Tigercat 220C Loader SERVICE MANUAL - PDF DOWNLOAD

SERVICE MANUAL Tigercat 220C Loader TABLE OF CONTENTS

ISSUE 1.0, NOVEMBER, 2007

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 SLASHER ........................................................................................................................ 18 CIRCLE SAW .................................................................................................................. 19

220C-SM00

220C Available Literature Operator's Manual ............................................. Part No. 30446A Service Manual (this manual) ............................ Part No. 30447A Parts Catalog ..................................................... Part No. 30448A

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

®

Tigercat 220C Loader

General Specifications

ii

Tigercat 220C Loader

Introduction

Tigercat 220C 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 220C Loader, serial number 2200501 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.

iii

Tigercat 220C 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 220C Loader

SECTION 1 - SAFETY NOVENBER, 2007

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, 1.8 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 .................................................................................................... 1.8 LOOSE CLOTHING HAZARD ............................................................................ 1.9 PROTECTIVE CLOTHING ................................................................................. 1.3 SAFE REMOVAL OF COUNTERBALANCE AND CHECK CARTRIDGE ............ 1.9 SAFETY PRECAUTIONS, OPERATING ........................................................... 1.5 SAFETY PRECAUTIONS, SERVICING ............................................................. 1.7 SAFETY SYMBOLS .......................................................................................... 1.2 SIGNAL WORDS ............................................................................................... 1.2

Tigercat 220C 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 indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

1.2

Tigercat 220C Loader

Safety 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.

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

Follow all instructions from safety inspector and supervisors.

KEEP CLEAR When approaching an operating machine on foot, stay at least 300 feet (90M) 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.

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 familiar with 1.3

Tigercat 220C 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.

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

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

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

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.

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.

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.

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

Do not operate the equipment with anyone in the cab, on platforms, or anywhere else within 300 feet 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.

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

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

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

Tigercat 220C Loader

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

OPERATING SAFETY PRECAUTIONS

Ensure that the windshield guard is installed and properly secured.

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

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

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.

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

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

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.

WARNING

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

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

1.5

Use only prearranged and approved signalling practices.

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

Tigercat 220C 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.

240B-003

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

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.

IMPORTANT

24 VOLT ELECTRICAL SYSTEM 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 220C Loader

Safety SAFETY INTERLOCK SWITCH ON LEFT ARMREST:

SERVICING SAFETY PRECAUTIONS

The left arm rest is equipped with a safety interlock switch (1) to prevent the machine from being operated while the armrest is in the raised position (pilot system is shut off).

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

ARMREST

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

• L.H. ARM REST IN DOWN POSITION AND LIMIT SWITCH ON

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.

1 LIMIT SWITCH ACTUATING LEVER ON SEAT BASE

••

• 247-25

PILOT SYSTEM SHUT OFF

To operate: 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.

WARNING

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

•

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

•

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

•

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

1.7

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

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

The 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.

Tigercat 220C Loader

Safety

SERVICING SAFETY PRECAUTIONS continued

WARNING Diesel fuel or hydraulic fluid under pressure can penetrate the skin and cause serious personal injury, blindness, or death. If any fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with treating this type of injury.

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.

240B-003

Never use your bare hand to check for fluid leaks.

Fluid leaks under pressure may not be visible. When searching for leaks, wear work gloves and use a wrench or piece of wood to move hydraulic hoses.

Do not grab hold of hydraulic hoses. Wear safety goggles for eye protection.

Turn the battery disconnect switch off and disconnect the battery negative terminal. Also, disconnect the engine ground connection from the frame.

•

• •• ••

DISCONNECT THE TWO MULTI-PIN PLUGS FROM THE ENGINE CPU

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

DISCONNECT THE TWO MULTI-PIN PLUGS FROM THE PLUS 1 CONTROLLER 250B-025

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

250B-030

Disconnect the engine CPU (Central Processing Unit) by unplugging the two multi-pin connectors from the left side of the engine. Also disconnect the two multi pin connectors on the optional Plus 1 controller (if equipped).

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

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

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

IMPORTANT

24 VOLT ELECTRICAL SYSTEM

1.8

Tigercat 220C Loader

Safety

SERVICING SAFETY PRECAUTIONS continued 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.

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.

If it becomes necessary to remove either the stabilizer 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.

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.

VERTICAL CENTERLINE

LOWER FRAME

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.

•

COUNTERBALANCE VALVE

•

STABILIZER UP IN VERTICAL POSITION

• • •

If the engine is running inside a building, ensure that sufficient ventilation is available to prevent a buildup of toxic exhaust fumes. Run the engine only when it is necessary for testing or adjustments.

CYLINDER

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.

STABILIZER COUNTERBALANCE/CHECK VALVE CARTRIDGE REMOVAL

230-06A

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.

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

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.

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

1.9

Tigercat 220C 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.

6.

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

7.

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

8.

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

9.

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

FIRE PREVENTION

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

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

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

1.

Maintain a CHARGED fire extinguisher on the machine at all times and KNOW HOW TO USE IT.

2.

Inspect the machine for any signs of fuel or hydraulic system leakage and check for worn or eroded fuel or hydraulic lines before starting up any equipment.

3.

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

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

4.

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

1.10

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 220C Loader

Safety

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

•

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

•

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

•

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

•

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

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

•

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

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

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

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

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

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

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

WHAT TO DO IN CASE OF A MACHINE FIRE

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

•

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.

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

•

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.

•

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

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.

*

1.11

*

Tigercat 220C Loader

Safety

FIRE PREVENTION continued •

•

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

•

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

Use the PASS method with most extinguishers.

•

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

•

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

•

WHAT TO DO AFTER A FIRE

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.

•

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

•

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

•

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

•

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

*

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

20229A

TYPICAL FIRE EXTINGUISHER ACCESS HOLE

•

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

•

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

•

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

**NOTE: Water mixing with dry chemical powder forms an acidic paste that will damage surfaces and wiring. See fire suppression systems manual for proper cleanup procedures.

