING FOOT PEDAL TO TANK

230B-04

PILOT MANIFOLD ASSEMBLY - DELIMBER/SLASHER 5.4

Tigercat 220 Loader

Pilot system

PILOT MANIFOLD - CIRCLE SAW

220-D55

PILOT MANIFOLD - CIRCLE SAW The pilot manifold is located below the floor plates in the hydraulic valve compartment.

The pilot manifold distributes oil to the following circuits: • • • • • • • • • • • •

Joysticks (both) Swing control foot pedal Stabilizer pilot manifold Gauge test port Butt Board down Butt Board up Saw retract Saw cut Stabilizers down Stabilizers up Spare Circle saw motor

(PB) port (PB) port (PB) port (G) port (1) solenoid valve (2) solenoid valve (3) solenoid valve (4) solenoid valve (5) solenoid valve (6) solenoid valve (7) solenoid valve (8) solenoid valve

STABILIZERS STABILIZERS DOWN SPARE UP CIRCLE SAW MOTOR

• •

•

SAW RETRACT

•

•

• •

•

'PB' TO JOYSTICK AND SWING FOOT PEDAL

BUTT BOARD DOWN BUTT BOARD UP

SAW CUT

PILOT SHUT OFF VALVE GAUGE TEST PORT

•

INLET

•

PILOT RELIEF VALVE

•

•

•

• • 'T' RETURN OIL, JOYSTICK AND SWING FOOT PEDAL TO TANK

230B-04

PILOT MANIFOLD ASSEMBLY - CIRCLE SAW 5.5

Tigercat 220 Loader

220-015

Pilot system

PILOT CIRCUIT COMPONENTS - STANDARD LOADER 5.6

Tigercat 220 Loader

220-016

Pilot system

PILOT CIRCUIT COMPONENTS - DELIMBER/SLASHER 5.7

Tigercat 220 Loader

220-017

Pilot system

PILOT CIRCUIT COMPONENTS - CIRCLE SAW 5.8

Tigercat 220 Loader

Pilot system

JOYSTICKS AND FOOT PEDALS These pilot valves are manually operated, directional control valves and operate on the same principle as a direct operating pressure reducing valve. Both the joystick and foot control valves (pedals) use similar spool arrangements.

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

5

• 3

•

4

•

•

TANK PORT

8

OPERATING DESCRIPTION

•

In the neutral position the joystick lever, or foot pedal is held centered by return springs (4).

When the lever (1) is operated, the plunger (5) is pushed against its return spring (4). At the same time the regulating spool (2) is moved down against the regulating spring (3). When the regulating stroke begins, there is a connection made between the pressure port, via holes (8) in the spool and work ports in the base of the valve.

1

•

•

• 2

•

•

WORK PORT AW015

PRESSURE PORT

WORK PORT

JOYSTICK PILOT VALVE (KAWASAKI)

•

1

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

•

5

1

•

5 4

• •

TANK PORT

•

•

TANK PORT

3

•

•

•

3

4

•

8

WORK PORT

•

2

•

• PRESSURE PORT

8

•

2

• •

•

WORK PORT

WORK PORT

FOOT PEDAL PILOT VALVE (KAWASAKI)

AW009

AW017

5.9

• PRESSURE PORT

WORK PORT

JOYSTICK PILOT VALVE (HUSCO)

Tigercat 220 Loader

Pilot system

PILOT SYSTEM ELECTRICAL CIRCUIT

PILOT SHUT OFF VALVE

Refer to circuit diagram; The pilot shut off valve solenoid is not energized until the armrest is down and the pilot reset switch is pushed. Wire 33 connects the armrest switch to the pilot shut off valve solenoid. Wire 95 connects the pilot reset switch to the armrest switch. When the pilot reset switch is pushed ON with the armrest DOWN, the coil on the pilot shut off relay is energized closing the circuit between wires 6 and 11 to energize the coil in the pilot shut off valve. With the coil energized the valve spool in the pilot shut off valve is shifted to supply oil to the pilot circuit. At the same time wire 95A from the pilot reset switch is connected back to the pilot shut off relay through a diode and thus latches the pilot shut off relay in the energized position.

•

• • PILOT MANIFOLD

The diode in the circuit prevents the flow of current to the pilot shut off valve solenoid when the armrest switch is open (armrest up). Even if the pilot reset switch is held down, it will not operate. Whenever the arm is raised and the switch opens, the voltage is interrupted to the pilot shut off relay coil and the relay contacts open resulting in the pilot shut off valve returning to the normally closed position. This prevents pilot oil from reaching the controls.

••

GAUGE TEST PORT CONNECTION PILOT RELIEF VALVE 240B-D22

PILOT RELIEF VALVE

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

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

3. Start engine and set throttle in FULL position.

4. Loosen locknut on pilot relief valve and turn adjusting screw IN until pressure gauge at pilot manifold reads 450 psi.

5. Stop engine, and remove pressure gauge.

PILOT MANIFOLD BODY

RELIEF VALVE CARTRIDGE

•

LOCKNUT ADJUSTING SCREW

•

240B-01

5.10

PILOT RELIEF VALVE

•

IN

•

OUT

Tigercat 220 Loader

220-048

Pilot system

PILOT SYSTEM CIRCUIT DIAGRAM - BASIC LOADER 5.11

Tigercat 220 Loader

220-047

Pilot system

PILOT SYSTEM CIRCUIT DIAGRAM - DELIMBER SLASHER 5.12

Tigercat 220 Loader

220-049

Pilot system

PILOT SYSTEM CIRCUIT DIAGRAM - CIRCLE SAW 5.13

Tigercat 220 Loader

Pilot system

5.14

Tigercat 220 Loader

SECTION 6 - ELECTRICAL, GAUGES & ALARMS JANUARY, 2006

CONTENTS - SECTION 6 DISPLAY MODULE ........................................................................................ 6.2 COMPONENT DESCRIPTION ................................................................... 6.2 FAULTS AND WARNINGS ......................................................................... 6.3 KEYPAD FUNCTIONS ............................................................................... 6.2 START-UP OPERATION ............................................................................ 6.2 ELECTRICAL SCHEMATIC DIAGRAMS .............. 6.19, 6.27, 6.28, 6.29, 6.30 INSTRUMENT PANEL WIRING DIAGRAM ...................... 6.7, 6.16, 6.17, 6.18 SENSOR LOCATIONS ............................................................. 6.13, 6.14, 6.15 WIRE COLOUR CODE CHART ................................................................... 6.11

Tigercat 220 Loader

Electrical, Gauges and Alarms

POWERVIEW DISPLAY MODULE 1

•

2

••

3

•• 4 244-007

7

••

••

•

5

• 6

POWERVIEW DISPLAY MODULE

COMPONENT DESCRIPTION 1. Amber Warning LED 244-046

2. Display

POWERVIEW DISPLAY MODULE

3. Menu Key

The PowerView Display Module is the operator interface with the electronic engine controls.The PowerView is a multifunction tool that enables the operator to view various engine parameters and service codes. The PowerView includes a graphical backlit LCD screen controlled via menu selection. The display can show either a single parameter or a quadrant display showing 4 parameters simultaneously. Diagnostic capabilities include fault codes with text translation for the most common fault conditions.

4. Left Arrow Key 5. Right Arrow Key 6. Enter Key 7. Red Shutdown LED START-UP OPERATION KEYPAD FUNCTIONS MENU KEY - This key is pressed to enter or exit menu screens.

The PowerView has four buttons used to navigate the display with ease.

LEFT ARROW KEY - This key is pressed to scroll through the screen either moving the parameter selection toward the left or down.

DISPLAY PARAMETERS The following are some of the functions displayed by the PowerView Display Module:

RIGHT ARROW KEY- This key is pressed to scroll through the screen either moving the parameter selection toward the right or up.

Engine RPM Engine Hours Machine Hours System Voltage % Engine Load at the current RPM Coolant Temperature Oil Pressure Fuel Economy Throttle Position Engine Manifold Air Temperature Current Fuel Consumption Active Service Codes Stored Service Codes from the engine Set Units for display (English or Metric) Engine Configuration Parameters

ENTER KEY - This key is pressed to select the parameter that is highlighted on the screen.

Refer to manufactures Operations Manual (supplied with the machine) for detailed information.

When power is first applied to the PowerView, the “Logo Screen” will be displayed, the “Wait to Start” message will be displayed. Once the “Wait to Start” message is no longer displayed the operator may start the engine. When the engine has started the display will show the single engine parameter display.

6.2

Tigercat 220 Loader

Electrical, Gauges and Alarms Some of the display and warning functions are: LOW ENGINE OIL PRESSURE - RED LED This light will come ON when the engine oil pressure falls below 15 psi. If this light comes ON stop the engine and determine cause.

ENGINE COOLANT TEMP. - RED LED This light will come ON when the engine coolant temperature rises above 215°F If this light comes ON stop engine and determine cause. Do not continue to operate machine.

SINGLE PARAMETER DISPLAY MAIN MENU NAVIGATION 244-007

1. Starting at the single or four engine parameter display, depress the “Menu Button”.

TACHOMETER This display indicates the RPM. of the engine.

HOUR METER There are two options available for displaying hours: TOTAL ENGINE HOURS - displays total hours the engine has run as provided by the engine computer.

244-047

2. The first seven items of the “Main Menu” will be displayed.

MACHINE HOURS - displays the total hours the engine has run as calculated by the display module.

3. Depressing the “Arrow Buttons” will scroll through the menu selections.

ENGINE OIL PRESSURE

4. Pressing the right arrow button will scroll down to reveal the last items of “Main Menu” screen highlighting the next item down.

Oil pressure at low idle and high idle will display 54 psi (372 kPa). If oil pressure drops below 7 psi (48 kPa) the display will read 0 and the LOW ENGINE OIL PRESSURE - RED LED will turn ON, stop engine and determine cause. Check engine oil pressure every time the engine is started.

5. Use the arrow buttons to scroll to the desired menu item or press the “Menu Button” to exit the Main menu and return to the engine parameter display.

ENGINE COOLANT TEMP.

FAULTS AND WARNINGS

Normal operating range is between 181°F and 203°F. If the temperature rises beyond 210°F, reduce the load on the engine and check for a plugged radiator. If the temperature does not drop, stop engine and determine cause. Do not continue to operate machine.

During normal operation the single or four parameter screen will be displayed. When the PowerView receives a fault code from an engine control unit the single or four parameter screen will be replaced with the “Active Fault Codes” message.

VOLTAGE DISPLAY

To acknowledge and “Hide” the fault and return to the single or four parameter display press the “Enter Button”. The display will return to the single or four parameter screen. Indicates Auxiliary Gage Fault. Indicates Fault Warning Indicates Derate or Shutdown Condition Fault

Normal operating range is between 12-13.5 volts.

A reading in excess of 15 volts indicates a possible faulty voltage regulator. A reading of less than 12 Volts indicates a possible faulty battery or alternator.

Refer to manufactures Operations Manual (supplied with the machine) for detailed information.

Pressing the “Enter Button” will redisplay the hidden fault. Pressing the “Enter Button” once again will hide the fault and return the screen to the single or four parameter display.

NOTE: The fault can only be cleared by correcting the cause of the fault condition.

6.3

Tigercat 220 Loader

Electrical, Gauges and Alarms

FUSE, RELAY AND DIODE BOX - ENGINE COMPARTMENT ~ SERIAL NUMBER 2200111 TO 2200200 125 AMP. FUSE ENGINE GRID HEATER NO. 1

RELAY ENGINE GRID HEATER NO. 1

••

125 AMP. FUSE ENGINE GRID HEATER NO. 2 125 AMP. FUSE START CIRCUIT AND "POWER" TO THE CONTROL PANEL

•

•

RELAY ENGINE GRID HEATER NO. 2

••

•

SPARE FUSE 5 AMP KEY SWITCH INPUT FUSE 7.5 AMP BAT + FUSE 7.5 AMP BAT + FUSE 7.5 AMP BAT + FUSE 10 AMP FUEL PUMP

• • ••• • •• • •

RELAY START CIRCUIT AND "POWER" TO THE CONTROL PANEL DIODE MODULE NO. 9

RELAY NO. 9

••

••

••

FUSE 10 AMP FUEL PUMP 220-D21

FUSE, RELAY AND DIODE PANEL - ENGINE COMPARTMENT (2200111 TO 2200200)

6.4

Tigercat 220 Loader

Electrical, Gauges and Alarms

240B-029

FUSES AND RELAYS - ELECTRICAL BOX - SERIAL NUMBER 2200111 TO 2200200

6.5

Tigercat 220 Loader

Electrical, Gauges and Alarms

FUSE, RELAY AND DIODE BOX - ENGINE COMPARTMENT ~ SERIAL NUMBER 2200201 AND UP

220-D44

FUSE, RELAY AND DIODE PANEL - ENGINE COMPARTMENT (2200201 AND UP)

6.6

Tigercat 220 Loader

Electrical, Gauges and Alarms

240B-011(23825B)

ELECTRICAL BOX WIRING DIAGRAM - SERIAL NUMBER 2200201 AND UP 6.7

Tigercat 220 Loader

Electrical, Gauges and Alarms

FUSE, RELAY AND DIODE PANEL - CAB BASIC MACHINES SERIAL NUMBER 2200111 TO 2200200 The fuse panel is located below the control panel and behind a removable cover.

same value. If the fuse blows again, the circuit should be inspected for possible short circuit or other malfunction.

Each circuit of the machine is protected by a fuse. If a fuse is blown it must be replaced by one of the

42

220-D12

BASIC FUSE, RELAY AND DIODE PANEL - CAB ~ (2200111 TO 2200200) 1

RELAY 1

RELAY 1A

RELAY 3

RELAY 2

RELAY 4 2

STOP BUZZER

WARNING BUZZER

PILOT LOCK-OUT

A/CHEATER

LOW HYD. OIL

3 4 5

RELAY 5

RELAY 6

RELAY 7

RELAY 8

WORK LIGHTS

DELIMBER CLOSE

DELIMBER OPEN

SAW CUT

DIODE MODULE 1

DIODE MODULE 2

DIODE MODULE 3

DIODE MODULE 4

DIODE MODULE 5

DIODE MODULE 6

DIODE MODULE 7

6

ENGINE DIAGNOSTICS CONNECTOR

7

GAUGES 5A SAFETY 15A KEY INPUT 5A JOYSTICKS 15A STABILIZERS 15A WIPER/WASH 15A SPARE

8 RADIO/DOME 15A 9 LIGHTER 20A 10 HORN 20A 11 AC/HEATER 25A 12 WORK LIGHTS 20A 13 SERV. LIGHT/ DIAG. 10A 14 AUX. POWER 20A

19739B R1

6.8

Tigercat 220 Loader

Electrical, Gauges and Alarms

FUSE, RELAY AND DIODE PANEL - CAB ~ BASIC MACHINES SERIAL NUMBER 2200201 AND UP

220-D43

BASIC FUSE, RELAY AND DIODE PANEL - CAB ~ (2200201 AND UP)

24952B R1

6.9

Tigercat 220 Loader

Electrical, Gauges and Alarms

FUSE, RELAY AND DIODE PANEL - CAB ~ CIRCLE SAW SERIAL NUMBER 2200171 AND UP The fuse panel is located below the control panel and behind a removable cover.

Each circuit of the machine is protected by a fuse. If a fuse is blown it must be replaced by one of the same value. If the fuse blows again, the circuit should be inspected for possible short circuit or other malfunction.

A time delay circuit is incorporated in the circle saw system for Auto Saw Retract. The time delay is adjusted via a potentiometer. Turn the screw clockwise to increase time delay or counterclockwise to decrease time delay.