1.12

Tigercat 220C Loader

SECTION 3 - LUBRICATION & MAINTENANCE CONTENTS - SECTION 3 AIR CLEANER FILTER RESTRICTION INDICATOR ........................................................... 3.14 IMPORTANT STEPS TO FOLLOW ............................................................ 3.13 IMPROPER SERVICING ........................................................................... 3.13 MAINTENANCE ......................................................................................... 3.13 UNLOADER VALVE .................................................................................. 3.14 AIR CONDITIONING ...................................................................................... 3.15 APPROVED HYDRAULIC OILS .................................................................... 3.10 ELECTRICAL SCHEMATIC ................. 3.24, 3.25, 3.26, 3.27, 3.28, 3.29, 3.30 EMERGENCY EXITS, CHECK MONTHLY ...................................................... 3.5 FILTER RESTRICTION INDICATOR ............................................................... 3.14 FIRE PREVENTION ........................................................................................ 3.5 FIRST 50-100 HOUR INSPECTION AND SERVICE ......................................... 3.2 GENERAL ....................................................................................................... 3.5 HYDRAULIC OIL RETURN FILTERS ............................................................. 3.11 NEW MACHINE MAINTENANCE .................................................................... 3.2 OIL LOST FROM LEAKAGE ........................................................................... 3.2 OIL SAMPLE COLLECTION PROCEDURES .................................................. 3.4 OIL SAMPLING PROGRAM ............................................................................ 3.3 PAG OIL ....................................................................................................... 3.15 PILOT PRESSURE FILTER ........................................................................... 3.12 PRE-DELIVERY INSPECTION ........................................................................ 3.2 PRESSURE SETTINGS ...................................................................... 3.18, 3.19 PREVENTIVE MAINTENANCE SCHEDULE ................................................... 3.2 REFRIGERANT ............................................................................................. 3.15 SCHEDULED MAINTENANCE EVERY 1000 HOURS .................................................................................. 3.7 EVERY 125 HOURS ................................................................................... 3.6 EVERY 2000 HOURS .................................................................................. 3.7 EVERY 24 HOURS ..................................................................................... 3.6 EVERY 250 HOURS ................................................................................... 3.7 EVERY 500 HOURS ................................................................................... 3.7 EVERY 8 HOURS ....................................................................................... 3.6 TORQUE CHART .......................................................................................... 3.16 TORQUE, FLUID CONNECTIONS ....................................................... 3.20, 3.22 TORQUE SPECIFICATIONS - GENERAL ..................................................... 3.16 UNLOADER VALVE ...................................................................................... 3.14 WEIGHTS OF COMMERCIAL WOOD .......................................................... 3.23

NOVEMBER, 2007

Tigercat 220C Loader

Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE 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

CAUTION

Swing motor mounting bolts

All handles, steps and platforms must be kept free of grease, oil, fuel mud, snow ice and forest debris to prevent risk of personal injury.

Cab securing bolts Boom pin nuts Heel pin nuts Trailer mounting studs Any other loose nut, bolt or fitting

*OIL LOST FROM LEAKAGE

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

PER DAY 0.424 0.852 4.26 14.2 90.83

LOST 0IL (LITERS) PER PER MONTH YEAR 12.72 152.0 25.6 306.6 127.76 1533.1 425.86 5110.31 2725.5 32706.0

3.2

PER DAY 0.112 0.225 1.125 3.75 24.00

LOST 0IL (GALLONS) PER PER MONTH YEAR 3.36 40.0 6.75 81.0 33.75 405.0 112.5 1350.0 720.0 8640.0

Tigercat 220C Loader

Lubrication and Maintenance

TIGERCAT OIL SAMPLING PROGRAM Effective for all 2008 model year 200 series log loaders sold in U.S.A. and Canada, oil sampling must be performed during the warranty period as per the schedule below. Warranty coverage of Powertrain components, specifically main pump, pilot pump (if applicable), swing pump (if applicable), rotary manifold, swing motor, swing gearbox and swing bearing, main control valves, track motors and final drive gearboxes (if applicable) is contingent on performance of regular oil sampling at the owner’s expense during the warranty period.

200 Series Location

First Sample

Follow-up Samples

Hydraulic Oil

100 hrs

Every 1000 hrs or 6 Months

Swing Drive Gearbox

100 hrs

Every Oil Change (500 hours or 3 Months)

Track Drive Gearboxes (if applicable)

100 hrs

Every 1000 hrs or 6 Months

FIRST SAMPLE There will be no charge for the first oil samples required to be taken during the 100-Hour Inspection Service that will be scheduled and performed by your Tigercat dealer. Refer to NEW MACHINE MAINTENANCE in THIS SECTION. FOLLOW-UP SAMPLES All follow-up samples must be taken as indicated in the chart above and will be the responsibility of the machine owner.

Copies of all oil analysis results must be forwarded to the Tigercat Warranty Department for continued warranty coverage. If samples are taken using the Tigercat Oil Analysis Program, a copy of all results will automatically be sent to Tigercat.

Tigercat Oil Analysis Kits are available from your Tigercat dealer parts department. If required, arrangements can also be made with your Tigercat dealer to supply and perform all of the required followup oil samples.

Refer also to OIL SAMPLE COLLECTION PROCEDURES in THIS SECTION for sample valve and drain plug locations.

TIGERCAT OIL ANALYSIS KITS Each kit includes a Pre-paid Sample Bottle and Sample Information Form. Pre-printed mailing labels are also included to ensure all samples are quickly returned directly to the lab for immediate analysis and results within 24 hours of receipt.

The same type of sample bottle can be used for all types of oil testing including: Hydraulic Circuits, Final Drives, Axles, Gearboxes, Engines, etc.

To ensure accurate and meaningful results are obtained, each kit also includes detailed instructions on how properly collect, prepare and ship the oil samples.

Contact your Tigercat Dealer Parts Department to order Kits.

3.3

Tigercat 220C Loader

Lubrication and Maintenance

TIGERCAT OIL SAMPLING PROGRAM OIL SAMPLE COLLECTION PROCEDURES Fill out the Sample Information Form (SIF) completely and accurately. When taking multiple oil samples, fill out all of the required SIF forms in their entirety, prior to taking any oil samples. Then, immediately package each completed SIF form together with the matching oil sample in the black outer shipping container as each individual sample is taken. This will reduce the possibility of mixing up or incorrectly identifying the SIF forms and oil samples. Incorrectly identified samples could result in a false warning alarm.

OIL SAMPLING CONNECTOR

•

230C-012

The accuracy of the lab analysis results is very dependent on the quality of the oil sample taken.

Collection of clean oil samples that are representative of the main body of oil are essential if meaningful lab results are to be obtained.

Hydraulic Oil Samples: • Hydraulic oil samples should be taken from the circulating oil flow at operating temperature, with no functions actuated, using sample valves that are permanently located on the machine whenever possible.

Erroneous readings may result if proper collection, handling, packaging and shipping practices are not followed prior to the sample being tested by the lab. To be able to accurately compare and trend the lab results over time, all follow-up samples should be consistently taken from the same location using the same techniques as all previous samples.

•

Ensure that all sample valves and drain plugs are clean and free of debris.

•

Remove the sample bottle cap only when ready to take the sample. Keep the cap clean – do not put it in your pocket or let it get contaminated in any way.

•

Do not allow any airborne dirt, etc. to enter the sample bottle.

•

Avoid contamination of the sample – replace the sample bottle cap immediately after filling the bottle to approximately ¾ full. All samples taken should be immediately forwarded to the lab for processing.

HYDRAULIC OIL RETURN MANIFOLD

•

To obtain a representative oil sample, sample valves must be purged before the actual oil sample is taken. Drain a minimum of 3 or 4 ounces of oil into a separate container and discard this oil using approved recycling methods.

•

Replace the dust cover on the sample valve immediately after taking the oil sample and sealing the sample bottle.

Gearbox Samples: • These samples can be taken during the oil change process.

Contact your Tigercat dealer to purchase additional or replacement hydraulic sample valves or drain plugs.