POTENTIOMETER

• 220-D43

-

+

FUSE, RELAY AND DIODE PANEL - CAB ~ CIRCLE SAW (2200171 AND UP)

25771B R0

6.10

+

Tigercat 220 Loader

Electrical, Gauges and Alarms

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 not fused) Ground Engine control ........................................ (fuel shut-off, start aid) Propulsion Control ................................. (transmission/reverser solenoids) Monitor, electrical and mechanical systems .............................. (air cleaner, alternator, wheel speed, engine speed) Electrical and electromechanical control ..................... (park brake, alternator excitation) (power door motor, backup alarm) Monitors ................................................. (flow, pressure, temperature, level) Standard monitor system ...................... (logic module to monitor) Lights Electro-hydraulic control ....................... (pilot solenoids) Accessories ........................................... (horn, A/C, heater)

6.11

Tigercat 220 Loader

Electrical, Gauges and Alarms

CONTROL PANEL - COMPONENT LOCATION AND WIRING DIAGRAM - TOP AND BOTTOM VIEW

220-20

CONTROL PANEL - COMPONENT LOCATION - SIDE VIEW

6.12

Tigercat 220 Loader

220-D60

220-26

Electrical, Gauges and Alarms

FRONT INSTRUMENT PANEL - COMPONENT LOCATION

FRONT INSTRUMENT PANEL - WIRING DIAGRAM - REAR VIEW

6.13

Tigercat 220 Loader

Electrical, Gauges and Alarms

SAFETY ALERT HORN (SWITCH ON CONTROL PANEL)

•• •

COOLANT LEVEL PROXIMITY SWITCH (RED LIGHT)

JOYSTICKS

••

•• •

LIMIT SWITCH, PILOT SHUT OFF

STABILIZER PILOT MANIFOLD

BATTERIES

• •

• •• ELECTRICAL BOX

••

•

• •• ••

PILOT MANIFOLD BATTERY DISCONNECT SWITCH

SENDER - HYDRAULIC OIL TEMPERATURE (GAUGE) SWITCH- HYDRAULIC OIL TEMPERATURE (RED LIGHT) SIGHT GAUGE/SWITCH HYDRAULIC OIL LEVEL (RED LIGHT)

220-25

SWITCH AND SENSOR LOCATIONS - STANDARD LOADER

6.14

Tigercat 220 Loader

Electrical, Gauges and Alarms

SAFETY ALERT HORN (SWITCH ON CONTROL PANEL)

• ••

COOLANT LEVEL PROXIMITY SWITCH (RED LIGHT)

JOYSTICKS

••

• ••

LIMIT SWITCH, PILOT SHUT OFF

STABILIZER PILOT MANIFOLD

BATTERIES

•• ••

•• •• ELECTRICAL BOX

•

••

•• • ••

PILOT MANIFOLD BATTERY DISCONNECT SWITCH

SENDER - HYDRAULIC OIL TEMPERATURE (GAUGE) SWITCH- HYDRAULIC OIL TEMPERATURE (RED LIGHT) SIGHT GAUGE/SWITCH HYDRAULIC OIL LEVEL (RED LIGHT)

20191B

SWITCH AND SENSOR LOCATIONS - DELIMBER/SLASHER OR CIRCLE SAW

6.15

Tigercat 220 Loader

Electrical, Gauges and Alarms

220-21

INSTRUMENT PANEL WIRING DIAGRAM (EXCLUDING CIRCLE SAW MACHINES) 6.16

Tigercat 220 Loader

Electrical, Gauges and Alarms

INSTRUMENT PANEL WIRING CONNECTION LIST (EXCLUDING CIRCLE SAW MACHINES)

6.17

Tigercat 220 Loader

220-61

Electrical, Gauges and Alarms

INSTRUMENT PANEL WIRING DIAGRAM - CIRCLE SAW 6.18

Tigercat 220 Loader

220-02

Electrical, Gauges and Alarms

ELECTRICAL SCHEMATIC DIAGRAM 23056B (REV. 0 SHEET 1 OF 3) SERIAL NUMBER 2200111 TO 2200260 (EXCLUDING CIRCLE SAW MACHINES) 6.19

Tigercat 220 Loader

220-03

Electrical, Gauges and Alarms

ELECTRICAL SCHEMATIC DIAGRAM 23056B (REV. 0 SHEET 2 OF 3) SERIAL NUMBER 2200111 TO 2200260 (EXCLUDING CIRCLE SAW MACHINES) 6.20

Tigercat 220 Loader

220-04

Electrical, Gauges and Alarms

ELECTRICAL SCHEMATIC DIAGRAM 23056B (REV. 0 SHEET 3 OF 3) SERIAL NUMBER 2200111 TO 2200260 (EXCLUDING CIRCLE SAW MACHINES) 6.21

Tigercat 220 Loader

220-10

Electrical, Gauges and Alarms

ELECTRICAL SCHEMATIC DIAGRAM 26662B (REV. 0 SHEET 1 OF 3) SERIAL NUMBER 2200261 AND UP (EXCLUDING CIRCLE SAW MACHINES) 6.22

Tigercat 220 Loader

220-11

Electrical, Gauges and Alarms

ELECTRICAL SCHEMATIC DIAGRAM 26662B (REV. 0 SHEET 2 OF 3) SERIAL NUMBER 2200261 AND UP (EXCLUDING CIRCLE SAW MACHINES) 6.23

Tigercat 220 Loader

220-12

Electrical, Gauges and Alarms

ELECTRICAL SCHEMATIC DIAGRAM 26662B (REV. 0 SHEET 3 OF 3) SERIAL NUMBER 2200261 AND UP (EXCLUDING CIRCLE SAW MACHINES) 6.24

Tigercat 220 Loader

220-07

Electrical, Gauges and Alarms

ELECTRICAL SCHEMATIC DIAGRAM 25386B (REV. 0 SHEET 1 OF 3) SERIAL NUMBER 2200171 TO 2200260 - CIRCLE SAW MACHINES 6.25

Tigercat 220 Loader

220-08

Electrical, Gauges and Alarms

ELECTRICAL SCHEMATIC DIAGRAM 25386B (REV. 0 SHEET 2 OF 3) SERIAL NUMBER 2200171 TO 2200260 - CIRCLE SAW MACHINES 6.26

Tigercat 220 Loader

220-09

Electrical, Gauges and Alarms

ELECTRICAL SCHEMATIC DIAGRAM 25386B (REV. 0 SHEET 3 OF 3) SERIAL NUMBER 2200171 TO 2200260 - CIRCLE SAW MACHINES 6.27

Tigercat 220 Loader

220-058

Electrical, Gauges and Alarms

ELECTRICAL SCHEMATIC DIAGRAM 31310B (REV. 0 SHEET 1 OF 3) SERIAL NUMBER 2200261 AND UP - CIRCLE SAW MACHINES 6.28

Tigercat 220 Loader

220-059

Electrical, Gauges and Alarms

ELECTRICAL SCHEMATIC DIAGRAM 31310B (REV. 0 SHEET 2 OF 3) SERIAL NUMBER 2200261 AND UP - CIRCLE SAW MACHINES 6.29

Tigercat 220 Loader

220-060

Electrical, Gauges and Alarms

ELECTRICAL SCHEMATIC DIAGRAM 31310B (REV. 0 SHEET 3 OF 3) SERIAL NUMBER 2200261 AND UP - CIRCLE SAW MACHINES 6.30

Tigercat 220 Loader

SECTION 7 - ENGINE START AND STOP JANUARY, 2006

CONTENTS - SECTION 7 CIRCUIT DESCRIPTION ............................................................................... 7.2 ENGINE START CIRCUIT ............................................................................. 7.2 START CIRCUIT DIAGRAMS ........................................................................ 7.3 STARTING THE ENGINE .............................................................................. 7.2

Tigercat 220 Loader

Engine start and stop

ENGINE START CIRCUIT

ELECTRONIC CONTROL MODULE

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

The engine normally installed on these Tigercat Loaders is a Cummins Diesel QSB5.9 Electronic Engine.

• ••

••

For engine starting and stopping procedures refer to STARTING ENGINE and STOPPING ENGINE in SECTION 2 of the OPERATOR’S MANUAL. For correct engine speeds, refer to THROTTLE CONTROL in SECTION 2 of the OPERATOR'S MANUAL.

MULTI PIN CONNECTORS 244-056

ENGINE ELECTRONIC CONTROL MODULE flows from the battery + RED wire (1) through wire (12) to the start solenoid coil to close the contacts and operate the start motor to start the engine.

STARTING THE ENGINE 1. Ensure Pre-Start Checks have been performed and that the area is clear of personnel prior to starting the machine.

When the ignition key is turned to the RUN position, the BATTERY remains connected to the KEY input relay (relay #9 not shown) which sends a continuous signal to the engine control module via the 23 pin connector. When the key switch is turned OFF, the voltage is removed from the key input relay and loss of signal to the control module causes the engine to stop.

2. Turn Battery Disconnect Switch ON. 3. Turn ignition key to RUN position and observe warning lights. Wait to Start and Water in Fuel indicator lights will turn on momentarily then turn off.

PowerView warning lights will turn on momentarily then turn off (as a bulb test).

In order to operate the machine functions after starting the engine, the arm rest must be in the latched DOWN position and the PILOT RESET button pushed. This will energize the pilot shut off relay, close the contacts and allow current to flow through wires (6) and (11) to energize the pilot shut off solenoid valve on the pilot manifold. After the PILOT RESET button is released current will continue to flow through wire (95) and the diode to latch the pilot shut off relay in the energized position and allow current to flow through wires (6) and (11) to the pilot shut off solenoid valve.

WAIT for Warning Lights to turn OFF before starting engine.

4. As a bulb test, depress Warning Light Bulb Test Switch and observe that all Warning lights turn on and turn off when switch is deactivated.

5. Sound horn to warn personnel of machine start-up.

6. Turn ignition key switch to the START position to crank the engine. When engine is started place key switch in RUN position and observe gauges and display module.

For additional information on the PILOT SYSTEM refer to SECTION 5 in THIS SERVICE MANUAL.

CIRCUIT DESCRIPTION With the battery disconnect switch ON, voltage is supplied the start solenoid contact, the positive connection on the alternator and the BATTERY contact of the key switch (ignition switch).

When the key switch is turned to the START position, the BATTERY contact is connected to the RELAY and START contacts. Current (voltage) then flows through wire (16) to energize the coil of the start solenoid relay. The start solenoid relay contacts also close and current

7.2

Tigercat 220 Loader

Engine start and stop

START CIRCUIT - AT REST

220-028

START CIRCUIT - AT REST BATTERY DISCONNECT SWITCH - ON

220-029

7.3

Tigercat 220 Loader

Engine start and stop

START CIRCUIT - START IGNITION KEY - START POSITION

220-030

START CIRCUIT - RUN IGNITION KEY - RUN POSITION

220-031

7.4

Tigercat 220 Loader SECTION 10 - OIL COOLER, RADIATOR AND FAN JANUARY, 2006

CONTENTS - SECTION 10 CHECK ENGINE COOLANT LEVEL ............................................................................. 10.2 COOLING SYSTEM COOLANT FLOW DIAGRAM ..................................................................................... 10.5 COOLANT FLOW DURING OPERATION ................................................................... 10.5 FILLING THE SYSTEM WITH COOLANT ................................................................... 10.5 OIL COOLER CIRCUIT DESCRIPTION ......................................................................... 10.6 OIL COOLER CIRCUIT DIAGRAM ................................................................................ 10.6 OIL COOLER, RADIATOR AND FAN ............................................................................ 10.2 RADIATOR ................................................................................................................... 10.3

Tigercat 220 Loader OIL COOLER, RADIATOR AND FAN

Oil Cooler, Radiator and Fan

•• The hydraulic oil cooler/radiator is mounted in front of the engine. The A/C condenser core is mounted in front of the oil cooler/radiator cooling assembly.

The fan draws air through the A/C condenser, the oil cooler/radiator cooling assembly.

FILLER CAP

COOLANT LEVEL INDICATOR

HINGE OUT A/C CONDENSER

RADIATOR

••

SURGE TANK

••

248-25

CHECK ENGINE COOLANT LEVEL

•• FAN BELT

• •• OIL COOLER

•

220-D39

ENGINE COMPARTMENT ACCESS RIGHT SIDE The A/C condenser core and the oil cooler/radiator cooling assembly should be checked every 8 hours (every shift) for accumulation of twigs, leaves, pine needles and dust. All of the engine enclosure doors should also be kept clean.

Part of the engine cooling system is the surge tank. The coolant surge tank (reservoir) can be filled through the access panel located on top of the engine compartment. A level sight gauge is conveniently located in the side of the surge tank.

A/C COMPRESSOR BELT 220-01

CHECK ENGINE BELT(S)

The cooling fan is belt driven and belt tension is automatically tightened by a spring loaded tensioner. The belt condition and tension should be checked every 8 hours (every shift).

•• ••

JAM NUTS

WARNING Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing Ensure that the engine has cooled down sufficiently before removing radiator cap. Prior to removing cap, relieve pressure in radiator by loosening cap slowly to first stop. Use the proper solution of coolant antifreeze when filling the surge tank.

220-051

A/C COMPRESSOR BELT TIGHTENER The A/C compressor is belt driven and belt tension is tighten by an adjuster on the mounting bracket.

Check belt condition and tension every 8 hours (every shift).

Loosen jam nuts and adjust belt to obtain a belt deflection of 1/4" to 3/8" in the middle of the belt span between the pulleys.

10.2

Tigercat 220 Loader

Oil Cooler, Radiator and Fan RADIATOR OIL COOLER

RAD CAP

SURGE TANK A/C CONDENSER CORE

••

••

• •• ••

220-050 220-055

OIL COOLER, RADIATOR AND A/C CONDENSER CORE ASSEMBLY 10.3

Tigercat 220 Loader

220-D14

220-D15

Oil Cooler, Radiator and Fan

ENGINE COMPARTMENT ACCESS REAR

ENGINE COMPARTMENT ACCESS FRONT 10.4

Tigercat 220 Loader

Oil Cooler, Radiator and Fan

ENGINE COOLING SYSTEM

The engine vent discharges air directly from the top of the engine to the surge tank.

COOLANT FLOW DURING OPERATION

Additional coolant stored in the surge tank flows slowly down the shunt hose to the water pump inlet replacing the air removed from the cooling system.

The water pump circulates coolant through the radiator, engine oil cooler, the engine block and cylinder head. If the thermostat is closed, coolant is returned to the water pump through a bypass inside the engine.

FILLING THE SYSTEM WITH COOLANT The coolant is added through the filler neck in the surge tank. This coolant fills the bottom radiator hose at the water pump through the shunt hose and then fills the radiator from the bottom upwards.

Air is displaced through the vent tubes to the surge tank. As the radiator is filled, coolant flows through the water pump and engine oil cooler to fill the engine. Coolant will flow out the top radiator hose through the thermostat bypass and into the engine once the radiator has filled. The engine and rad vent discharge air directly from the engine and rad to the surge tank.

The thermostat opens when the coolant reaches operating temperature. Then the coolant flows across the radiator core to the outlet and back to the water pump through the bottom radiator hose.

A surge tank is located above the radiator. A small vent tube is connected between the surge tank and the thermostat housing. The anti-freeze/water solution used in the cooling system always contains small amounts of gas produced by combustion leakage. This gas must be vented to the outside to prevent cavitation of the engine water pump and to promote efficient heat transfer between the engine block and the coolant. These gases separate from the coolant in the radiator top tank and are carried up through the vent tube where they collect in the surge tank and eventually discharge through the pressure cap.

FLOW OF COOLANT WITH ENGINE RUNNING AT OPERATING TEMPERATURE AND THERMOSTAT OPEN ENGINE VENT •

•

SHUNT HOSE

SURGE TANK

When the engine has been run up to operating temperature and the thermostat has opened, any remaining air is purged through the vent tube and the engine vent. The system will then require more coolant to fully top off both the engine and the radiator.

TOP RADIATOR HOSE

RAD VENT

••

••

RADIATOR

•

•• ••

THERMOSTST HOUSING

•• •• •

•• SHUNT HOSE

ENGINE OIL COOLER 220-057

ENGINE COOLING SYSTEM 10.5

BOTTOM RADIATOR HOSE

Tigercat 220 Loader

Oil Cooler, Radiator and Fan

OIL COOLER CIRCUIT DESCRIPTION The oil cooler is situated down stream from the swing valve. The swing valve receives hydraulic oil from the swing gear pump. The control spool sections of the swing valve are all "open center" type, therefore oil surplus to requirements is allowed to pass through the valve to the outlet section of the valve. Oil flow is routed to the oil cooler inlet through the cooler to the return filter and on to the hydraulic tank.

2200-052

Cooling of the oil occurs as air is drawn over the oil cooler cooling fins by the engine fan. Cooled oil then passes through the return filter and into the hydraulic tank.

A 50 psi relief valve, installed in the line between the cooler inlet and outlet at the filter, provides a bypass route for oil to flow in the event the oil cooler is plugged.

OIL COOLER CIRCUIT DIAGRAM 10.6

Tigercat 220 Loader

SECTION 12 - BOOM JANUARY, 2006

CONTENTS - SECTION 12 CIRCUIT DESCRIPTION ............................................................................. 12.4 CIRCUIT DIAGRAM ..................................................................................... 12.5 CONTROL VALVES HOIST CONTROL VALVE ........................................................................ 12.2 JOYSTICK CONTROL VALVE. SEE SERVICE MANUAL SECTION 5 STICK CONTROL VALVE ........................................................................ 12.2 FILTERS HYDRAULIC RETURN ............................................................................. 12.3 HOIST VALVE RELIEF VALVE SETTINGS ................................................. 12.6 PRESSURE SETTINGS SUMMARY ..................................................................................... 12.6, 12.7 STICK VALVE RELIEF VALVE SETTINGS .................................................. 12.7

Tigercat 220 Loader BOOM SYSTEM COMPONENTS

Boom functions The operation of a typical external gear pump (so called because the gear teeth are on the external surface of the hub) is shown in Figure gear1.

BOOM PUMP The pump is bolted onto the bell housing and driven directly off the engine. To ensure optimum performance of the hydraulic system when operating the machine, the engine must always be set at FULL throttle.

A gear pump carries oil from the inlet to the outlet in the spaces between gear teeth. The pumping chamber is formed by the gears, the pump housing, and side plates. One of the two gears, called the drive gear, will be connected to the drive shaft. The other idler gear is driven by the drive gear.

BOOM PUMPS

JOYSTICK CONTROL VALVE

SWING PUMP

•

• BELL HOUSING

The hoist boom and stick boom functions are controlled by the left and right joysticks which when operated send proportional pilot signals to the two boom control valves which supply oil to the two boom cylinders.

• ••

For a detailed description of the joystick control valve refer to SECTION 5 in THIS MANUAL. BOOM CONTROL VALVES

GEAR PUMP A gear pump consisting of three gear housing sections, all connected together internally supply hydraulic oil to all of the functions on the machine except the pilot system. The first two gear housings at the shaft end supply oil for the boom functions and the end gear housing supplies oil for the swing circuit.

220-050

The hoist boom and stick boom are each controlled by two spool sections located in two separate identical control valves. Each control valve consists of two (standard loader) or three (delimber/slasher or circle saw) pilot operated, open center spool sections, an inlet section and an outlet section. The outlet section directs return oil back to tank. The control valves are located in the upper frame below the floor plates inside the valve compartment.

OUTLET DRIVEN (IDLER) GEAR

CONTROL VALVE OPERATING DESCRIPTION Oil enters the inlet section and is allowed to pass through the spool sections and back to tank via the outlet section. Each of these spool sections has a self centering 3-position spool which is open centered. A spring in the spool end cap holds the spool in the center neutral position. The spool is shifted by pilot pressure being applied to either end of the spool. Shifting the spool directs oil to operate any one of the three functions (or all at the same time if required but with reduced flow to each).

DRIVE GEAR

•

•

INLET GEAR1

To protect components and hoses when the valve is closed, each work port in the valve sections have a port relief valve with an anti-cavitation function.

TYPICAL GEAR PUMP

A main relief valve is installed in the inlet section of the valve to protect the hydraulic system against overload pressures.

12.2

Tigercat 220 Loader

Boom functions

HYDRAULIC RETURN FILTERS

DOUBLE FILTER HEAD

FROM FROM RETURN MANIFOLD, ("STICK"/ SWING "TILT"/SWING MOTOR 'T' PORTS) VALVE

The majority of return oil entering the hydraulic tank passes through 4 spin-on hydraulic oil filters.

One of the filters is a water absorbing filter (color blue) which is in place to assist with the removal of unwanted moisture from the hydraulic oil (the filters are rated 10m abs).

••

• •

Each filter head has a bypass valve with a 25 psi cracking pressure so that oil can bypass the filters if they become restricted. The "in" side of the filter heads are connected to a return manifold. A filter restriction indicator and an oil sampling connector are mounted onto the manifold. To check the condition of the filter elements; With the hydraulic oil at normal operating temperature, place engine throttle control to FULL and with no machine functions operating, the filter restriction indicator should be in the GREEN zone. If the pointer is in the RED zone replace all four filter elements.

• •

TO OIL COOLER "IN" OIL COOLER BYPASS CHECK VALVE (50 PSI)

••

••

1-WATER ABSORBING RETURN FILTER (COLOUR BLUE)

•• 2-HYDRAULIC RETURN FILTERS

HYDRAULIC RETURN FILTERS

220-D17

••

•

•• FROM OIL COOLER "OUT" AND HAND FILL PUMP 220-D18

RELIEF VALVE PORT 'A'

OIL COOLER BYPASS CHECK VALVE (50 PSI)

FILTER RESTRICTION INDICATOR

HYDRAULIC RETURN FILTERS

SEAL GROOVES

A

RELIEF VALVE PORT 'B'

B

SPOOL CENTERING SPRINGS

•

• • •

•

•

•

• •

•

• PILOT END CAP

AT047IL2

•

•

•

• SPOOL TANK PASSAGE

PARALLEL PASSAGE

LOAD CHECK VALVE

THRU' NEUTRAL PASSAGE

WORK PORT BRIDGE

CROSS SECTION OF SPOOL SECTIONS 12.3

TANK PASSAGE

PILOT END CAP

Tigercat 220 Loader HOIST 'DOWN' PORT RELIEF (1500 PSI)

Boom functions STICK 'DOWN' PORT RELIEF (1500 PSI)

MAIN RELIEF (2750 PSI)

MAIN RELIEF (2750 PSI)

OUTLET SECTION

OUTLET SECTION

•

•

•

•

•

• •

GRAPPLE ROTATE

STICK

GRAPPLE OPEN/ CLOSE

• SAW RETRACT

DELIMBER OPEN

HOIST

SAW CUT

SAW CUT

•

• •

GAUGE TEST PORT

GAUGE TEST PORT INLET SECTION

INLET SECTION STICK 'UP' PORT RELIEF (3400 PSI)

HOIST 'UP' PORT RELIEF (3400 PSI) AT047IL

•

BOOM CONTROL VALVES

CIRCUIT DESCRIPTION The boom circuit is supplied with oil from two of the three gear housing sections on the main pump. Each of the two boom valves receive oil at the inlet sections and directs the oil through the open center spool sections, to the outlet section.

From there it is directed back to tank via a check valve to the return manifold and two dual element filters, which are equipped with an internal 25 psi element bypass valve.

Moving either of the joysticks in the cab will direct pilot oil to the ends of the hoist or stick spool sections in the boom valves to shift the spools and direct hydraulic oil from the pump to the hoist or stick hydraulic cylinders to raise or lower to booms. Return oil from the cylinders is directed back through the spool sections, to the outlet section, through the return manifold, the two dual head return oil filters and back to tank.

12.4

Tigercat 220 Loader

220-032

Boom functions

BOOM CIRCUIT 12.5

Tigercat 220 Loader PRESSURE SETTINGS

Boom functions IMPORTANT

CAUTION

Approach the gauge reading slowly and deliberately by turning the adjusting screw in a little at a time. The pressure setting must not exceed the above value.

Use caution when in the cab as a slight touch of the controls can cause sudden rotation of the upper frame and booms or movement of the stabilizers

8. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

CAUTION

9. While holding the L.H. joystick in the HOIST DOWN position (fully retracted), check gauge pressure reading. If less than set value, turn relief valve adjusting screw in until set value is obtained on gauge.

Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

10. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

WARNING Ensure that no one is standing near the grapple during this procedure.

11. Repeat steps 7 and 9 to verify settings. reset main relief valve: 12. Loosen locknut on "hoist" main relief and unscrew adjusting screw 3 full turns.

IMPORTANT Avoid blowing oil over relief for longer than five seconds, as this will cause excessive heating of the hydraulic fluid.

13. While holding the L.H. joystick in the HOIST UP position (fully extended), check gauge pressure reading. If less than set value, turn relief valve adjusting screw in until set value is obtained on gauge.

HOIST VALVE RELIEF VALVE SETTINGS Hoist main relief setting ..................... 2750 psi

14. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

Hoist up port relief setting .................. 3400 psi Hoist down port relief setting ............. 1500 psi

15. Stop engine. Remove pressure gauge and wipe up any excess oil from test port area.

1. Position machine on flat level ground with stabilizers down.

SUMMARY:

2. Ensure that the hydraulic oil is at operating temperature.

1. Ensure hydraulic oil is at operating temperature.

3. Connect a 0 - 5000 p.s.i. pressure gauge to the "hoist" control valve test port on the inlet section of the valve.

2. Connect gauge to "hoist" valve.

3. Turn main relief fully "in".

4. Loosen the locknut on the "hoist" main relief valve and turn the relief adjusting screw all the way in, tighten locknut.

4. Turn both "hoist" port reliefs out.

5. Start engine.

6. Set HOIST UP port relief.

5. Turn both port relief valve adjusting screws on the "hoist" spool section of the valve out until spring pressure is relieved then turn adjusting screws one full turn in.

7. Set HOIST DOWN port relief.

8. Reset main relief.

6. Start the engine, and put the throttle control to the FULL position.

7. While holding the L.H. joystick in the HOIST UP position (fully extended), check gauge pressure reading. If less than set value, turn relief valve adjusting screw in until set value is obtained on gauge.

12.6

Tigercat 220 Loader

Boom functions

CAUTION

IMPORTANT

Use caution when in the cab as a slight touch of the controls can cause sudden rotation of the upper frame and booms or movement of the stabilizers

Approach the gauge reading slowly and deliberately by turning the adjusting screw in a little at a time. The pressure setting must not exceed the above value.

8. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

CAUTION

9. While holding the R.H. joystick in the STICK IN position (fully retracted), check gauge pressure reading. If less than set value, turn relief valve adjusting screw in until set value is obtained on gauge.

Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

WARNING

10. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

Ensure that no one is standing near the grapple during this procedure.

11. Repeat steps 7 and 9 to verify setting. reset main relief valve:

IMPORTANT

12. Loosen locknut on "stick" main relief and unscrew adjusting screw 3 full turns.

Avoid blowing oil over relief for longer than five seconds, as this will cause excessive heating of the hydraulic fluid.

13. While holding the R.H. joystick in the stick OUT position (fully extended), check gauge pressure reading. If less than set value, turn relief valve adjusting screw in until set value is obtained on gauge.

STICK VALVE RELIEF VALVE SETTINGS Stick main relief setting:- .................... 2750 psi Stick out port relief setting .................. 3400 psi Stick in port relief setting .................... 1500 psi

14. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

1. Position machine on flat level ground with stabilizers down.

15. Stop engine. Remove pressure gauge and wipe up any excess oil from test port area.

2. Ensure that the hydraulic oil is at operating temperature.

SUMMARY: 1. Ensure hydraulic oil is at operating temperature.

3. Connect a 0 - 5000 p.s.i. pressure gauge to the "stick" control valve test port on the inlet section of the valve.

2. Connect gauge to "stick" valve.

3. Turn main relief fully "in".

4. Loosen the locknut on the "stick" main relief valve and turn the relief adjusting screw all the way in, tighten locknut.

4. Turn both "stick" port reliefs out.

5. Turn both port relief valve adjusting screws on the "stick" spool section of the valve out until spring pressure is relieved then turn adjusting screws one full turn in.

6. Set STICK UP port relief.

5. Start engine.

7. Set STICK DOWN port relief.

8. Reset main relief.

6. Start the engine, and put the throttle control to the FULL position.

7. While holding the R.H. joystick in the STICK OUT position (fully extended), check gauge pressure reading. If less than set value, turn relief valve adjusting screw in until set value is obtained on gauge.

12.7

Tigercat 220 Loader

Boom functions

12.8

Tigercat 220 Loader

SECTION 15 - SWING JANUARY, 2006

CONTENTS - SECTION 15 CIRCUIT DESCRIPTION ............................................................................. 15.6 CIRCUIT DIAGRAM ..................................................................................... 15.7 CONTROL VALVES FOOT PEDAL CONTROL VALVE. SEE SERVICE MANUAL SECTION 5 SWING CONTROL VALVE ...................................................................... 15.2 GEARBOX, SWING DRIVE ......................................................................... 15.5 PRESSURE SETTINGS SET SWING MOTOR CROSSLINE RELIEF VALVES ............................. 15.9 SET SWING RELIEF VALVES ................................................................. 15.8 SUMMARY ............................................................................................... 15.9 SWING MOTOR ........................................................................................... 15.4 MOTOR CROSSLINE RELIEF VALVE ........................................... 15.6, 15.8 MOTOR REMOVAL NOTE ....................................................................... 15.4 SWING PUMP .............................................................................................. 15.2

Tigercat 220 Loader

Swing

SWING DRIVE COMPONENTS

In the neutral position the foot pedal is held centered by return springs (4). When the lever (1) is operated, the plunger (5) is pushed against its return spring (4). At the same time the regulating spool (2) is moved down against the regulating spring (3). When the regulating stroke begins, there is a connection made between the pressure port, via holes (8) in the spool and work ports in the base of the valve.

SWING PUMP The swing pump is a fixed displacement external triple gear pump.

BOOM PUMPS

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

SWING PUMP

SWING CONTROL VALVE

••

••

•• •

BELL HOUSING

The swing drive is controlled by one of three spool sections in a three section control valve.

The control valve consists of three pilot operated, open center spool sections, an inlet section and an outlet section. The outlet section directs return oil back to tank. The control valve is located in the upper frame below the floor plates inside the valve compartment.

GEAR PUMP

220-050

The swing drive system utilizes the third gear housing from the shaft end of the pump to supply hydraulic oil to the swing valve.

CONTROL VALVE OPERATING DESCRIPTION Oil enters the inlet section and is allowed to pass through the three spool sections and back to tank via the outlet section. Each of these spool sections has a self centering 3-position spool which is open centered. A spring in the spool end cap holds the spool in the center neutral position.

The spool is shifted by pilot pressure being applied to either end of the spool. Shifting the spool directs oil to operate any one of the three functions (or all at the same time if required but with reduced flow to each).

For a more detailed description of the triple gear pump, refer to SECTION 12 in THIS SERVICE MANUAL.

1

•

5

•

•

•

TANK PORT

3

To protect components and hoses when the valve is closed, each work port in the valve sections have a port relief valve with an anti-cavitation function.

4

A main relief valve is installed in the inlet section of the valve to protect the hydraulic system against overload pressures.

•

8

• • WORK PORT

•

2

• PRESSURE PORT

WORK PORT

FOOT PEDAL PILOT VALVE (KAWASAKI) AW017

FOOT PEDAL CONTROL VALVE The swing function is controlled by the center foot pedal valve which sends proportional pilot signals to the swing valve which supplies oil to the swing motor.