In cases where oil samples must be pumped or otherwise drawn out of a reservoir or housing, a hand operated oil suction pump is also available from your Tigercat dealer.

3.4

•

To obtain a representative oil sample, ensure the oil is warm and has not settled very long (within 30 minutes of shutdown).

•

Place the required drain container under the machine to capture the used oil to be discarded using approved recycling methods.

•

Remove the drain plug and allow approximately 50% of the oil to drain, then place the sample bottle in the stream of draining oil to obtain a representative sample.

Tigercat 220C Loader

Lubrication and Maintenance

GENERAL Clean around filler caps before checking or adding fluids.

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

CHECK EMERGENCY EXITS, MONTHLY:~ An alternate exit route is provided: skylight/ emergency exit. This exit is only to be used if the side door cannot be opened.

It is therefore essential that this emergency exit be checked at least once per month to ensure it is fully operational.

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.

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

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

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

Clean up oil spills in engine enclosure immediately.

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

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

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

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

Clean away all branches, bark and chips.

Clean up all traces of oil to avoid fires.

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

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

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

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

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

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.

3.5

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

Tigercat 220C Loader

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 8 HOURS:~

• Exhaust system for leaks.

• 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. • Check hydraulic oil level

EVERY 24 HOURS:~ • Perform 8 hour maintenance 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:1. Ensure machine is on level ground 2. Fully extend stick boom cylinder

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

3. Lower main boom and rest grapple firmly on ground or stable trailer

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

4. While in this position lubricate all cylinder retaining pins and boom joints

Check:~ • Fluid level in batteries unless maintenance free

• Yoke pins; 2-fittings - purge

• Engine RPM

• Grapple rotate pinion; 1-fitting - 4 shots, rotate 90° after each shot

• All hydraulic pressures • Hydraulic pumps and motor securing bolts

• Grapple arm pins; 6-fittings - purge

• Torque tightening points as per new machine maintenance

• Grapple cylinder pins; 4-fittings - purge

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

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

• Lower frame, stabilizer arms and cylinders

• Remove potentially damaging limbs or sticks and all debris

• Attachment

• Swing bearing area Make repairs immediately

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

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

• For loose nuts, bolts and fittings

• Wear in any other components

• Condition and tension of fan belts.

3.6

Tigercat 220C Loader

Lubrication and Maintenance

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

EVERY 1000 HOURS:~

• Cab fresh air filter

• Perform 8 hour maintenance

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

• Perform 24 hour maintenance • Perform 125 hour maintenance • Perform 250 hour maintenance • Perform 500 hour maintenance

EVERY 250 HOURS:~

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

• Perform 8 hour maintenance • Perform 24 hour maintenance

• Replace air cleaner unloader valve.

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

EVERY 2000 HOURS:~

• Check fire extinguisher and turn it to mix contents

• Perform 8 hour maintenance • Perform 24 hour maintenance • Perform 125 hour maintenance

EVERY 500 HOURS:~

• Perform 250 hour maintenance

• Perform 8 hour maintenance

• Perform 500 hour maintenance

• Perform 24 hour maintenance

• Perform 1000 hour maintenance And in addition:~ • Drain and refill hydraulic oil tank with recommended hydraulic oil. Refer to APPROVED HYDRAULIC OILS in THIS SECTION.

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

______________________________________________

• Replace fuel/water separator filter • Replace oil in swing gearbox. Fill reservoir to half way mark

WARNING

• Replace hydraulic oil return filters † • Replace hydraulic oil pilot pressure filter † • Lubricate door and cover hinges; 8 fittings - 1 shot

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

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.

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

3.7

•

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

•

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

•

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

Tigercat 220C Loader

Lubrication and Maintenance

3.8

Tigercat 220C Loader

Lubrication and Maintenance

36482B R0

3.9

Tigercat 220C Loader

Lubrication and Maintenance

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

3.10

Tigercat 220C Loader

Lubrication and Maintenance •

FILTER HEAD

• GASKET

•

FILTER ELEMENT

SQUARE SECTION GASKET INSTALLATION FILTR_SEALS 2

Square Section Gasket 1-WATER ABSORBING RETURN FILTER (COLOUR BLUE)

•• •

•

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.

•

HYDRAULIC RETURN FILTERS

HYDRAULIC RETURN FILTERS 250B-014 HYDRAULIC OIL RETURN 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 10 micron abs).

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

Each filter head has a bypass valve with a 1.7 Bar (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 allfilter elements.

Changing the filters: 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.

• FILTR_SEALS 2

FILTER ELEMENT

'O' RING GASKET INSTALLATION

'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.

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

7. Start the engine and check for leaks.

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.

3.11

Tigercat 220C Loader

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

LOCATED LOWER LEFT SIDE OF ENGINE COMPARTMENT

•

PILOT FILTER ELEMENT

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.

230C-007

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

HYDRAULIC PILOT FILTER

PILOT PRESSURE FILTER This single full flow filter, is mounted in the output line between the pilot pump and the pilot manifold.

For service and replacement intervals see SERVICE AND LUBRICATION CHART in THIS SECTION.

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.

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.

9. Start the engine and check for leaks.

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.

3.12

Tigercat 220C Loader

Lubrication and Maintenance

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

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.

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.

234-006

AIR CLEANER

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.

••

IMPORTANT STEPS TO FOLLOW

SAFETY ELEMENT

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.

3.13

AIR CLEANER .PLT

PRIMARY ELEMENT

AIR FILTER ELEMENTS

Tigercat 220C Loader

Lubrication and Maintenance

•

INDICATOR

SAFETY ELEMENT

••

250B-023

FILTER RESTRICTION INDICATOR

FILTER RESTRICTION INDICATOR A filter restriction indicator is located in the engine enclosure to the left of the frame access panel.

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.

•

PRIMARY ELEMENT

••

UNLOADER VALVE AIR CLEANER .PLT

AIR FILTER ELEMENTS

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.

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

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

The valve should suck closed at engine warm-up speed.

234-006

AIR CLEANER

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

3.14

Tigercat 220C Loader

Lubrication and Maintenance

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

R134a REFRIGERANT

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

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

PAG OIL (polyalkylene glycol)

1.5 KG (3.25 LBS)

AIR CHARGE COOLER

0.06 KG (2 OZ)

••

Any service work must be performed by authorized A/C technicians. The system should be charged with 1.5 kg (3.25 lbs) of R134a refrigerant. At least 0.06 kg (2 oz) of PAG (polyalkylene glycol) oil should be present in the system and must be used on 'O' rings and fittings during assembly.

RADIATOR

•• A/C CONDENSER

•

A/C COMPRESSOR

OIL COOLER

•

250B-023

CAUTION

230C-002

•

RADIATOR COMPARTMENT RIGHT SIDE

Use the following checklist to maintain system between service intervals. The compressor and charge valves are located on the left side of the engine and accessible through the engine compartment door. The receiver dryer is located in the lower engine compartment beside the front left engine mount and accessible from either underneath the engine compartment or through the engine compartment door.