15.2

Tigercat 220 Loader

Swing SWING 'CW' PORT RELIEF (3000 PSI)

•

MAIN RELIEF (2600 PSI)

•

SWING

STABILIZER

GAUGE TEST PORT

•

•

•

INLET SECTION

OUTLET SECTION

•

SWING 'CCW' PORT RELIEF (3000 PSI)

SWING CONTROL VALVE

AT041ZIL

RELIEF VALVE PORT 'A'

SEAL GROOVES

RELIEF VALVE PORT 'B'

A

B SPOOL CENTERING SPRINGS

•

• • •

•

•

•

• • • PILOT END CAP

AT041YIL

•

•

• •

• SPOOL TANK PASSAGE

PARALLEL PASSAGE

LOAD CHECK VALVE

THRU' NEUTRAL PASSAGE

WORK PORT BRIDGE

CROSS SECTION OF SPOOL SECTIONS 15.3

TANK PASSAGE

PILOT END CAP

Tigercat 220 Loader

Swing

SWING MOTOR

coupling, and the other is an idler gear. Not shown in the illustration are the side plates, which create a sealing wear surface on the sides of the gear set.

The swing motor is a gear motor with two, 2-stage crossline relief valves mounted on the port end cover. The crossline relief valves provide a

Gear motors operate because of a pressure differential, between the motor inlet and outlet.

This pressure differential acts across the gear teeth, creating a force that tries to rotate the gear.

As the diagram shows, there are two paths around the periphery of the gears, and one path through the intersection of the two gears. In each path, the pressure works against the area of one tooth so that there are two tooth forces working in one direction, and one tooth force working in the opposite direction. The net result is the force of one tooth working around the periphery to rotate the output shaft.

CROSS LINE RELIEF VALVES

•• PRESSURE PORTS

•• •

•

• CASE DRAIN LINE

SWING DRIVE MOTOR

SWING MOTOR

220-D53

cushion to the high forces that occur during start and stop of the boom swing. The 2-stage relief involves increasing the relief setting by 1000 psi during swing acceleration. When coasting to a stop, the relief valve opens at a lower pressure resulting in a soft stop.

••

4. THESE TWO TEETH HAVE ONLY TANK LINE PRESSURE OPPOSING THEM. 3. PRESSURE BETWEEN TEETH IN THIS SEGMENT PUSHES BOTH WAYS AND DOES NOT AFFECT TORQUE AS OIL IS CARRIED AROUND TO OUTLET.

•

••

3. PRESSURE BETWEEN TEETH IN THIS SEGMENT PUSHES BOTH WAYS AND DOES NOT AFFECT TORQUE AS OIL IS CARRIED AROUND TO OUTLET.

•

CONNECTING HOSE FROM OIL RESERVOIR

OIL FILL TUBE

• •

•

• •

•

SWING DRIVE GEARBOX 220-D54

1. THESE TWO TEETH ARE SUBJECT TO HIGH PRESSURE AND TEND TO ROTATE GEARS IN DIRECTION OF ARROWS.

•

2. SEGMENTS OF TWO MESHING TEETH TEND TO OPPOSE ROTATION MAKING NET TORQUE AVAILABLE A FUNCTION OF ONE TOOTH.

SWING DRIVE GEARBOX

MOTOR REMOVAL NOTE: Before removing the drive motor, drain the oil from the reservoir bottle by disconnecting the hose at the oil fill tube. Replace the oil fill tube.

GEAR3 TYPICAL GEAR MOTOR A cross sectional view of an external gear hydraulic motor is shown in Figure Gear3 This design is referred to as “external gear” design because the gear teeth are machined on the outside of the gears. One of the gears is connected to an output shaft which in turn is connected to the swing drive gearbox input

IMPORTANT: Do not allow dirt to enter the gearbox during and after the motor has been removed.

After the motor has been replaced, partly fill the reservoir with correct oil. Bleed swing gearbox by loosening air bleed plug. Add oil to reservoir until half full.

15.4

Tigercat 220 Loader

Swing

SWING DRIVE GEARBOX Power is transmitted from the motor to a double reduction planetary gearbox. The swing gearbox upper gearing is lubricated by oil stored in a reservoir attached to the side of the gearbox cover.

The reservoir must remain half full of oil* at all times. The lower bearing area is lubricated by grease where the cavity is filled with grease at assembly, a grease fitting is not provided since additional greasing is not necessary.

RESERVOIR

• CONNECTING HOSE TO GEARBOX

•

SWING DRIVE LUBRICATION To drain the gearbox unscrew the drain plug and allow oil to drain into a suitable container. To facilitate draining, the oil should be warm.

206-16A

To fill the gearbox with oil, unscrew the air bleed plug located on the motor flange, remove the cap on the reservoir and add oil to the reservoir. When oil begins to come out of the air bleed hole replace the plug and continue to add oil until the reservoir is half full. Replace the cap on the reservoir.

*For correct oil specification and maintenance schedule, refer to SECTION 3 in THIS MANUAL.

TO OIL RESERVOIR

•

MOTOR MOUNTING FLANGE

• •

AIR BLEED PLUG

MOTOR DRIVE SHAFT COUPLING

UPPER GEARING AREA LUBRICATED WITH OIL

• • TWO STAGE PLANETARY GEARING

GEARBOX MOUNTING FLANGE

• •

OIL DRAIN HOSE CONNECTION

•

•

LOWER BEARING AREA FILLED WITH GREASE

DRIVE PINION

•

BK0011-5

SWING DRIVE GEARBOX 15.5

Tigercat 220 Loader

Swing

SWING CIRCUIT DESCRIPTION The swing circuit is supplied with hydraulic oil by a fixed displacement gear pump. The swing valve receives oil at the inlet section and directs it through the three open center spool sections, to the outlet section. From there it is directed back to tank via the oil cooler and return filter. A 50 psi. relief valve is installed in the oil cooler line to bypass the oil around the oil cooler, usually on cold start ups when the oil is cold and thicker.

Pressing the foot pedal in the cab directs pilot oil to either end of the swing spool section on the swing valve to shift the spool and direct hydraulic oil to the swing motor causing it to rotate either clockwise or counterclockwise.

RELIEF VALVE LOCKNUT HIGH ADJUSTER PRESSURE ADJUSTING SHIMS FOR HOSE SECOND STAGE ADDITIONAL 1000 PSI RELIEF SETTING CONNECTION (FACTORY SET)

•

•

•

AQ014-2

MOTOR CROSSLINE RELIEF VALVE

Crossline relief valves on the motor provide a cushion to the high forces that occur during start and stop of the boom swing. The crossline relief valves used on this motor are 2-stage which means that when the foot pedal is pressed and the control valve spool shifts to swing the upper frame, inertia caused by the mass of the upper frame creates a pressure increase at the inlet section of the control valve. This pressure increase is transmitted through a hose line connected to the ends of the crossline relief valves. A piston in the end of each relief valve moves to activate the high pressure relief setting to provide a faster swing acceleration time. During deceleration the relief valve opens at the low pressure setting resulting in a softer stop. Internal leakage in the swing motor is returned to tank via the case drain port on the motor, through the dual element return filter.

15.6

Tigercat 220 Loader

220-038

Swing

SWING DRIVE CIRCUIT 15.7

Tigercat 220 Loader

Swing

PRESSURE SETTINGS

6. Install a 0-5000 psi pressure gauge on the test port at the inlet section of the swing valve.

CAUTION Use caution when in the cab as a slight touch of the controls can cause sudden rotation of the upper frame and booms or movement of the stabilizers

7. Start engine and place throttle control in FULL. 8. Lower boom assembly to the ground and restrict boom swing movement in both directions.

CAUTION

9. With the aid of an assistant, Press and hold the swing foot pedal in the SWING LEFT position, check gauge pressure reading. If less than set value, turn swing left relief valve adjusting screw in until set value is obtained on gauge.

Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

WARNING

IMPORTANT

Ensure that no one is standing near the grapple during this procedure.

Approach the gauge reading slowly and deliberately by turning the adjusting screw in a little at a time. The pressure setting must not exceed the above value.

IMPORTANT Avoid blowing oil over relief for longer than five seconds, as this will cause excessive heating of the hydraulic fluid.

10. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

11. Press and hold the swing foot pedal in the SWING RIGHT position, check gauge pressure reading. If less than set value, turn swing right relief valve adjusting screw in until set value is obtained on gauge.

SET SWING RELIEF VALVES Swing main relief valve setting ........... 2600 psi Swing left port relief setting ................ 3000 psi Swing right down port relief setting ... 3000 psi

12. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

Motor crossline relief valves ............... 1750 psi 1. Position machine on flat level ground with stabilizers down.

13. Repeat steps 9 and 11 to verify settings. reset main relief valve:

2. Ensure that the hydraulic oil is at operating temperature.

14. Loosen locknut on swing main relief and unscrew adjusting screw 3 full turns.

3. Loosen locknut on the swing main relief valve and turn main relief adjusting screw all the way in, tighten locknut.

4. Turn both port relief valve adjusting screws on the swing spool section of the valve out until spring pressure is relieved then turn adjusting screws one full turn in.

RELIEF VALVE LOCKNUT HIGH ADJUSTER PRESSURE ADJUSTING SHIMS FOR HOSE SECOND STAGE ADDITIONAL 1000 PSI RELIEF SETTING CONNECTION (FACTORY SET)

•

•

•

AQ014-2

MOTOR CROSSLINE RELIEF VALVE

5. Loosen locknut on motor crossline relief valves and turn relief valve adjusters (count number of turns) all the way in, tighten locknut.

15.8

15. While holding the foot pedal in the SWING LEFT position, check gauge pressure reading. If less than set value, turn swing main relief valve adjusting screw in until set value is obtained on gauge.

16. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

Tigercat 220 Loader

Swing

SET SWING MOTOR CROSSLINE RELIEF VALVES 17. Set engine throttle control to IDLE. 18. Disconnect each hose from the ends of the crossline relief valves and install steel plugs in hose ends. Install caps on crossline relief valves. Loosen locknut and adjust crossline relief valves back to original position.

19. While holding the foot pedal in the SWING LEFT position, check gauge pressure reading. If adjustment is required turn relief valve in to increase pressure or out to decrease pressure until set value is obtained on gauge.

20. Tighten locknut on adjuster taking care not to turn the adjuster.

21. While holding the foot pedal in the SWING RIGHT position, check gauge pressure reading.

If adjustment is required turn relief valve in to increase pressure or out to decrease pressure until set value is obtained on gauge.

22. Tighten locknut on adjuster taking care not to turn the adjuster.

23. Repeat steps 18 and 21 to verify settings.

24. Stop engine. Remove pressure gauge and wipe up any excess oil from test port area.

25. Reconnect two hoses to ends of crossline relief valves.

SUMMARY: 1. Ensure hydraulic oil is at operating temperature.

2. Turn main relief on "swing" valve fully in.

3. Turn both "swing" port reliefs out.

4. Turn motor crossline relief full in.

5. Connect gauge to "swing" valve.

6. Start engine.

7. Set SWING LEFT port relief.

8. Set SWING RIGHT port relief.

9. Reset main relief.

Set swing motor crossline reliefs:10. Disconnect hoses from both crossline reliefs and plug hoses and fittings.

11. Set SWING LEFT crossline relief.

12. Set SWING RIGHT crossline relief.

13. Reconnect hoses to crossline reliefs.

15.9

Tigercat 220 Loader

Swing

15.10

Tigercat 220 Loader

SECTION 16 - STABILIZERS JANUARY, 2006

CONTENTS - SECTION 16 CIRCUIT DIAGRAM ..................................................................................... 16.9 LOWER FRAME HYDRAULIC CONNECTIONS ...................... 16.5, 16.6, 16.7 PILOT MANIFOLD ....................................................................................... 16.2 PRESSURE SETTINGS ............................................................................. 16.10 SAFE REMOVAL OF COUNTERBALANCE AND CHECK CARTRIDGE ..... 16.4 STABILIZER CIRCUIT DESCRIPTION ........................................................ 16.8 LOWERING STABILIZERS ...................................................................... 16.8 RAISING STABILIZERS ........................................................................... 16.8 STABILIZER CONTROL VALVE .................................................................. 16.2 STABILIZER CYLINDERS AND COUNTERBALANCE VALVES ................. 16.4 STABILIZER PILOT MANIFOLD .................................................................. 16.2 STABILIZER PUMP ...................................................................................... 16.2 SWING PUMP .............................................................................................. 16.2

Tigercat 220 Loader

Stabilizers

STABILIZER CIRCUIT COMPONENTS

STABILIZER CONTROL VALVE

STABILIZER PUMP

The stabilizer UP/DOWN/OFF functions are controlled by one of three spool sections in the three section "swing" control valve.

BOOM PUMPS

For a detailed description of the swing/stabilizer control valve, refer to SECTION 15 in THIS MANUAL.

STABILIZER/ SWING PUMP

'D' REAR RIGHT

•

•

'E' FRONT RIGHT

••

•

BELL HOUSING

•

•

'B' REAR LEFT

'C' FRONT LEFT

•

'A' SYSTEM PRESSURE SUPPLY

GEAR PUMP 220-050 The stabilizer pump is a fixed displacement external triple gear pump.

The stabilizer system utilizes the third gear housing from the shaft end of the pump to supply hydraulic oil to the stabilizer spool section of the swing valve.

STABILIZER MANIFOLD 220-061

This stabilizer manifold consists of an aluminum housing containing four solenoid operated valves.

Port 'A' is connected to the stabilizer control valve and supplies oil at system pressure to the four directional valves. Ports 'B', 'C', 'D' and 'E' supply oil at system pressure to the stabilizer cylinders.

PILOT MANIFOLD Two solenoid operated pilot valves (positions 5 and 6) on the pilot manifold control the UP and DOWN movement of the stabilizers.

OPERATING DESCRIPTION When any (or ALL) of the four solenoid operated valves are energized (by pressing a switch in the operator's cab), shifts one (or ALL) of the spools and connects either port 'B', 'C', 'D', 'E' (or ALL) with a counterbalance valve mounted to the base end of one of the stabilizer cylinders to raise or lower the stabilizer. When the stabilizers are stationary, the spools in the directional control valves are in the closed position.

For a detailed description of the pilot manifold refer to SECTION 5 in THIS MANUAL. STABILIZERS STABILIZERS PILOT SHUT OFF VALVE UP DOWN

• • •

PILOT RELIEF VALVE

• •

• RETURN OIL FROM STABILIZER PILOT MANIFOLD 230B-04

VIEWED FROM ABOVE

STABILIZER PILOT MANIFOLD

For a more detailed description of the triple gear pump, refer to SECTION 12 in THIS SERVICE MANUAL.

'PB' TO STABILIZER PILOT MANIFOLD

••

••

•

GAUGE TEST PORT

PILOT MANIFOLD ASSEMBLY

16.2

Tigercat 220 Loader

Stabilizers STABILIZER "UP" PORT RELIEF (2000 PSI)

EARLY MACHINES ONLY

•

GAUGE TEST PORT

SWING

DELIMBER

STABILIZER

•

•

MAIN RELIEF (2600 PSI)

• •

•

INLET SECTION

OUTLET SECTION

• STABILIZER "DOWN" PORT RELIEF (3000 PSI)

STABILIZER CONTROL VALVE

AT041ZIL

RELIEF VALVE PORT 'A'

RELIEF VALVE PORT 'B'

SEAL GROOVES

A

B SPOOL CENTERING SPRINGS

•

• • •

•

•

•

• • • PILOT END CAP

AT041YIL

•

•

• •

• SPOOL TANK PASSAGE

PARALLEL PASSAGE

LOAD CHECK VALVE

THRU' NEUTRAL PASSAGE

WORK PORT BRIDGE

CROSS SECTION OF SPOOL SECTIONS

16.3

TANK PASSAGE

PILOT END CAP

Tigercat 220 Loader

Stabilizers

STABILIZER CYLINDERS AND COUNTERBALANCE VALVES

counterbalance valve to the 'VR' port and back to tank via the stabilizer control valve.

The base end of the cylinders are connected to the lower frame of the loader and the rod end to the stabilizers. A counterbalance valve is mounted to the base end of each cylinder.

When raising the stabilizers, oil enters the 'VR' port and has free flow through the valve to the 'CB' port, to the rod end of the cylinder. The counterbalance valve is also opened via an internal pilot port which also opens the check valve to allow return oil from the base end of the cylinder to return to tank via the 'VC' port.

CHECK CARTRIDGE

COUNTERBALANCE CARTRIDGE

WARNING When the stabilizers are on the ground, Hydraulic oil in the cylinders can be under very high pressure. Never remove the check valve or the counterbalance cartridges when the stabilizers are on the ground.

275-15

STABILIZER CYLINDER COUNTERBALANCE VALVE

VERTICAL CENTERLINE

LOWER FRAME

Each counterbalance valve assembly includes a counterbalance cartridge and a "pilot-to-open" check valve cartridge. On earlier cylinders the counterbalance cartridge and the check valve cartridge were screwed directly into the base end of the cylinder but the operating function remains the same.

•

COUNTERBALANCE VALVE

•

STABILIZER UP IN VERTICAL POSITION

• • •

The purpose of the counterbalance valve assembly is to; (a) Ensure that the stabilizers remain firmly placed on the ground during the loading/unloading operation by preventing oil from leaving either end of the cylinders. (b) To prevent the raised stabilizers from falling down when transporting the loader. (c) To prevent the buildup of pressure caused by thermal expansion.

CYLINDER

230-06A

The counterbalance cartridge relief pressure range is adjustable and factory set to 1000 psi.

This relief valve will open either when system pressure is applied to the 'VC' port or when pressure in the rod end of a cylinder exceeds the 1000 psi setting.

COUNTERBALANCE/CHECK CARTRIDGE REMOVAL

SAFE REMOVAL OF COUNTERBALANCE AND CHECK CARTRIDGES If it becomes necessary to remove either the counterbalance or check cartridge from the housing, or cylinder base end on earlier machines; Raise the stabilizer until it is in the "overcenter" position and stop the engine. In this position, the weight of the stabilizer will not influence pressures in either end of the cylinder.

The "pilot-to-open" check valve cartridge cracking pressure is factory set to 30 psi. When the cylinders are in the stationary position this check valve prevents oil from leaving the cylinder base end. The check valve opens when oil is directed to the rod end of the cylinder.

If a stabilizer cannot be moved to the vertical position due to a malfunction, move the other stabilizers in conjunction with the boom so that the stabilizer pad is clear of the ground. In this position the pilot operated check valve may be removed followed by the counterbalance valve.

When lowering the stabilizers, oil enters the 'VC' port and opens the counterbalance valve via an internal pilot port, oil then opens the check valve to allow oil to flow to the base end of the cylinder.

Return oil from the rod end of the cylinder flows to the 'CB' port and through the open 16.4

Tigercat 220 Loader

220-062

Stabilizers

LOWER FRAME HYDRAULIC CONNECTIONS - BASIC LOADER 16.5

Tigercat 220 Loader

Stabilizers

220-063

LOWER FRAME HYDRAULIC CONNECTIONS - DELIMBER/SLASHER OPTION

220-064

LOWER FRAME HYDRAULIC CONNECTIONS - SELF PROPELLED OPTION 16.6

Tigercat 220 Loader

220-034

Stabilizers

LOWER FRAME HYDRAULIC CONNECTIONS - CIRCLE SAW OPTION 16.7

Tigercat 220 Loader

Stabilizers

STABILIZER CIRCUIT DESCRIPTION

manifold, through the stabilizer manifold, to the stabilizer control valve and the oil cooler.

Refer to STABILIZER CIRCUIT DIAGRAM

LOWERING STABILIZER(S)

The stabilizer circuit is supplied with hydraulic oil by a fixed displacement gear pump. The stabilizer/swing valve receives oil at the inlet section and directs it through the open center spool sections, to the outlet section. From there it is directed back to tank via the oil cooler, a check valve to the return manifold and two dual element filters, which are equipped with an internal 25 psi element bypass valve. A 50 psi. relief valve is installed in the oil cooler line to bypass the oil around the oil cooler, usually on cold start ups when the oil is cold and thicker.

Place direction switch in DOWN position. Press and hold one of the stabilizer control switches.

Electrical current will flow along wire RED 3, through a series of diodes and energize the DOWN solenoid operated pilot valve on the pilot manifold. Pilot oil will then be directed to the stabilizer control valve spool DOWN pilot end cap to shift the spool.

Current will also flow to energize a solenoid directional valve(s) on the stabilizer. In this condition, hydraulic oil will flow from the DOWN side of stabilizer control valve, through the stabilizer manifold to the rotary manifold and on to the cylinder counterbalance valve where it will be directed to the BASE end of the selected cylinder.

Return oil from the ROD end of the cylinder will be directed back to tank via the counterbalance valve, through the rotary manifold to the stabilizer control valve and the oil cooler.

Six switches on the instrument panel control the stabilizers, One 3-position switch OFF/UP/DOWN and five more switches to operate the stabilizers either ALL at the same time or each one INDIVIDUALLY. For a detailed description of these switches, refer to SECTION 2 in the OPERATOR'S MANUAL. Placing the 3-position stabilizer direction switch in the OFF position removes all current from the stabilizer circuit to prevent the stabilizers from operating. The switch should remain in this position when the stabilizers are in the stationary position, either UP or DOWN.

To raise or lower all of the stabilizers at the same time; Press direction switch, Press and hold the center 'ALL' switch, Electrical current will flow through all of the diodes to supply electrical current to all four solenoid operated directional valves on the stabilizer manifold and also through the direction switch and energize the solenoid operated pilot valve on the pilot manifold.

Hydraulic oil will then flow as described above for either UP or DOWN except that all cylinders will operate at the same time.

CAUTION When loading/unloading, the Operator must always ensure that all four stabilizers are firmly placed on the ground. Soft ground conditions can cause instability.

RAISING STABILIZER(S) Place direction switch in UP position. Press and hold one of the stabilizer control switches.

Electrical current will flow along wire RED 3, through a series of diodes and energize the UP solenoid operated pilot valve on the pilot manifold.

Pilot oil will then be directed to the stabilizer control valve spool UP pilot end cap to shift the spool.

Current will also flow to energize a solenoid directional valve(s) on the stabilizer manifold. In this condition, hydraulic oil will flow from the UP side of stabilizer control valve to the rotary manifold and on to the cylinder counterbalance valve where it will be directed to the rod end of ALL selected cylinders. Return oil from the base end of the cylinder will be directed back to tank via the counterbalance valve, through the rotary 16.8

Tigercat 220 Loader

220-065

Stabilizers

STABILIZER CIRCUIT - CIRCLE SAW SHOWN 16.9

Tigercat 220 Loader

Stabilizers

PRESSURE SETTINGS

6. Start engine and place throttle control in FULL. 7. Place stabilizer control switch in UP position.

CAUTION

8. With the aid of an assistant, Press ONE of the stabilizer switches to RAISE stabilizer. While holding stabilizer switch in UP position, check gauge pressure reading. If less than set value, turn stabilizer UP relief valve adjusting screw in until set value is obtained on gauge.

Use caution when in the cab as a slight touch of the controls can cause sudden rotation of the upper frame and booms or movement of the stabilizers

CAUTION

IMPORTANT

Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

Approach the gauge reading slowly and deliberately by turning the adjusting screw in a little at a time. The pressure setting must not exceed the above value.

IMPORTANT

9. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

Avoid blowing oil over relief for longer than five seconds, as this will cause excessive heating of the hydraulic fluid.

10. Place stabilizer control switch in DOWN position.

11. With the aid of an assistant, Press ONE of the stabilizer switches to LOWER stabilizer. While holding stabilizer switch in DOWN position, check gauge pressure reading. If less than set value, turn stabilizer DOWN relief valve adjusting screw in until set value is obtained on gauge.

SET STABILIZER RELIEF VALVES Stabilizer/"Swing" main relief valve setting .... ......................................................... 2600 psi Stabilizer up port relief setting ............ 2000 psi Stabilizer down port relief setting ....... 3000 psi Counterbalance relief valves* ............. 1000 psi

CAUTION

*NOTE: The counterbalance valve cartridge is factory set to 1000 psi, it cannot be set in the field without removing it from the cylinder and using special test equipment. If this valve is suspect, example; stabilizers will not stay in UP position, it should be replaced with a new one.

The check valve cartridge should also be replaced if faulty, example; stabilizers start to creep UP (more than normal) off ground.

1. Position machine on flat level ground with stabilizers down.

Be aware of machine stability; it may be necessary to lower all stabilizers to the end of the cylinder stroke in order to develope enough pressure to set the relief valves.

12. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

13. Repeat steps 8 and 11 to verify settings. reset main relief valve: 14. Loosen locknut on swing main relief and unscrew adjusting screw 3 full turns.

2. Ensure that the hydraulic oil is at operating temperature.

3. Loosen locknut on the "swing" main relief valve and turn main relief adjusting screw all the way in, tighten locknut.

4. Loosen locknuts on both port relief valve adjusting screws on the stabilizer spool section of the valve and turn adjusting screws out until spring pressure is relieved then turn adjusting screws one full turn in.

15. With the aid of an assistant, While holding stabilizer switch in DOWN position, check gauge pressure reading. If less than set value, turn stabilizer MAIN relief valve adjusting screw in until set value is obtained on gauge.

16. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

17. Remove pressure gauge and wipe up any spills from around gauge test port.

5. Install a 0-5000 psi pressure gauge on the test port at the inlet section of the "swing" valve.

16.10

Tigercat 220 Loader

SECTION 17 - GRAPPLE JANUARY, 2006

CONTENTS - SECTION 17 CIRCUIT DESCRIPTION ............................................................................. 17.4 CIRCUIT DIAGRAM ..................................................................................... 17.5 GRAPPLE CONNECTIONS TO BOOM ....................................................... 17.2 GRAPPLE CONTROL VALVES ................................................................... 17.2 GRAPPLE PUMP ......................................................................................... 17.2 JOYSTICK CONTROL VALVE ..................................................................... 17.2 PRESSURE SETTINGS GRAPPLE OPEN/CLOSE ......................................................................... 17.6 GRAPPLE ROTATE ................................................................................. 17.7 SUMMARY ............................................................................................... 17.8

Tigercat 220 Loader GRAPPLE SYSTEM COMPONENTS

Grapple GRAPPLE CONTROL VALVES

PUMP

The grapple open/close function is controlled by one of three spool sections in the "hoist" valve and the grapple rotate motor is controlled by one of three spool section in the "stick" valve. The control valves are located in the upper frame below the floor plates inside the valve compartment.

This is a fixed displacement external triple gear pump.

GRAPPLE PUMPS

SWING PUMP

• BELL HOUSING

•

For a detailed description of the "hoist" and "stick" control valves, refer to SECTION 12 in THIS MANUAL. GRAPPLE CONNECTIONS TO BOOM

•• ••

When a factory installed grapple is not specified, hydraulic lines are provided up to the end of the boom and sealed off with steel plugs.

GEAR PUMP The grapple circuit utilizes two of the three gear housings of this pump to supply hydraulic oil to the grapple open/close control valve spool section and the grapple rotate control valve spool section in of the "hoist" valve and the "stick" valve.

220-050

For a more detailed description of the triple gear pump, refer to SECTION 12 in THIS SERVICE MANUAL. 277-8

JOYSTICK CONTROL VALVE The grapple open/close and grapple rotate functions are controlled by the left and right joysticks which when operated send proportional pilot signals to the "hoist" and "stick" control valves to shift a spool(s) and supply system oil to the grapple open/close cylinders and the grapple rotate motor.

For a detailed description of the joystick control valve refer to SECTION 5 in THIS MANUAL.

17.2

GRAPPLE CONNECTIONS

Tigercat 220 Loader

Grapple

GRAPPLE 'CLOSE' PORT RELIEF (3000 PSI)

GRAPPLE ROTATE 'CLOCKWISE' PORT RELIEF (1750 PSI)

MAIN RELIEF (2750 PSI)

MAIN RELIEF (2750 PSI)

OUTLET SECTION

OUTLET SECTION

•

•

•

•

•

•

•

GRAPPLE ROTATE

STICK

• SAW RETRACT

DELIMBER OPEN

HOIST

GRAPPLE OPEN/ CLOSE

SAW CUT

SAW CUT

•

•

• •

GAUGE TEST PORT

GAUGE TEST PORT INLET SECTION

INLET SECTION

GRAPPLE 'OPEN' PORT RELIEF (3000 PSI)

GRAPPLE ROTATE 'COUNTERCLOCKWISE' PORT RELIEF (1750 PSI)

GRAPPLE CONTROL VALVES

AT047IL

RELIEF VALVE PORT 'A'

SEAL GROOVES

A

RELIEF VALVE PORT 'B'

B

SPOOL CENTERING SPRINGS

•

• • •

•

•

•

• •

•

• PILOT END CAP

AT047IL2

•

•

•

• SPOOL TANK PASSAGE

PARALLEL PASSAGE

LOAD CHECK VALVE

THRU' NEUTRAL PASSAGE

WORK PORT BRIDGE

CROSS SECTION OF SPOOL SECTIONS 17.3

TANK PASSAGE

PILOT END CAP

Tigercat 220 Loader

Grapple

CIRCUIT DESCRIPTION The grapple circuit is supplied with oil from two of the three gear housing sections on the main pump. The "hoist" and "stick" valves receive oil at their inlet sections and direct the oil through the three open center spool sections, to the outlet section. From there it is directed back to tank via a check valve to the return manifold and two dual element filters, which are equipped with an internal 25 psi element bypass valve.

Moving L.H. joystick in the cab will direct pilot oil to the ends of the open/close spool section in the "hoist" valve to shift the spool and direct hydraulic oil from the pump to the grapple open/close hydraulic cylinders to OPEN or CLOSE the grapple arms.

Return oil from the cylinders is directed back through the spool sections, to the outlet section, through the dual head return oil filter and back to tank.

Moving R.H. joystick in the cab will direct pilot oil to the ends of the grapple rotate spool section in the "stick" valve to shift the spool and direct hydraulic oil from the pump to the swing motor to rotate the grapple in either a CLOCKWISE or COUNTERCLOCKWISE direction.

17.4

Tigercat 220 Loader

220-066

Grapple

GRAPPLE CIRCUIT 17.5

Tigercat 220 Loader

Grapple 7. While holding the L.H. joystick in the GRAPPLE OPEN position (cylinders fully retracted), check gauge pressure reading. If less than set value, turn relief valve adjusting screw in until set value is obtained on gauge.

CAUTION Use caution when in the cab as a slight touch of the controls can cause sudden rotation of the upper frame and booms or movement of the stabilizers

IMPORTANT CAUTION

Approach the gauge reading slowly and deliberately by turning the adjusting screw in a little at a time. The pressure setting must not exceed the above value.

Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

8. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

WARNING

9. While holding the L.H. joystick in the GRAPPLE CLOSE position (cylinders fully extended), check gauge pressure reading. If less than set value, turn relief valve adjusting screw in until set value is obtained on gauge.

Ensure that no one is standing near the grapple during this procedure.

IMPORTANT Avoid blowing oil over relief for longer than five seconds, as this will cause excessive heating of the hydraulic fluid.

10. Tighten locknut on adjusting screw taking care not to turn the adjusting screw. reset main relief valve:

PRESSURE SETTINGS

11. Loosen locknut on "hoist" main relief and unscrew adjusting screw 3 full turns.

GRAPPLE OPEN/CLOSE RELIEF VALVE SETTINGS

Grapple close port relief setting ......... 3000 psi

12. While holding the L.H. joystick in the GRAPPLE CLOSE position (cylinders fully extended), check gauge pressure reading. If less than set value, turn relief valve adjusting screw in until set value is obtained on gauge.

1. Position machine on flat level ground with stabilizers down.

13. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

2. Ensure that the hydraulic oil is at operating temperature.

14. Stop engine. Remove pressure gauge and wipe up any excess oil from test port area.

Grapple open/close "Hoist" main relief setting:......................................................... 2750 psi Grapple open port relief setting .......... 3000 psi

3. Loosen the locknut on the "hoist" main relief valve and turn the relief adjusting screw all the way in, tighten locknut.