A/C COMPRESSOR

Perform the following checks on system: a. Check and adjust compressor drive belt tension. Do not over tighten. b. Check fresh air filter and re-circulating air filter.

Clean or replace as required. c. Check to see that compressor clutch will engage. d. Check blower operation and air vents. e. Check the condenser core for dirt and debris.

3.15

Tigercat 220C Loader

Lubrication and Maintenance

TORQUE CHART LOCATION

THREAD DIAMETER

TORQUE (LUBRICATED) lbf-ft Nm

Cylinders Hoist, Piston nut Hoist, Keeper plate bolts Stick, Piston nut Stick, Keeper plate bolts Stabilizer, Piston nut Stabilizer, Gland Heel, Piston nut Heel, Keeper plate bolts

2"-12 UNF (GC) 3/4"-16 UNF (G8) 2"-12 UNF (GC) 3/4"-16 UNF (G8) 2"-12 UNF (GC) M14-2.0 2" -12 UNF (GC) 3/4"-10 UNC (G8)

2500 250 2500 250 2100 129 1640 282-310

3390 340 3390 340 2847 175 2224 382-420

Boom joint and cylinder pin retaining bolts

3/4"-10 UNC (G8)

282-310

393-420

2"-12 UNF (G8)

400

540

Heel to Stick boom pin retaining nut

1 3/4"-12 UNF (G8)

400

540

Cab securing bolts Trailer mounting studs

7/8"-9 UNC (G8) 1 1/4"-7 UNC (G5)

400-450 500

542-610 680

Swing bearing bolts Swing gearbox mounting bolts

7/8"-9 UNC (G8) M20 (12.9)

400-450 400

542-610 540

Engine mounting Bolts, bracket/mount to chassis Bolts, bracket to engine Flex drive coupling hub setscrew Engine cooling fan mounting bolts

7/8"-9 UNC (G8) M12-1.75 (10.9) M10 (12.9)

400-450 75 63 40

542-610 100 83 54

Pump drive Drive plate to flywheel Bell housing to engine

3/8"-16 UNC (G8) M10 (10.9)

33-36 47

45-49 63

Pump mounting Main Pump to Engine

1/2" 13 UNC (G8)

80

108

Main and Stick boom pin retaining nut

*

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.

3.16

Tigercat 220C Loader

Lubrication and Maintenance

GENERAL TORQUE SPECIFICATIONS The torque values listed below are for general use only.

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

IMPERIAL GRADE 8 BOLTS

GRADE 5 BOLTS

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

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

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

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

METRIC

METRIC BOLT TORQUE SPECIFICATIONS SIZE

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

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

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

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

M6 M8 M10

4.8 12.0 23.0

3.5 8.5 17.0

6.0 15.0 29.0

4.5 11.0 21.0

9.0 22.0 43.0

6.5 16.0 32.0

11.0 28.0 55.0

8.5 20.0 40.0

13.0 32.0 63.0

9.5 24.0 47.0

17.0 40.0 80.0

12.0 30.0 60.0

15.0 37.0 75.0

11.5 28.0 55.0

19.0 47.0 95.0

14.5 35.0 70.0

M12 M14 M16

40.0 63.0 100.0

29.0 47.0 73.0

50.0 80.0 125.0

37.0 60.0 92.0

75.0 120.0 190.0

55.0 88.0 140.0

95.0 150.0 240.0

70.0 110.0 175.0

110.0 175.0 275.0

80.0 130.0 200.0

140.0 225.0 350.0

105.0 165.0 225.0

130.0 205.0 320.0

95.0 150.0 240.0

165.0 260.0 400.0

120.0 190.0 300.0

M18 M20 M22

135.0 190.0 260.0

100.0 140.0 190.0

175.0 240.0 330.0

125.0 180.0 250.0

260.0 375.0 510.0

195.0 275.0 375.0

330.0 475.0 650.0

250.0 350.0 475.0

375.0 530.0 725.0

275.0 400.0 540.0

475.0 675.0 925.0

350.0 500.0 675.0

440.0 625.0 850.0

325.0 560.0 460.0 800.0 625.0 1,075.0

410.0 580.0 800.0

M24 M27 M30

330.0 490.0 675.0

250.0 360.0 490.0

425.0 625.0 850.0

310.0 650.0 450.0 950.0 625.0 1,300.0

M33 900.0 M36 1,150.0

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

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

TORQUECHARTGENERAL.XLS

3.17

Tigercat 220C Loader

Lubrication and Maintenance

PRESSURE SETTINGS Engine RPM Cummins 'QSB6.7 160 HP’ ................ 2280 - 2320 rpm ........................................................................................... 2200 rpm ................................................................................... 800 - 900 rpm Pilot Valve Main relief ................................................................ 31 Bar/450 psi STICK valve Main and Port reliefs: Main relief .............................................................. 190 Bar/2750 psi Port relief Grapple Rotate CCW ......................... ¶ 207 Bar/3000 psi Port relief Grapple Rotate CW ........................... ¶ 207 Bar/3000 psi Port relief Stick OUT .......................................... 234.4 Bar/3400 psi Port relief Stick IN ............................................... 103.4 Bar/1500 psi Port relief Saw RETRACT (option) ..................... 1103.4 Bar/500 psi Port relief Slasher CUT (option) ......................... § 207 Bar/3000 psi Port relief Drive FWD. (SP option) ........................ 172 Bar/2500 psi Port relief Drive REV. (SP option) .......................... 172 Bar/2500 psi Port relief Live Heel IN (option) ............................. 207 Bar/3000 psi Port relief Live Heel OUT (option) ......................... 207 Bar/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

HOIST valve Main and Port reliefs: Main relief .............................................................. 190 Bar/2750 psi Port relief Grapple OPEN ...................................... 207 Bar/3000 psi Port relief Grapple CLOSE .................................... 207 Bar/3000 psi Port relief Hoist UP ............................................. 234.4 Bar/3400 psi Port relief Hoist DOWN ...................................... 103.4 Bar/1500 psi Port relief Slasher CUT (option) ......................... § 207 Bar/3000 psi Port relief Top Saw CUT (option) ........................... 207 Bar/3000 psi Port relief Drive FWD. (SP option) ........................ 172 Bar/2500 psi Port relief Drive REV. (SP option) .......................... 172 Bar/2500 psi Port relief Butt Board UP(CS option) ..................... 138 Bar/2000 psi Port relief Butt Board DOWN (CS option) ............. 138 Bar/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 .............................................................. 179 Bar/2600 psi Port relief Swing CCW .......................................... 207 Bar/3000 psi Port relief Swing CW ............................................. 207 Bar/3000 psi Port relief Stabilizer DOWN ................................... 207 Bar/3000 psi Port relief Stabilizer UP ......................................... 138 Bar/2000 psi Port relief Delimber OPEN (option) ....................... 207 Bar/3000 psi Port relief Spare (option) ....................................... 207 Bar/3000 psi Port relief Steer LEFT (SP option) ......................... 138 Bar/2000 psi Port relief Steer RIGHT (SP option) ...................... 138 Bar/2000 psi Port relief Saw CUT (CS option) ........................... 138 Bar/2000 psi Port relief Saw RETRACT (CS option) .................. 138 Bar/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 motor Crossline Reliefs ................................................. **121 Bar/1750 psi

@ Idle

BRAKE valve (SP option) ......................................... 4.8 Bar/70 psi

@ Full throttle

CIRCLE valve Main and Port reliefs: Main relief .............................................................. 172 Bar/2500 psi Port relief ............................................................... 207 Bar/3000 psi

@ Full throttle @ Full throttle

@ Full throttle

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

3.18

Tigercat 220C Loader

Lubrication and Maintenance

PRESSURE SETTINGS 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. ¶ 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 214 Bar (3100 psi) before setting port relief on "STICK" valve. * Do not adjust pressure over 207 Bar (3000 psi) or pump may be damaged. *** Factory set at 10 gpm.

20089B-R1.06/09/04

3.19

Tigercat 220C Loader

Lubrication and Maintenance

Par ker ark

Assemb que Assemblly Tor orque The four-bolt port is simply a circular opening (flow passage) surrounded by four tapped holes in a certain pattern for acceptance of the flange clamping bolts.

The flat surface of the port compresses the O-ring contained in the groove in the flange head when the clamp bolts are torqued. In some instances, the groove is in the port and not in the flange head. The bolts, through the clamp halves, clamp down the flange head on to the flat surface of the port compressing and trapping the O-ring in the groove and leaving no gap for it to extrude under pressure. The hydraulic pressure is thus sealed by the compressed O-ring as long as the bolts are tightened enough to maintain solid metal to metal contact between the flange head at the outside diameter of the O-ring and the top of the port.

The 4-Bolt Split Flange consists of four main components: • A body (flange head) • An O-ring • One “captive” or two “split” flange clamps

• Four bolts and washer

WASHERS

•• •• •

BOLTS FLANGE CLAMP

Flange Port Assembly FLANGE HEAD

The steps to properly assemble the flange port clamping bolts are: 1. Make sure sealing surfaces are free of burrs, nicks, scratches or any foreign particles.

2. Lubricate the O-ring.

3. Position flange and clamp halves.

4. Place lock washers on bolts and insert through clamp halves.

5. Hand tighten bolts.

6. Torque bolts in diagonal sequence (see Fig. T9) in small increments to the appropriate torque level listed in Table T6 or Table T7 on this page.

O-RING

•• •

TAPPED HOLES

•• FLANGE.TIFF

Fig. T8 - 4 Bolt Split Flange Components

FLANGE2.TIFF

Fig. T9 - Flange Bolt Tightening Sequence

Dash Size

Flange Size

Inch Bolt (J518)

Torque ft. lbs.

Metric Bolt (ISO 6162)

Torque N-m

8 12 16 20 24 32 40 48 56 64 80

1/2 3/4 1 1-1/4 1-1/2 2 2-1/2 3 3-1/2 4 5

5/16-18 3/8-16 3/8-16 7/16-14 1/2-13 1/2-13 1/2-13 5/8-11 5/8-11 5/8-11 5/8-11

17 +/- 2 25 +/- 3.5 31 +/- 4.5 41 +/- 5 52 +/- 6 60 +/- 6 85 +/- 9 144 +/- 15 125 +/- 8 125 +/- 8 125 +/- 8

M8 M10 M10 M12* M12 M12* M12 M16 M16 M16 M16

25 49 49 85 85 135 95 220 220 220 220

DASH SIZE 8 12 16 20 24 32

FLANGE SIZE 1/2 3/4 1 1 1/4 1 1/2 2 SO

INCH BOLT (J518) 5/16-18 3/8-16 7/16-14 1/2-13 5/8-11 3/4-10

TORQUE METRIC BOLT TORQUE FT LBS (ISO 6162) N-M 17 +/- 2 M8 25 30 +/- 4.5 M10 49 46 +/- 4.5 M12 85 69 +/- 6 M14* 135 125 +/- 8 M16 210 208 +/- 20 M20 425

* Does not meet ISO 6162 specification.

Table T7 - Code 62 Flange Recommended Bolt Torque

* Does not meet ISO 6162 specification.

Table T6 - Code 61 Flange Recommended Bolt Torque

3.20

Tigercat 220C Loader

Lubrication and Maintenance

Par ker ark

Assemb que Assemblly Tor orque

JIC 37 Degree Flare SAE Dash Size

Tube Connection Swivel or Hose Connection FFWR FFWR

Thread Size

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

NPTF

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

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

-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

O'ring Face Seal / Seal-Lok

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

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

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

BSPT

Tube Connection Swivel or Hose Connection FFWR FFWR

Thread Size

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

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

SAE Dash Size

Tube Connection Swivel or Hose Connection TFFT TFFT

Thread Size

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

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

Thread Size

Tube Connection Swivel or Hose Connection TFFT TFFT

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

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

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

SAE J1926 Straight Thread Port Assembly Torques ASSEMBLY TORQUE (+10 % - 0) SAE Dash Size

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

Non-Adjustable Thread Size

Seal-Lok

ft. lbs (in. lbs) 5/16-24 (310) 3/8-24 (310) 7/16-20 (310) 1/2-20 (360) 9/16-18 (420) 3/4-16 60 7/8-14 100 1 1/16-12 135 1 3/16-12 175 1 5/16-12 200 1 5/8-12 250 1 7/8-12 305 2 1/2-12 375

N-m 20 20 20 40 46 80 135 185 235 270 340 415 510

Adjustable

Triple-Lok Ferulok Pipe Fittings ft. lbs (in. lbs) (85) (155) (260) (280) (350) (620) 85 135 175 200 250 305 375

N-m 10 18 29 32 40 70 115 183 237 271 339 414 509

Plugs Hollow Hex

Seal-Lok ft. lbs (in. lbs) (310) (310) (310) (360) (420) 60 100 135 175 200 250 305 375

3.21

N-m 20 20 20 40 46 80 135 185 235 270 340 415 510

Triple-Lok Ferulok ft. lbs (in. lbs) (60) (100) (180) (250) (350) (620) 85 135 175 200 250 305 375

N-m 7 11 20 28 40 70 115 183 237 271 339 414 509

HP5ON-S ft. lbs (in. lbs) (30) (55) (120) (170) (410) 60 100 135 175 200 250 305 375

N-m 3.5 6 13.5 19 46 80 135 185 235 270 340 415 510

Hex Head P5ON-S ft. lbs (in. lbs) (85) (155) (260) (280) (350) (620) 85 135 175 200 250 305 375