4. Loosen the locknuts on both port relief valve adjusting screws for the GRAPPLE OPEN AND GRAPPLE CLOSE spool section of the "hoist" valve and turn the adjusting screws out until spring pressure is relieved then turn adjusting screws one full turn in.

5. Connect a 0 - 5000 p.s.i. pressure gauge to the "hoist" control valve test port on the inlet section of the valve.

6. Start the engine, and put the throttle control to the FULL position.

17.6

Tigercat 220 Loader

Grapple 8. While holding the R.H. joystick in the ROTATE CLOCKWISE position, check gauge pressure reading. If less than set value, turn relief valve adjusting screw in until set value is obtained on gauge.

CAUTION Use caution when in the cab as a slight touch of the controls can cause sudden rotation of the upper frame and booms or movement of the stabilizers

IMPORTANT CAUTION

Approach the gauge reading slowly and deliberately by turning the adjusting screw in a little at a time. The pressure setting must not exceed the above value.

Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

9. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

IMPORTANT

10. While holding the R.H. joystick in the ROTATE COUNTERCLOCKWISE position, check gauge pressure reading. If less than set value, turn relief valve adjusting screw in until set value is obtained on gauge.

Avoid blowing oil over relief for longer than five seconds, as this will cause excessive heating of the hydraulic fluid.

GRAPPLE ROTATE RELIEF VALVE SETTINGS Grapple rotate/"Stick" main relief setting:-

11. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

......................................................... 2750 psi Rotate clockwise port relief setting .... 3000 psi

12. Release grapple from it's secured position. reset main relief valve:

Rotate counterclockwise port relief setting .................................. 3000 psi

13. Loosen locknut on "stick" main relief and unscrew adjusting screw 3 full turns.

1. Position machine on flat level ground with stabilizers down.

14. While holding the R.H. joystick in the STICK OUT position (fully extended), check gauge pressure reading. If less than set value, turn relief valve adjusting screw in until set value is obtained on gauge.

2. Ensure that the hydraulic oil is at operating temperature.

3. Position and secure grapple to prevent from rotating in either direction.

15. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

WARNING

16. Remove pressure gauge and wipe up any excess oil from test port area.

Ensure that no one is standing near the grapple during this procedure.

4. Loosen the locknut on the "stick" main relief valve and turn the relief adjusting screw all the way in, tighten locknut.

5. Loosen the locknuts on both port relief valve adjusting screws for the GRAPPLE ROTATE spool section of the "stick" valve and turn the adjusting screws out until spring pressure is relieved then turn adjusting screws one full turn in.

6. Connect a 0 - 5000 p.s.i. pressure gauge to the "stick" control valve test port on the inlet section of the valve.

7. Start the engine, and put the throttle control to the FULL position.

17.7

Tigercat 220 Loader SUMMARY:

Grapple

1. Ensure that hydraulic oil is at operating temperature.

2. Turn main relief on "hoist" valve fully in.

3. Turn GRAPPLE OPEN and CLOSE port reliefs on "hoist" valve out.

4. Connect gauge to "hoist" valve.

5. Start engine.

6. Set GRAPPLE OPEN port relief on "hoist" valve.

7. Set GRAPPLE CLOSE port relief on "hoist" valve.

8. Reset main relief.

Grapple rotate/"stick" valve:1. Secure grapple to prevent from rotating.

2. Ensure that hydraulic oil is at operating temperature.

3. Turn main relief on "stick" valve fully in.

4. Turn GRAPPLE ROTATE C/W and CC/W port reliefs on "stick" valve out.

5. Connect gauge to "stick" valve.

6. Set GRAPPLE ROTATE C/W port relief on "stick" valve.

7. Set GRAPPLE ROTATE CC/W port relief on "stick" valve.

8. Reset main relief.

17.8

Tigercat 220 Loader

SECTION 18 - DELIMBER/SLASHER JANUARY, 2006

CONTENTS - SECTION 18 CIRCUIT DESCRIPTION ......................................................................... 18.6 CIRCUIT DIAGRAM ............................................... 18.8, 18.11, 18.14, 18.15 CONTROL VALVE, DELIMBER (SWING VALVE) ................................... 18.2 CONTROL VALVE, DELIMBER OPEN/DUMP VALVE ............................ 18.4 CONTROL VALVE, SAWS RETRACT SLASHER CUT (STICK VALVE) ........................................................................................ 18.2 CONTROL VALVE, TOP SAW CUT (HOIST VALVE) .............................. 18.2 DELIMBER OPEN/DUMP VALVE ............................................................

DELIMBER/SLASHER CIRCUIT DESCRIPTION .....................................

DELIMBER/SLASHER CONNECTIONS ..................................................

DELIMBER/SLASHER PUMP ..................................................................

18.4 18.6 18.5 18.2

ELECTRICAL CIRCUIT ............................................................... 18.22, 18.25 HYDRAULIC CIRCUIT LOWER FRAME EARLY MACHINES ...................................................................... 18.9, 18.12 LATER MACHINES ................................................................................ 18.15 MAIN HYDRAULIC CIRCUIT UPPER FRAME EARLY MACHINES ...................................................................... 18.8, 18.11 LATER MACHINES ................................................................................ 18.14 OPEN/DUMP VALVE, DELIMBER ........................................................... 18.4 PILOT CIRCUIT - DELIMBER/SLASHER EARLY MACHINES ...................................................................... 18.6, 18.10 LATER MACHINES ................................................................................ 18.12 PILOT MANIFOLD ................................................................................... 18.2 PRESSURE SETTINGS ......................................................................... 18.16 TROUBLE SHOOTING DELIMBER RELAY CIRCUIT ........................... 18.19

Tigercat 220 Loader

Delimber/Slasher

DELIMBER/SLASHER CIRCUIT COMPONENTS

'PB' TO STABILIZER PILOT MANIFOLD

PUMP

TOP SAW CUT DELIMBER OPEN

SLASHER CUT TOP/SLASHER SAWS RETRACT

•

•

This is a fixed displacement external triple gear pump.

•

PILOT RELIEF VALVE

•

•

TOP SAW AND SLASHER CUT PUMP

PILOT SHUT OFF VALVE

•

SLASHER CUT AND SAWS RETRACT PUMP

RETURN OIL FROM STABILIZER PILOT MANIFOLD

SWING PUMP

•

•

• GAUGE TEST PORT

PILOT MANIFOLD ASSEMBLY For a detailed description of the pilot manifold refer to SECTION 5 in THIS MANUAL. 230B-04

•

•

BELL HOUSING

• ••

DELIMBER CONTROL VALVE (SWING VALVE) The delimber arms OPEN/CLOSE functions are controlled by one of three spool sections in the three section "swing" control valve.

GEAR PUMP

220-050

TOP SAW CUT CONTROL VALVE (HOIST VALVE)

The delimber and slasher circuits utilize all three gear housings of this pump to supply hydraulic oil to the three main control valve spool sections of the swing valve, hoist valve and stick valve.

The Top saw cutting function is controlled by one of three spool sections in the "hoist" control valve.

SLASHER SAW CUT AND SAWS RETRACT CONTROL VALVE (STICK VALVE)

For a more detailed description of the triple gear pump, refer to SECTION 12 in THIS SERVICE MANUAL.

The slasher saw cutting function and the retraction of both the slasher saw and the top saw are controlled by one of three spool sections in the "stick" control valve.

PILOT MANIFOLD Four solenoid operated pilot valves (positions 1, 2, 3 and 4) on the pilot manifold control the flow of pilot oil to operate the delimber, top saw and slasher saw functions.

RELIEF VALVE PORT 'A'

For a detailed description of the "swing", "hoist" and "stick" control valves, refer to SECTION 12 and 15 in THIS MANUAL.

SEAL GROOVES

RELIEF VALVE PORT 'B'

A

B SPOOL CENTERING SPRINGS

•

• • •

•

•

•

• • • PILOT END CAP

AT041YIL

•

•

• •

• SPOOL TANK PASSAGE

PARALLEL PASSAGE

LOAD CHECK VALVE

THRU' NEUTRAL PASSAGE

WORK PORT BRIDGE

CROSS SECTION OF SPOOL SECTIONS 18.2

TANK PASSAGE

PILOT END CAP

Tigercat 220 Loader TOP SAW 'CUT' PORT RELIEF (3000 PSI)

MAIN RELIEF

•

•

•

SLASHER CUT

GRAPPLE OPEN/ CLOSE

HOIST

TOP SAW CUT

SWING

STABILIZERS

DELIMBER

• •

• •

•

GRAPPLE ROTATE

•

•

•

•

MAIN RELIEF

•

•

•

SLASHER 'CUT' PORT RELIEF (3000 PSI)

STICK

MAIN RELIEF (2600 PSI)

SAW RETRACT

'SPARE' PORT RELIEF (3000 PSI)

Delimber/Slasher

•

• •

AT047IL AT041ZIL

AT047IL

OUTLET SECTION

OUTLET SECTION INLET DELIMBER 'OPEN' SECTION PORT RELIEF (3000 PSI)

GAUGE TEST PORT

INLET SECTION

OUTLET SECTION SAWS 'RETRACT' GAUGE PORT RELIEF TEST PORT (1500 PSI)

GAUGE TEST PORT INLET SECTION

SPARE PORT RELIEF (3000 PSI)

"SWING", "HOIST" AND "STICK" CONTROL VALVES - 2200111 TO 2200200

TOP SAW 'CUT' PORT RELIEF (3000 PSI)

MAIN RELIEF

SLASHER 'CUT' PORT RELIEF (3000 PSI)

•

•

•

•

• •

•

STICK

SLASHER CUT

GRAPPLE OPEN/ CLOSE

HOIST

TOP SAW CUT

SWING

STABILIZERS

•

GRAPPLE ROTATE

•

•

•

MAIN RELIEF

•

•

SAW RETRACT

MAIN RELIEF (2600 PSI)

•

• •

AT047IL AT047IL 220-067

OUTLET SECTION

OUTLET SECTION INLET SECTION

GAUGE TEST PORT

INLET SECTION

OUTLET SECTION SAWS 'RETRACT' GAUGE PORT RELIEF TEST PORT (1500 PSI)

SPARE PORT RELIEF (3000 PSI)

"SWING", "HOIST" AND "STICK" CONTROL VALVES - 2200201 AND UP 18.3

GAUGE TEST PORT INLET SECTION

Tigercat 220 Loader

Delimber/Slasher

DELIMBER OPEN/DUMP VALVE - EARLY DELIMBER OPEN/DUMP VALVE LATER MACHINES S/N 2200146 and up MACHINES S/N 2200111 TO 2200145 The delimber open/dump valve is a solenoid operated three way directional valve consisting of an aluminum valve body, a screw-in poppet type, solenoid operated valve cartridge and a screw-in check valve cartridge. On early machine the valve is located in the valve compartment.

The delimber open/dump valve on later machines is a pilot operated three way directional valve consisting of an aluminum valve body, a screw-in poppet type, pilot operated valve cartridge and a screw-in check valve cartridge. On later machines the valve is located on the lower frame.

SOLENOID VALVE CARTRIDGE "D" TO DELIMBER ARMS CYLINDER BASE END, VIA ROTARY MANIFOLD CHECK VALVE

•

•

••

"V" SUPPLY FROM DELIMBER VALVE (SWING VALVE) "T" TANK LINE TO STICK VALVE OUTLET SECTION

240B-D25

••

DELIMBER OPEN/DUMP VALVE LATER MACHINES

•

DELIMBER OPEN/DUMP VALVE EARLY MACHINES

DELIMBER OPEN/DUMP VALVE SCHEMATIC LATER MACHINES In the neutral position with the pilot de-activated, port 'D' is open to tank port 'T', allowing oil to flow from the base end of the delimber arms cylinder and "dump" to tank. An orifice in the connecting port controls the flow of this return oil so that the delimber arms do not CLOSE too fast.

240B-027

230B-25

DELIMBER OPEN/DUMP VALVE SCHEMATIC EARLY MACHINES

In the neutral position with the solenoid deenergized, port 'D' is open to tank port 'T', allowing oil to flow from the base end of the delimber arms cylinder and "dump" to tank. An orifice in the connecting port controls the flow of this return oil so that the delimber arms do not CLOSE too fast.

When the LH. joystick switch is pressed to OPEN the delimber arms, the solenoid on the open/dump valve is energized to block the connection between ports 'D' and 'T' and instead allow system oil to flow from port 'V', "through" the check valve to port 'D' to the base end of the cylinder to open the delimber arms.

When the LH. joystick switch is pressed to OPEN the delimber arms, a solenoid on the pilot valve directs pilot oil to the valve cartridge on the open/ dump valve shifting the valve cartridge to block the connection between ports 'D' and 'T' and instead allow system oil to flow from port 'V', "through" the check valve to port 'D' to the base end of the cylinder to open the delimber arms.

The purpose of the valve in the circuit is to direct hydraulic oil either to or from the base end of the delimber arms cylinder to open or close the delimber arms. An accumulator in the hydraulic system of the delimber builds up enough pressure to act on the ROD end of the delimber cylinders to close the delimber arms.

18.4

Tigercat 220 Loader

Delimber/Slasher

DELIMBER/SLASHER CONNECTIONS Hydraulic connections for the delimber and the slasher are located on the lower frame. The delimber connections, located at the front of the lower frame and accessed from below, consist of three No.12 JIC elbows and one No. 16 JIC elbow. The slasher connections, located at the rear of the lower frame consist of two No. 16 JIC fittings and one No. 12 JIC fitting. All fittings are capped when not in use with special steel caps to prevent leakage. Always ensure caps are tightly in place when not operating a delimber or slasher.

When making the hydraulic connection to either the delimber or the slasher, it is very important to clean around the fittings before disconnecting them to prevent dirt from entering the system.

IMPORTANT Always check hydraulic oil level after connecting and running the delimber and/or slasher.

DELIMBER OPEN

TANK

TOP SAW CUT

TOP SAW RETRACT

TOP SAW CUT

•• •

••

•

• TANK

••

•

DELIMBER CONNECTIONS EARLY MACHINES

277-3

DELIMBER OPEN

240B-039

DELIMBER CONNECTIONS LATER MACHINES

SLASHER RETRACT

TANK

SLASHER CUT

•• •

•

275-16 SLASHER CONNECTIONS For information on the DELIMBER or SLASHER, please refer to the MANUFACTURERS MANUAL.

18.5

TOP SAW RETRACT

••

Tigercat 220 Loader

Delimber/Slasher

DELIMBER/SLASHER CIRCUIT DESCRIPTION

Close delimber arms; Push RIGHT side of L.H. Joystick switch, Current flows through wire 86 (96 on later machines) and energizes DELIMBER CLOSE RELAY (6).

REFER TO CIRCUIT DIAGRAMS The delimber/slasher circuit is supplied with hydraulic oil by a fixed displacement gear pump.

One spool section in each of the three main control valves hydraulically control all of the delimber or slasher functions. The three main control valves each receive oil at their inlet sections, that is directed through the three open center spool sections, to the outlet sections. Oil from the hoist and stick valves it is directed back to tank via a return manifold and a dual element filter, which is equipped with an internal 25 psi element bypass valve. Oil from the swing valve is directed back to tank via the oil cooler to a single element filter also equipped with an internal 25 psi element bypass valve.

In this condition oil from the base end of the DELIMBER ARMS CYLINDER is returned to tank via the DELIMBER OPEN/DUMP VALVE, due to oil entering the rod end of the cylinders from the DELIMBER ACCUMULATOR to close the arms.

Cut with delimber top saw; Push RIGHT side of L.H. Joystick switch, Push LEFT side of R.H. joystick switch, Current flows through wire 87 (97 on later machines), through contacts on SAW CUT RELAY (8), wire 41 and energizes TOP SAW SOLENOID valve on pilot manifold.

Pilot oil flows through the TOP SAW solenoid pilot valve to shift the spool in the TOP SAW (hoist valve) to allow system oil to flow through the ROTARY MANIFOLD to the TOP SAW MOTOR and the rod end of the TOP SAW CYLINDER to run the saw motor and cut with the saw bar.