N-m 10 18 29 32 40 70 115 183 237 271 339 414 509

Tigercat 220C 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

3.22

Tigercat 220C Loader

Lubrication and Maintenance

Weights of Commercial Wood

Species

kg/m3

lb/ft3

Species

kg/m3

lb/ft3

Alder, Red Ash, White Aspen, Quaking Bald Cypress Basswood, American Beech, American Birch, Paper Birch, Yellow Cedar, Alaska Cedar, Incense Cedar, Northern White Cedar, Port-Orford Cedar, Western Red Cherry, Black Cottonwood, Eastern Douglas Fir, Coast Douglas Fir, Inland North Elm, American Fir, Alpine Fir, Balsam Fir, Nobel Fir, Red Fir, Silver Fir, White Gum, Black Gum, Blue Gum, Red Gum, Tupelo Hemlock, Eastern Hemlock, Western Hickory, Pecan Hickory, True Larch, Western Locust, Black Magnolia, Cucumber

737 769 689 817 673 865 801 929 577 721 449 897 433 721 785 881 577 865 449 721 481 769 577 753 721 1121 801 897 801 657 993 1009 769 929 785

46 48 43 51 42 54 50 58 36 45 28 36 57 45 49 55 36 54 28 45 30 48 36 47 45 70 50 56 50 41 62 63 48 58 49

Maple, Big Leaf Maple, Black Maple, Red Maple, Silver Maple, Sugar Oak, Black Oak, Chestnut Oak, Red Oak, Red, Swamp Oak, Swamp Chestnut Oak, White Oak, White, Swamp Pine, Jack Pine, Loblolly Pine, Lodgepole Pine, Long Leaf Pine, Norway, Red Pine, Short Leaf Pine, Slash Pine, Sugar Pine, Western Yellow Pine, White-Western Pine, White-Eastern Poplar, Yellow Redwood Spruce, Black Spruce, Engleman Spruce, Red Spruce, Sitka Spruce, White Sweetgum Sycamore, American Tamarack Walnut, Black Willow, Black

753 865 801 721 897 1009 977 1009 1073 1041 993 1105 801 993 625 993 673 993 993 817 721 561 577 609 801 513 625 545 529 545 801 833 753 929 801

47 54 50 45 56 63 61 63 67 65 62 69 50 62 39 62 42 62 62 51 45 35 36 38 50 32 39 34 33 34 50 52 47 58 50

Note: The values shown here are green weights.

3.23

Tigercat 220C Loader

220C-018

Lubrication and Maintenance

ELECTRICAL SCHEMATIC - STANDARD MACHINES 33562B R0 - SHEET 1 OF 3 3.24

Tigercat 220C Loader

220C-019

Lubrication and Maintenance

ELECTRICAL SCHEMATIC - STANDARD MACHINES 33562B R0 - SHEET 2 OF 3 3.25

Tigercat 220C Loader

220C-020

Lubrication and Maintenance

ELECTRICAL SCHEMATIC - STANDARD MACHINES 33562B R0 - SHEET 3 OF 3 3.26

Tigercat 220C Loader

220C-014

Lubrication and Maintenance

ELECTRICAL SCHEMATIC - CIRCLE SAW MACHINES 36091B R0 SHEET 1 OF 4) 3.27

Tigercat 220C Loader

220C-015

Lubrication and Maintenance

ELECTRICAL SCHEMATIC - CIRCLE SAW MACHINES 36091B R0 SHEET 2 OF 4) 3.28

Tigercat 220C Loader

220C-016

Lubrication and Maintenance

ELECTRICAL SCHEMATIC - CIRCLE SAW MACHINES 36091B R0 SHEET 3 OF 4) 3.29

Tigercat 220C Loader

220C-017

Lubrication and Maintenance

ELECTRICAL SCHEMATIC - CIRCLE SAW MACHINES 36091B R0 SHEET 4 OF 4) 3.30

Tigercat 220C Loader

SECTION 5 - PILOT SYSTEM NOVEMBER, 2007

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

Tigercat 220C Loader

Pilot system

PILOT SYSTEM COMPONENTS

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 31 Bar (450 psi).

Refer to SET PILOT PRESSURE in THIS SECTION.

LEFT SIDE OF ENGINE

•• PILOT PUMP

LOCATED LOWER LEFT SIDE OF ENGINE COMPARTMENT

••

220C-008 PILOT PUMP The pilot circuit is supplied with oil from the pilot pump which is driven by the flywheel on 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 installed in the pilot manifold maintains the pilot system pressure at 31 Bar (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.

220C-007

PILOT FILTER ELEMENT

HYDRAULIC PILOT FILTER 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 3.4 Bar (50 psi) this valve will bypass the pilot oil back to the tank.

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

STABILIZER PILOT MANIFOLD

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.

5.2

Tigercat 220C Loader

Pilot system PILOT SHUT "IN" CONNECTION OFF VALVE FROM PILOT FILTER

PILOT MANIFOLD

"PB" POWER BEYOND PORT CONNECTIONS TO JOYSTICKS AND FOOT PEDAL VALVES "T" TANK CONNECTION

• •

••

•

"T" TANK CONNECTION

•

PILOT MANIFOLD STANDARD PILOT MANIFOLD 220C-007

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

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

GAUGE TEST PORT CONNECTION

PILOT RELIEF 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 standard and circle saw 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 (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

•• •

•

PILOT MANIFOLD

220C-006

• • • • •

••

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 220C 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 5.4

Tigercat 220C Loader

220-015

Pilot system

PILOT CIRCUIT COMPONENTS - STANDARD LOADER 5.5

Tigercat 220C Loader

220-017

Pilot system

PILOT CIRCUIT COMPONENTS - CIRCLE SAW 5.6

Tigercat 220C 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.

1

•

5

•

•

•

TANK PORT

3

• 4

1

•

8

•

•

5

•

• WORK PORT

3 AW017

4

•

•

8

•

•

• 2

• WORK PORT

• PRESSURE PORT

WORK PORT

FOOT PEDAL PILOT VALVE

• TANK PORT

• PRESSURE PORT

WORK PORT

JOYSTICK PILOT VALVE AW015 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.

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

5.7

2

Tigercat 220C 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.

•

••

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.

•• ••

PILOT MANIFOLD

PILOT RELIEF VALVE

GAUGE TEST PORT CONNECTION 220C-006

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

5.8

PILOT RELIEF VALVE

•

IN

•

OUT

Tigercat 220C Loader

220C-011

Pilot system

PILOT SYSTEM CIRCUIT DIAGRAM - BASIC LOADER 5.9

Tigercat 220C Loader

220C-013

Pilot system

PILOT SYSTEM CIRCUIT DIAGRAM - CIRCLE SAW 5.10

Tigercat 220C Loader

SECTION 6 - ELECTRICAL, GAUGES & ALARMS NOVEMBER, 2007

CONTENTS - SECTION 6 CAB WIRING AND ELECTRICAL COMPONENT LOCATIONS .................... 6.3 DISPLAY MODULE ........................................................................................ 6.4 COMPONENT DESCRIPTION ................................................................... 6.4 FAULTS AND WARNINGS ......................................................................... 6.5 KEYPAD FUNCTIONS ............................................................................... 6.4 START-UP OPERATION ............................................................................ 6.4 ELECTRICAL SCHEMATIC ............... 6.14, 6.15, 6.16, 6.17, 6.18, 6.19, 6.20 FUSE AND RELAY PANEL - CAB .................................................................. 6.6 FUSES AND RELAYS - ELECTRICAL BOX .................................................. 6.7 GAUGES AND ALARMS ................................................................................ 6.2 GAUGES AND WARNING LIGHTS ....................................................... 6.3, 6.9 INSTRUMENT PANEL WIRING DIAGRAM ....................................... 6.10, 6.11 SENSOR LOCATIONS ............................................................... 6.9, 6.12, 6.13 WARNING LIGHTS ................................................................................ 6.3, 6.9 WIRE COLOUR CODE CHART ..................................................................... 6.8

Tigercat 220C Loader GAUGES AND ALARMS

Electrical, Gauges and Alarms

The 220C Loaders are monitored for proper operation by sensors located in the hydraulic system and on the engine. These sensors are connected to the PowerView Display and warning lights.

The operator may sound the warning horn at any time.

For operation of the PowerView Display and warning lights listed in the sensor chart below, refer to SECTION 2 of the OPERATOR'S MANUAL. For replacement parts information, refer to GAUGES AND SENDERS in GROUP 600 of the PARTS CATALOG.

SENSOR FUNCTION

DISPLAY

LIGHT

Engine oil pressure

PowerView

YES

RED Light comes ON below 15psi. * STOP engine below 15 psi

Engine coolant temp.

PowerView

YES

181°F-203°F operating range (Cummins engine) RED light comes ON above 215°F *

Engine coolant level

NONE

YES

RED light comes ON when level in surge tank is LOW

Hydraulic oil temp.

Gauge

YES

RED light comes ON above 205°F *

SIGHT GLASS

YES

Red light comes ON indicates 13 gallons below FULL *

NONE

NONE

Wait to start

PowerView

YES

YELLOW light turns ON when grid heater elements ON

Water in fuel

NONE

YES

YELLOW light comes ON when fuel/water separator needs to be drained

Safety Alert HORN

NONE

NONE

Hydraulic oil level LOW Pilot Pressure

*NOTE: Panel buzzer sounds when engine oil pressure too low OR engine coolant temperature too high OR hydraulic oil temperature too high OR hydraulic oil level too low.

6.2

INFORMATION

Sensor provides pilot pressure signal for Plus 1 Control Module (Idle Down function)

Switch on control panel - press to sound horn

Tigercat 220C Loader

Electrical, Gauges and Alarms DEFROSTER FAN

234-030

CB RADIO

DOME LIGHT

GAUGES AND WARNING LIGHT PANEL

•

•

••

INSTRUMENT PANEL

DIAGNOSTIC CONNECTOR

• ••

•• ELECTRICAL CONNECTORS

FUSE AND RELAY PANEL (SEE DETAILS IN THIS SECTION)

220C-026

••

CAB WIRING AND ELECTRICAL COMPONENT LOCATIONS 6.3

Tigercat 220C 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.

6.4

Tigercat 220C 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.

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.

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.

FAULTS AND WARNINGS

ENGINE COOLANT TEMP.

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.

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.

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.

VOLTAGE DISPLAY

! ! !

Normal operating range is between 24-28 volts. A reading in excess of 30 volts indicates a possible faulty voltage regulator. A reading of less than 23 Volts indicates a possible faulty battery or alternator.

- Indicates Auxiliary Gage Fault.

- Indicates Fault Warning

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

- Indicates Derate or Shutdown Fault

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.

6.5

Tigercat 220C Loader

234-007

Electrical, Gauges and Alarms

FUSE AND RELAY PANEL

FUSE AND RELAY PANEL 39. FUSE AND RELAY PANEL - CAB The fuse panel is located below the control panel behind a removable cover.

IMPORTANT

24 VOLT

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.

ELECTRICAL SYSTEM 6.6

Tigercat 220C Loader

230C-017

Electrical, Gauges and Alarms

MAIN FUSE AND RELAY ELECTRICAL BOX

40. FUSES AND RELAYS - ELECTRICAL BOX This Main Fuse and Relay electrical box is located in the engine compartment.

6.7

Tigercat 220C Loader

220C-021

Electrical, Gauges and Alarms

CONTROL PANEL - COMPONENT LOCATION - TOP & SIDE VIEW

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)

6.8

Tigercat 220C Loader

Electrical, Gauges and Alarms

GAUGES AND WARNING LIGHTS 1

2

4

•

•

5

••

6

• 3

••

7

••

••

Component description

4. Hydraulic Oil Temperature - Gauge

1. Windshield Wiper Switch

5. Hydraulic Oil Temperature - Red

2. PowerView Display Module

6. Low Hydraulic Oil Light - Red

3. Bulb Test Switch

7. Low Fuel Light - Yellow

220C-010

220-26

FRONT INSTRUMENT PANEL - COMPONENT LOCATION

FRONT INSTRUMENT PANEL - WIRING DIAGRAM - REAR VIEW

6.9

Tigercat 220C Loader

220C-022

Electrical, Gauges and Alarms

INSTRUMENT PANEL WIRING DIAGRAM 6.10

Tigercat 220C Loader

220C-023

Electrical, Gauges and Alarms

INSTRUMENT PANEL WIRING AND PIN ASSIGNMENT 6.11

Tigercat 220C Loader

Electrical, Gauges and Alarms

JOYSTICKS

••

••

LIMIT SWITCH, PILOT SHUT OFF

PILOT MANIFOLD

••

• STABILIZER PILOT MANIFOLD

••

BATTERY DISCONNECT SWITCH

FUSE & RELAY ELECTRICAL BOX (SHOWN MOVED OVER & TURNED UP)

••

COOLANT LEVEL PROXIMITY SWITCH (RED LIGHT)

•

•

•

A/C COMPRESSOR

••

••

SIGHT GAUGE AND HYDRAULIC OIL LEVEL SENDER

••

••••

STARTER

• ••

••

ALTERNATOR

BATTERIES

SWITCH- HYDRAULIC OIL TEMPERATURE (RED LIGHT)

•• A/C PRESSURE SWITCH

SAFETY ALERT HORN (SWITCH ON CONTROL PANEL)

SENDER - HYDRAULIC OIL TEMPERATURE (GAUGE)

220C-003

SWITCH AND SENSOR LOCATIONS - STANDARD LOADER 6.12

Tigercat 220C Loader

Electrical, Gauges and Alarms

JOYSTICKS

••

••

LIMIT SWITCH, PILOT SHUT OFF PILOT MANIFOLD

••

•• STABILIZER PILOT MANIFOLD

•

BATTERY DISCONNECT SWITCH

FUSE & RELAY ELECTRICAL BOX (SHOWN MOVED OVER & TURNED UP)

•

COOLANT LEVEL PROXIMITY SWITCH (RED LIGHT)