Two 3-position joystick switches and three relays (numbers 6, 7 and 8) electrically control the delimber and slasher functions:Open delimber arms; Push LEFT side of L.H. Joystick switch, Current flows through wires 18 to energize a DELIMBER OPEN SOLENOID valve on the pilot manifold and allow pilot oil to shift the spool in the delimber spool section of the swing valve and direct system oil to the delimber arms cylinders. Current also flows through wire 18 to energize the DELIMBER OPEN RELAY (7) and allow current to energize the DELIMBER OPEN/ DUMP VALVE SOLENOID. This will allow system oil from the delimber spool section of the swing valve to flow through the ROTARY MANIFOLD to the base end of the DELIMBER ARM CYLINDERS to open the arms.

Cut with slasher saw; Push LEFT side of L.H. Joystick switch, Push LEFT side of R.H. joystick switch, Current flows from L.H. joystick switch through wire 18 and 19, to energize SAW CUT RELAY (8). Current also flows from R.H. joystick switch through wire 87 (97 on later machines), the SAW CUT RELAY CONTACTS (8) and wire 39, to energize SLASHER CUT solenoid valve on pilot manifold.

Pilot oil flows through the SLASHER CUT solenoid pilot valve on the pilot manifold to shift the spool in the SAW RETRACT/SLASHER CUT (stick valve) to allow system oil to flow through the ROTARY MANIFOLD to the SLASHER SAW MOTOR and the rod end of the BAR CYLINDER to run the saw motor and cut with the saw bar.

Current also flows via the contacts of DELIMBER CLOSE RELAY (6) through wire 88 and jumper wire 19 to "latch" RELAY (7) in the energized position so that the joystick switch may be released to the spring return center position while the delimber arms remain in the OPEN position. A diode in diode module #1 in wire 18 prevents the current from traveling back to the joystick switch and also the DELIMBER OPEN SOLENOID valve on the pilot manifold, which was de-energized when the joystick switch was released.

Retract delimber top saw and/or slasher saw; Push RIGHT side of R.H. joystick switch, Current flows through wire 40 and energizes TOP SAW/ SLASHER SAW RETRACT solenoid valve on pilot manifold.

Pilot oil flows through the TOP SAW/SLASHER SAW RETRACT solenoid pilot valve to shift the spool in the SAW RETRACT VALVE (stick valve) to allow system oil to flow through the ROTARY MANIFOLD to the base end of the TOP SAW BAR CYLINDER and the SLASHER SAW CYLINDER base end to retract the saw bar(s).

The pilot line connected to the SPARE spool section end cap (opposite the DELIMBER end cap) is a "vent" to allow the spool to shift when pilot pressure is applied to the DELIMBER pilot end cap.

18.6

Tigercat 220 Loader

220-046

Delimber/Slasher

PILOT CIRCUIT - DELIMBER/SLASHER EARLY MACHINES - SERIAL NUMBER 2200111 TO 2200145 18.7

Tigercat 220 Loader

220-045

Delimber/Slasher

DELIMBER/SLASHER MAIN HYDRAULIC CIRCUIT UPPER FRAME EARLY MACHINES - SERIAL NUMBER 2200111 TO 2200145 18.8

Tigercat 220 Loader

Delimber/Slasher

DELIMBER/SLASHER HYDRAULIC CIRCUIT LOWER FRAME EARLY MACHINES - SERIAL NUMBER 2200111 TO 2200145 220-042

18.9

Tigercat 220 Loader

220-046

Delimber/Slasher

PILOT CIRCUIT - DELIMBER/SLASHER EARLY MACHINES - SERIAL NUMBER 2200146 TO 2200200 18.10

Tigercat 220 Loader

220-045

Delimber/Slasher

DELIMBER/SLASHER MAIN HYDRAULIC CIRCUIT UPPER FRAME EARLY MACHINES - SERIAL NUMBER 2200146 TO 2200200 18.11

Tigercat 220 Loader

Delimber/Slasher

DELIMBER/SLASHER HYDRAULIC CIRCUIT LOWER FRAME EARLY MACHINES - SERIAL NUMBER 2200146 TO 2200200 220-042

18.12

Tigercat 220 Loader

220-016

Delimber/Slasher

PILOT CIRCUIT - DELIMBER/SLASHER LATER MACHINES - SERIAL NUMBER 2200201 AND UP 18.13

Tigercat 220 Loader

Delimber/Slasher

DELIMBER/SLASHER MAIN HYDRAULIC CIRCUIT UPPER FRAME LATER MACHINES - SERIAL NUMBER 2200201 AND UP 220-040

18.14

Tigercat 220 Loader

220-043

Delimber/Slasher

DELIMBER/SLASHER HYDRAULIC CIRCUIT LOWER FRAME LATER MACHINES - SERIAL NUMBER 2200201 AND UP 18.15

Tigercat 220 Loader

Delimber/Slasher

PRESSURE SETTINGS FOR TOP SAW CUT, SLASHER CUT AND DELIMBER

4. Loosen the locknut on port relief valve adjusting screw for the TOP SAW CUT spool section of the "hoist" valve and turn the adjusting screw out until spring pressure is relieved then turn adjusting screw one full turn in.

CAUTION Use caution when in the cab as a slight touch of the controls can cause sudden rotation of the upper frame and booms or movement of the stabilizers

5. Connect a 0 - 5000 psi.. pressure gauges to the "hoist" control valve test port on the inlet section of the valve.

6. Start the engine, and put the throttle control to the FULL position.

CAUTION

7. While holding the R.H. joystick switch in the SAW EXTEND position, check gauge pressure reading at "hoist" valve test connection. If less than set value, turn TOP SAW CUT port relief valve adjusting screw in until set value is obtained on gauge.

Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

WARNING

8. Tighten locknut on adjusting screw taking care not to turn the adjusting screw. TOP SAW CUT port relief on "hoist" valve is now set.

Ensure that no one is standing near the grapple during this procedure.

NOTE: The SPARE port relief is not used, it is factory set to 3000 psi and serves only as a plug. The pilot line connected to the spool section pilot end cap is a "vent" to allow the spool to shift when pilot pressure is applied to the opposite end.

IMPORTANT Avoid blowing oil over relief for longer than five seconds, as this will cause excessive heating of the hydraulic fluid.

NOTE: The Delimber and/or Slasher hydraulic hoses must be disconnected at the loader bulkhead connections before carrying out the following procedure. Cap the hoses to keep clean and use the appropriate steel caps on the bulkhead fittings to prevent leakage during the pressure setting procedure.

RELIEF VALVE SETTINGS TOP SAW CUT (HOIST VALVE)

reset main relief valve: 9. Loosen locknut on "hoist" main relief and unscrew adjusting screw 3 full turns.

10. While holding the L.H. joystick in the HOIST UP position (fully extended), check HOIST gauge pressure reading. If less than set value, turn "hoist" main relief valve adjusting screw in until set value is obtained on gauge.

11. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

Top saw cut/"Hoist" main relief setting:......................................................... 2750 psi Top saw cut port relief setting ............ 3000 psi

12. Stop engine, remove pressure gauges and wipe up any excess oil from test port area.

Spare port relief setting ....................... 3000 psi 1. Position machine on level ground with stabilizers down.

2. Ensure that the hydraulic oil is at operating temperature.

3. Loosen the locknut on the "hoist" main relief valve and turn the relief adjusting screw all the way in, tighten locknut.

18.16

Tigercat 220 Loader

Delimber/Slasher

RELIEF VALVE SETTINGS SLASHER CUT, SAW RETRACT (STICK VALVE) Slasher cut/"Stick" main relief setting:......................................................... 2750 psi Slasher cut port relief setting ............. 3000 psi Saw retract port relief setting ............. 1500 psi

10. Tighten locknut on adjusting screw taking care not to turn the adjusting screw. SAW RETRACT port relief on "stick" valve is now set. reset main relief valve: 11. Loosen locknut on "stick" main relief and unscrew adjusting screw 3 full turns.

12. While holding the R.H. joystick in the STICK OUT position (fully extended), check STICK gauge pressure reading. If less than set value, turn "stick" main relief valve adjusting screw in until set value is obtained on gauge.

1. Position machine on level ground with stabilizers down.

2. Ensure that the hydraulic oil is at operating temperature.

3. Loosen the locknut on the "stick" main relief valve and turn the relief adjusting screw all the way in, tighten locknut.

13. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

4. Loosen the locknuts on port relief valve adjusting screws for the SLASHER CUT and SAW RETRACT spool section of the "stick" valve and turn the adjusting screw out until spring pressure is relieved then turn adjusting screw one full turn in.

RELIEF VALVE SETTINGS DELIMBER ARMS (SWING VALVE)

5. Connect a 0 - 5000 psi.. pressure gauges to the "stick" control valve test port on the inlet section of the valve.

6. Start the engine, and put the throttle control to the FULL position.

7. While holding the L.H. joystick switch in the DELIMBER OPEN position and the R.H. joystick switch in the SAW EXTEND position, check gauge pressure reading at "stick" valve test connection. If less than set value, turn SLASHER CUT port relief valve adjusting screw in until set value is obtained on gauge.

8. Tighten locknut on adjusting screw taking care

14. Stop engine, remove pressure gauges and wipe up any excess oil from test port area.

Delimber/"Swing" main relief setting:- .. 2600 psi Delimber open port relief setting:- ...... 3000 psi Spare port relief setting:- ..................... 3000 psi 1. Position machine on level ground with stabilizers down.

2. Ensure that the hydraulic oil is at operating temperature.

3. Loosen the locknut on the "swing" main relief valve and turn the relief adjusting screw all the way in, tighten locknut.

4. Loosen the locknut on the delimber port relief valve adjusting screw and turn the adjusting screw out until spring pressure is relieved then turn adjusting screw one full turn in.

5. Connect a 0 - 5000 psi.. pressure gauge to the "swing" control valve test ports on the inlet section of the valve.

IMPORTANT Approach the gauge reading slowly and deliberately by turning the adjusting screw in a little at a time. The pressure setting must not exceed the above value.

6. Start the engine, and put the throttle control to the FULL position.

not to turn the adjusting screw. SLASHER CUT port relief on "stick" valve is now set.

9. While holding the R.H. joystick switch in the SAW RETRACT position, check gauge pressure reading at "stick" valve test connection. If less than set value, turn SAW RETRACT port relief valve adjusting screw in until set value is obtained on gauge.

7. While holding the L.H. joystick switch in the DELIMBER OPEN position, check gauge pressure reading at "swing" valve test connection. If less than set value, turn DELIMBER port relief valve adjusting screw in until set value is obtained on gauge.

18.17

Tigercat 220 Loader

Delimber/Slasher

8. Tighten locknut on adjusting screw taking care not to turn the adjusting screw. DELIMBER port relief on "swing" valve is now set.

NOTE: The SPARE port relief is not used, it is factory set to 3000 psi and serves only as a plug. The pilot line connected to the spool section pilot end cap is a "vent" to allow the spool to shift when pilot pressure is applied to the opposite end. reset main relief valves: 9. Loosen locknut on "swing" main relief and unscrew adjusting screw 3 full turns.

SUMMARY: 1. Disconnect Delimber and Slasher hoses from Loader.

2. Ensure hydraulic oil is at operating temperature.

Top saw cut/"hoist" valve:3. Turn main relief on "hoist" valve fully in.

4. Turn TOP SAW CUT port reliefs on "hoist" valve out.

5. Connect gauge to "hoist" valve.

6. Start engine.

7. Set TOP SAW CUT port relief on "hoist" valve.

10. While holding the L.H. joystick switch in the 8. Re-set main relief.

DELIMBER OPEN position, check gauge Slasher cut, saw retract/"stick" valve:pressure reading. If less than set value, turn "swing" main relief valve adjusting screw in until 1. Turn main relief on "stick" valve fully in. set value is obtained on gauge.

2. Turn SLASHER CUT and SAW RETRACT port 11. Tighten locknut on adjusting screw taking care reliefs on "stick" valve out. not to turn the adjusting screw.

3. Connect gauge to "stick" valve.

12. Stop engine, remove pressure gauges and wipe 4. Start engine. up any excess oil from test port area.

5. Set SLASHER CUT port relief on "stick" valve.

13. Re-connect delimber and slasher hoses to bulkhead fittings on loader.

6. Set SAW RETRACT port relief on "stick" valve.

7. Re-set main relief.

Delimber/"swing" valve:1. Connect gauge to "swing" valve.

2. Turn main relief fully in.

3. Turn DELIMBER port relief out.

4. Set DELIMBER port relief.

5. Re-set "swing" main relief.

6. Stop engine.

7. Remove all gauges.

8. Re-connect Delimber and Slasher units to Loader.

18.18

Tigercat 220 Loader

Delimber/Slasher

TROUBLESHOOTING DELIMBER RELAY CIRCUIT If an electrical problem is suspected, the operation of the joystick switches and the delimber relays can be verified with the following procedure.

1. With the delimber arms switch in OPEN position, voltage should be present at wires 18 and 19; if so, go to step 2. If voltage is not present in wire 18, operate the joystick switch in the other direction (ARMS CLOSE) and check wire 86/96. If voltage is present at wire 86/96, there may be problem in the joystick switch or in wire 18 from the joystick switch to the instrument panel. If voltage is not present in wire 86/96, check for voltage at wire 15 in the instrument panel. If voltage is not present at wire 15, check 15 amp fuse; if voltage is present at wire 15, check joystick switch and wiring to switch.

2. With the delimber arms switch RELEASED to center position, voltage should still be present at wire 19 but not at wire 18. If this is the case go to step 3. If voltage is present at wire 18, check diode module no. 1. If voltage is not present at wire 19, check relays 6 & 7.

3. With the delimber arms switch in CLOSED position, voltage should be present at wire 86/ 96 and voltage at wire 19 will drop to zero. If voltage on wire 19 does not drop to zero, check relay 6 for operation.

4. With the delimber arms switch RELEASED to center position, voltage will drop to zero on wire 86/96 and will remain at zero on wire 19. If this does not happen suspect the joystick switch.

5. With the delimber arms switch in CLOSED position and the saw switch in the CUT (SAW EXTEND) position, voltage should be present at wire 41. If this is not the case, recheck voltage in wire 19 and, if it is not present, check relay 8 for proper operation.

6. With the delimber arms switch in OPEN position and the saw switch in the CUT position, voltage should be present in wire 39.

If voltage is not present in wire 39, check wire 19 which should have voltage, if this is the case check relay 8 for proper operation.

7. When the saw switch is in the RETRACT position, voltage should be present in wire 40 regardless of the delimber arms position.

18.19

Tigercat 220 Loader

Delimber/Slasher

FUSE, RELAY AND DIODE PANEL - CAB BASIC MACHINES SERIAL NUMBER 2200111 TO 2200200 42

220-D12

BASIC FUSE, RELAY AND DIODE PANEL - CAB ~ (2200111 TO 2200200)

1

RELAY 1

RELAY 1A

RELAY 2

RELAY 3

RELAY 4

STOP BUZZER

WARNING BUZZER

PILOT LOCK-OUT

A/CHEATER

LOW HYD. OIL

2 3 4 5

RELAY 5

RELAY 6

RELAY 7

RELAY 8

WORK LIGHTS

DELIMBER CLOSE

DELIMBER OPEN

SAW CUT

DIODE MODULE 1

DIODE MODULE 2

DIODE MODULE 3

DIODE MODULE 4

DIODE MODULE 5

DIODE MODULE 6

DIODE MODULE 7

6

ENGINE DIAGNOSTICS CONNECTOR

7

GAUGES 5A SAFETY 15A KEY INPUT 5A JOYSTICKS 15A STABILIZERS 15A WIPER/WASH 15A SPARE

8 RADIO/DOME 15A 9 LIGHTER 20A 10 HORN 20A 11 AC/HEATER 25A 12 WORK LIGHTS 20A 13 SERV. LIGHT/ DIAG. 10A 14 AUX. POWER 20A

19739B R1

18.20

Tigercat 220 Loader

Delimber/Slasher

FUSE, RELAY AND DIODE PANEL - CAB ~ BASIC MACHINES SERIAL NUMBER 2200201 AND UP

220-D43

BASIC FUSE, RELAY AND DIODE PANEL - CAB ~ (2200201 AND UP)

24952B R1

18.21

Tigercat 220 Loader

Delimber/Slasher

DELIMBER/SLASHER CIRCUIT AT REST EARLY MACHINES (2200111 TO 2200200) 230B-19

OPEN DELIMBER ARMS EARLY MACHINES (2200111 TO 2200200) 230B-20

18.22

Tigercat 220 Loader

Delimber/Slasher

CLOSE DELIMBER ARMS EARLY MACHINES (2200111 TO 2200200) 230B-21

CUT WITH DELIMBER TOP SAW EARLY MACHINES (2200111 TO 2200200) 230B-22

18.23

Tigercat 220 Loader

Delimber/Slasher

CUT WITH SLASHER SAW EARLY MACHINES (2200111 TO 2200200) 230B-23

RETRACT DELIMBER TOP SAW AND SLASHER SAW EARLY MACHINES (2200111 TO 2200200) 230B-24

18.24

Tigercat 220 Loader

Delimber/Slasher

DELIMBER/SLASHER CIRCUIT AT REST LATER MACHINES (2200201 AND UP) 220-071

OPEN DELIMBER ARMS LATER MACHINES (2200201 AND UP) 220-072

18.25

Tigercat 220 Loader

Delimber/Slasher

CLOSE DELIMBER ARMS LATER MACHINES (2200201 AND UP) 220-073

SAWS CUT LATER MACHINES (2200201 AND UP) 220-074

18.26

Tigercat 220 Loader

Delimber/Slasher

RETRACT DELIMBER TOP SAW AND SLASHER SAW LATER MACHINES (2200201 AND UP) 220-075

18.27

Tigercat 220 Loader

Delimber/Slasher

18.28

Tigercat 220 Loader

SECTION 19 - Circle Saw JANUARY, 2006

CONTENTS - SECTION 19 BUTT BOARD/HOIST/ GRAPPLE CONTROL VALVE ............................. 19.3 CIRCLE SAW CIRCUIT COMPONENTS ................................................. 19.2 CIRCLE SAW CONNECTIONS ................................................................ 19.4 CIRCLE SAW MOTOR CONTROL VALVE ..................................... 19.3, 19.8 ELECTRICAL DIAGRAM - CIRCLE SAW ................................................ 19.7 LOWER FRAME HYDRAULIC CONNECTIONS ...................................... 19.4 MAIN HYDRAULIC CIRCUIT ................................................................... 19.5 MAIN VALVES .......................................................................................... 19.8 PILOT CIRCUIT - CIRCLE SAW .............................................................. 19.6 PRESSURE SETTINGS ........................................................................... 19.9 SWING/STABLIZER/SAW CUT/RETRACT CONTROL VALVE .............. 19.3

Tigercat 220 Loader

Circle Saw CIRCLE SAW MOTOR CONTROL VALVE

CIRCLE SAW CIRCUIT COMPONENTS PUMP

The circle saw motor function is controlled by this single spool section control valve.

This is a fixed displacement external quadruple gear pump.

BUTT BOARD CONTROL VALVE (HOIST VALVE) The Butt Board function is controlled by one of three spool sections in the "hoist" control valve.

SAW CUT AND SAW RETRACT CONTROL VALVE (STABILIZERS/SWING VALVE)

BOOM PUMPS

The circle saw cutting function and the retraction of the saw are controlled by one of three spool sections in the "swing" control valve.

SWING PUMP

•• CIRCLE SAW PUMP

•

••

For a detailed description of the "swing", "saw" and "stabilizer" control valve, refer to SECTION 15 in THIS MANUAL.

•

GEAR PUMP

220-050

The circle saw circuits utilize all four gear housings of this pump to supply hydraulic oil to the main control valve spool sections of the swing valve, hoist valve, stick valve, circle saw valve and motor .

For a more detailed description of the gear pump, refer to SECTION 12 in THIS SERVICE MANUAL. PILOT MANIFOLD Four solenoid operated pilot valves (positions 1, 2, 3 and 4) on the pilot manifold control the flow of pilot oil to operate the butt board, saw cut and saw retract functions.

'PB' TO STABILIZER PILOT MANIFOLD

SAW RETRACT BUTT BOARD DOWN BUTT BOARD UP SAW CUT PILOT SHUT OFF VALVE

•

•

•

•

•

PILOT RELIEF VALVE

• •

• RETURN OIL FROM STABILIZER PILOT MANIFOLD

•

GAUGE TEST PORT

230B-04 PILOT MANIFOLD ASSEMBLY For a detailed description of the pilot manifold refer to SECTION 5 in THIS MANUAL.

19.2

Tigercat 220 Loader

Circle Saw

SAW 'RETRACT' PORT RELIEF (2000 PSI)

BUTT BOARD PORT RELIEF (2000 PSI)

SAW RETURN PORT RELIEF (3000 PSI)

•

•

•

•

•

•

•

CIRCLE SAW

GRAPPLE OPEN/ CLOSE

HOIST

•

BUTT BUTT BOARD BOARD UP DOWN

SWING

STABILIZERS

CIRCLE SAW

•

•

•

•

MAIN RELIEF (2500 PSI)

MAIN RELIEF (2750 PSI)

MAIN RELIEF (2600 PSI)

• •

•

•

220-033

AT047IL

AT041ZIL

OUTLET SECTION

OUTLET SECTION INLET SECTION

GAUGE TEST PORT

SAW 'CUT' PORT RELIEF (2000 PSI)

SWING/STABLIZER/SAW CUT/ RETRACT CONTROL VALVE

INLET SECTION

GAUGE TEST PORT

OUTLET SECTION SAW PRESSURE PORT RELIEF (3000 PSI)

BUTT BOARD PORT RELIEF (2000 PSI)

BUTT BOARD/HOIST/ GRAPPLE CONTROL VALVE

RELIEF VALVE PORT 'A'

CIRCLE SAW MOTOR CONTROL VALVE

SEAL GROOVES

RELIEF VALVE PORT 'B'

A

B SPOOL CENTERING SPRINGS

•

• • •

•

•

•

• • • PILOT END CAP

AT041YIL

•

•

• •

• SPOOL TANK PASSAGE

PARALLEL PASSAGE

LOAD CHECK VALVE

THRU' NEUTRAL PASSAGE

WORK PORT BRIDGE

CROSS SECTION OF SPOOL SECTIONS 19.3

TANK PASSAGE

PILOT END CAP

Tigercat 220 Loader

Circle Saw

CIRCLE SAW CONNECTIONS

IMPORTANT

Hydraulic hoses for the circle saw motor, butt board and saw cut/retract are bundled up and placed in the lower frame. The hose connections are labeled as follows: Butt Board Up (No. 08 JIC fitting) Butt Board Down (No. 08 JIC fitting) Case Drain (No. 08 JIC fitting) Saw Motor (No. 16 JIC fitting) Tank (No. 16 JIC fitting) Slasher Retract (No. 08 JIC fitting) Slasher Cut (No. 08 JIC fitting)

Always check hydraulic oil level after connecting and running the circle saw motor, butt board and saw cut/retract.

All fittings are capped when not in use with special steel caps to prevent leakage. Always ensure caps are tightly in place when not operating the circle saw motor, butt board or saw cut/retract. When making the hydraulic connections to either the circle saw motor, butt board and saw cut/retract, it is very important to clean around the fittings before connecting or disconnecting them to prevent dirt from entering the system.

For information on the circle saw motor, butt board and saw cut/retract, please refer to the MANUFACTURERS MANUAL.

220-034A

LOWER FRAME HYDRAULIC CONNECTIONS 19.4

Tigercat 220 Loader

220-035

Circle Saw

MAIN HYDRAULIC CIRCUIT - CIRCLE SAW 19.5

Tigercat 220 Loader

220-017

Circle Saw

PILOT CIRCUIT - CIRCLE SAW 19.6

Tigercat 220 Loader

220-036

Circle Saw

CIRCLE SAW - ELECTRICAL DIAGRAM 19.7

Tigercat 220 Loader

220-D51

220-D51

Circle Saw

MAIN VALVES

CIRCLE SAW MOTOR CONTROL VALVE 19.8

Tigercat 220 Loader

Circle Saw

PRESSURE SETTINGS FOR CIRCLE SAW MOTOR, SAW CUT/ RETRACT AND BUTT BOARD

4. Connect a 0 - 5000 psi. pressure gauge to the "Circle Saw Motor" control valve test port on the inlet section of the valve.

5. Start the engine, and put the throttle control to the FULL position.

CAUTION

6. Depress the Circle Saw switch (on the switch panel) to the forward ON position, check gauge pressure reading at "Circle Saw Motor" valve test connection. If adjustment is required, lossen locknut and turn port relief valve adjusting screw in to increase pressure or out to decrease pressure until set value is obtained on gauge.

Use caution when in the cab as a slight touch of the controls can cause sudden rotation of the upper frame and booms or movement of the stabilizers

CAUTION Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

7. Tighten locknut on adjusting screw taking care not to turn the adjusting screw. Circle Saw Motor drive pressure port relief valve is now set.

WARNING

NOTE: The return port relief is not used, it is factory set to 3000 psi and serves only as a plug. The pilot line connected to the spool section pilot end cap is a "vent" to allow the spool to shift when pilot pressure is applied to the opposite end.

Ensure that no one is standing near the grapple during this procedure.

IMPORTANT Avoid holding oil pressure over relief for longer than five seconds, as this will cause excessive heating of the hydraulic fluid.

Reset main relief valve:

NOTE:

8. Loosen locknut on "Circle Saw Motor Valve" main relief and unscrew adjusting screw 3 full turns.

The Butt Board, Saw Motor and Saw Cut/Retract hydraulic hoses must be disconnected at the loader connections before carrying out the following procedure. Cap the hoses to keep clean and use the appropriate steel caps on the fittings to prevent leakage during the pressure setting procedure.

9. Depress the Circle Saw switch (on the switch panel) to the forward ON position, check gauge pressure reading at "Circle Saw Motor" valve test connection. If less than set value, turn main relief valve adjusting screw in until set value is obtained on gauge.

RELIEF VALVE SETTINGS CIRCLE SAW MOTOR VALVE

10. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

Circle saw motor valve main relief setting:-

11. Procede to Saw Cut/Saw Retract Relief Valve Setting, or if no further testing is required, stop engine, remove pressure gauges and wipe up any excess oil from test port area. Clean hoses and fittings and re-connect Butt Board, Saw Motor and Saw Cut/Retract units to Loader.

................................................................ 2500 psi Pressure port relief setting.................. 3000 psi Spare port relief setting ....................... 3000 psi 1. Position machine on level ground with stabilizers down.

2. Ensure that the hydraulic oil is at operating temperature.

3. Loosen the locknut on the "Circle Saw Motor" main relief valve and turn the relief adjusting screw all the way in, tighten locknut.

19.9

Tigercat 220 Loader

Circle Saw

RELIEF VALVE SETTINGS SAW CUT, SAW RETRACT (SWING VALVE) Saw cut/"Swing" main relief setting:- ...... 2600 psi Saw cut port relief setting ................... 2000 psi Saw retract port relief setting ............. 2000 psi 1. Position machine on level ground with stabilizers down.

11. Procede to Butt Board Relief Valve Settings or if no further testing is required, stop engine, remove pressure gauges and wipe up any excess oil from test port area. Clean hoses and fittings and re-connect Butt Board, Saw Motor and Saw Cut/Retract units to Loader.

RELIEF VALVE SETTINGS BUTT BOARD UP/DOWN (HOIST VALVE)

2. Ensure that the hydraulic oil is at operating temperature and that the AUTO RETRACT switch is OFF.

Butt Board/"Hoist" main relief setting:- .. 2750 psi Butt Board Up port relief setting .......... 2000 psi

3. Connect a 0 - 5000 psi. pressure gauge to the "swing" control valve test port on the inlet section of the valve.

4. Start the engine, and put the throttle control to the FULL position.

5. While holding the R.H. joystick switch in the SAW CUT position, check gauge pressure reading at "swing" valve test connection. If adjustment is required, lossen locknut and turn port relief valve adjusting screw in to increase pressure or out to decrease pressure until set value is obtained on gauge.

6. Tighten locknut on adjusting screw taking care not to turn the adjusting screw. SAW CUT port relief on "swing" valve is now set.

7. While holding the R.H. joystick switch in the SAW RETRACT position, check gauge pressure reading at "swing" valve test connection. If adjustment is required, lossen locknut and turn port relief valve adjusting screw in to increase pressure or out to decrease pressure until set value is obtained on gauge.

Butt Board Down port relief setting ..... 2000 psi 1. Position machine on level ground with stabilizers down.

2. Ensure that the hydraulic oil is at operating temperature.

3. Connect a 0 - 5000 psi. pressure gauge to the "hoist" control valve test port on the inlet section of the valve.

4. Start the engine, and put the throttle control to the FULL position.

5. While holding the L.H. joystick switch (left push button) in the Butt Board Up position, check gauge pressure reading at "hoist" valve test connection. If adjustment is required, lossen locknut and turn port relief valve adjusting screw in to increase pressure or out to decrease pressure until set value is obtained on gauge.

6. Tighten locknut on adjusting screw taking care not to turn the adjusting screw. Butt Board Up port relief on "hoist" valve is now set.

7. While holding the L.H. joystick switch (right push button) in the Butt Board Down position, check gauge pressure reading at "hoist" valve test connection. If adjustment is required, Check main relief valve: lossen locknut and turn port relief valve adjusting screw in to increase pressure or out to 9. Select stabilizer ALL and hold stabilizer UP decrease pressure until set value is obtained on switch in the UP position, check gauge pressure gauge. reading at "swing" valve test connection. If adjustment is required, lossen locknut and turn 8. Tighten locknut on adjusting screw taking care main relief valve adjusting screw in to increase not to turn the adjusting screw. BUTT BOARD pressure or out to decrease pressure until set DOWN port relief on "hoist" valve is now set. value is obtained on gauge.

8. Tighten locknut on adjusting screw taking care not to turn the adjusting screw. SAW RETRACT port relief on "swing" valve is now set.

10. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

19.10

Tigercat 220 Loader

Circle Saw

Check main relief valve:

Butt Board/"hoist" valve:-

9. While holding the L.H. joystick in the HOIST UP position, check gauge pressure reading. If adjustment is required, lossen locknut and turn port relief valve adjusting screw in to increase pressure or out to decrease pressure until set value is obtained on gauge.

1. Connect gauge to "swing" valve.

10. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

2. Start engine.

3. Check Butt Board Up port relief.

4. Check Board Down port relief.

5. Check "hoist" main relief.

6. Stop engine.

11. Stop engine, remove pressure gauges and wipe 7. Remove all gauges. up any excess oil from test port area.

8. Clean hoses and fittings and re-connect Butt Board, Saw Motor and Saw Cut/Retract units 12. Clean hoses and fittings and re-connect Butt to Loader.

Board, Saw Motor and Saw Cut/Retract units to Loader.

SUMMARY: 1. Disconnect Circle Saw and Butt Board hoses from Loader.

2. Ensure hydraulic oil is at operating temperature.

Circle Saw Motor valve:3. Turn relief on "Circle Saw Motor" valve fully in.

4. Connect gauge to "Circle Saw Motor" valve.

5. Start engine.

6. Check Motor pressure port relief on "Circle Saw Motor" valve.

7. Check main relief.

Saw cut, saw retract/"stick" valve:1. Connect gauge to "swing" valve.

2. Start engine.

3. Check SAW CUT port relief on "swing" valve.

4. Check SAW RETRACT port relief on "swing" valve.

5. Check main relief.

19.11

Tigercat 220 Loader

Circle Saw

19.12