••

••

••

A/C COMPRESSOR

•

•

SIGHT GAUGE AND HYDRAULIC OIL LEVEL SENDER

• ••

•••

STARTER

••

••

ALTERNATOR

BATTERIES

SWITCH- HYDRAULIC OIL TEMPERATURE (RED LIGHT)

• A/C PRESSURE SWITCH

SAFETY ALERT HORN (SWITCH ON CONTROL PANEL)

SENDER - HYDRAULIC OIL TEMPERATURE (GAUGE)

220C-003A

SWITCH AND SENSOR LOCATIONS - CIRCLE SAW 6.13

Tigercat 220C Loader

220C-018

Electrical, Gauges and Alarms

ELECTRICAL SCHEMATIC - STANDARD MACHINES 33562B R0 - SHEET 1 OF 3 6.14

Tigercat 220C Loader

220C-019

Electrical, Gauges and Alarms

ELECTRICAL SCHEMATIC - STANDARD MACHINES 33562B R0 - SHEET 2 OF 3 6.15

Tigercat 220C Loader

220C-020

Electrical, Gauges and Alarms

ELECTRICAL SCHEMATIC - STANDARD MACHINES 33562B R0 - SHEET 3 OF 3 6.16

Tigercat 220C Loader

220C-014

Electrical, Gauges and Alarms

ELECTRICAL SCHEMATIC - CIRCLE SAW MACHINES 36091B R0 SHEET 1 OF 4) 6.17

Tigercat 220C Loader

220C-015

Electrical, Gauges and Alarms

ELECTRICAL SCHEMATIC - CIRCLE SAW MACHINES 36091B R0 SHEET 2 OF 4) 6.18

Tigercat 220C Loader

220C-016

Electrical, Gauges and Alarms

ELECTRICAL SCHEMATIC - CIRCLE SAW MACHINES 36091B R0 SHEET 3 OF 4) 6.19

Tigercat 220C Loader

220C-017

Electrical, Gauges and Alarms

ELECTRICAL SCHEMATIC - CIRCLE SAW MACHINES 36091B R0 SHEET 4 OF 4) 6.20

Tigercat 220C Loader

SECTION 7 - ENGINE START AND STOP NOVEMBER, 2007

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

Tigercat 220C Loader

Engine start and stop

ENGINE START CIRCUIT

ELECTRONIC CONTROL MODULE

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

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.

••

•• ••

To start engine; Turn battery disconnect switch to the ON position. Turn ignition key to the START position and releasing it to the RUN position after the engine starts.

MULTI PIN CONNECTORS 220C-014

ENGINE ELECTRONIC CONTROL MODULE

CIRCUIT DESCRIPTION With the battery disconnect switch ON, current is supplied to 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 to energize the coils of the start solenoid relay. The start solenoid relay contacts also close and current flows from the alternator + RED wire (1) through wire (12) to the starter solenoid coil to close the contacts and operate the start motor to crank the engine.

For the engine computer module (ECM) to supply fuel, there needs to be power at the vehicle key switch input pin on the 50 pin ECM connector.

Key input relay (#10) and 2 fuses control the signal to the ECM, which together with the start motor, start the engine.

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 (36) 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 (36) and (11) to the pilot shut off solenoid valve.

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

7.2

Tigercat 220C Loader

Engine start and stop

START CIRCUIT - AT REST

220C-027

7.3

Tigercat 220C Loader

Engine start and stop

START CIRCUIT - AT REST BATTERY DISCONNECT SWITCH - ON

220C-028

7.4

Tigercat 220C Loader

Engine start and stop

START CIRCUIT - START IGNITION KEY - START POSITION 220C-029

7.5

Tigercat 220C Loader

Engine start and stop

START CIRCUIT - RUN IGNITION KEY - RUN POSITION

220C-030

7.6

Tigercat 220C Loader

Engine start and stop

START CIRCUIT - RUN IGNITION KEY - RUN POSITION PILOT RESET SWITCH - HELD ON ARM REST DOWN/ARM REST SWITCH - ON

220C-031

7.7

Tigercat 220C Loader

Engine start and stop

START CIRCUIT - RUN IGNITION KEY - RUN POSITION PILOT RESET SWITCH - RELEASED ARM REST DOWN/ARM REST SWITCH - ON

220C-032

7.8

Tigercat 220C Loader SECTION 10 - OIL COOLER, RADIATOR AND FAN NOVEMBER, 2007

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 220C Loader OIL COOLER, RADIATOR AND FAN

Oil Cooler, Radiator and Fan

•• The Charge Air Cooler,Radiator, A/C Condenser and Hydraulic Oil Cooler package is mounted in front of the engine.The engine driven fan draws air through the cooler package.

SURGE TANK

FILLER CAP

• COOLANT LEVEL INDICATOR

220C-017 220C-018

CHARGE AIR COOLER

CHECK ENGINE COOLANT LEVEL

•• RADIATOR

• A/C CONDENSER

FAN BELT

••

• OIL COOLER

230C-002

••

•

COOLER PACKAGE

The cooler package 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 220C-037

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).

•• ••

WARNING

JAM NUTS

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 220-051

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.

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 6.35 mm to 9.5 mm (1/4" to 3/8" in) the middle of the belt span between the pulleys.

10.2

Tigercat 220C Loader

Oil Cooler, Radiator and Fan

RAD CAP

COOLANT LEVEL SIGHT GLASS

SURGE TANK

•• ••

CHARGE AIR COOLER

••

• RADIATOR

••

COOLANT LEVEL SENDER

A/C CONDENSER CORE

•• ••

•

•• RAD SHROUD

OIL COOLER

•• FAN FINGER GUARD

220C-040 220C-005

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

Tigercat 220C Loader

220-D14

220-D15

Oil Cooler, Radiator and Fan

ENGINE COMPARTMENT ACCESS REAR

ENGINE COMPARTMENT ACCESS FRONT 10.4

Tigercat 220C 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 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.

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 engine and are carried up through a vent tube where they collect in the surge tank and eventually discharge through the pressure cap.

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.

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.

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.

FLOW OF COOLANT WITH ENGINE RUNNING AT OPERATING TEMPERATURE AND THERMOSTAT OPEN OVERFLOW VENT TUBE SURGE TANK

TOP RADIATOR HOSE THERMOSTST HOUSING

• •

RAD VENT

ENGINE VENT

•• ••

••

••

SHUNT HOSE

RADIATOR

••

• •

•

• ENGINE OIL COOLER 220C-041

SHUNT HOSE

BOTTOM RADIATOR HOSE

ENGINE COOLING SYSTEM 10.5

Tigercat 220C 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 return manifold and on to the oil cooler inlet through the cooler to the return filter and on to the hydraulic tank.

220C-046

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 4.2 Bar (60 psi) relief valve, installed in the return manifold between the cooler inlet and outlet ports of the manifold, provides a bypass route for oil to flow in the event the oil cooler is plugged.

OIL COOLER CIRCUIT DIAGRAM 10.6

Tigercat 220C Loader

SECTION 12 - BOOM NOVEMBER, 2007

CONTENTS - SECTION 12 CIRCUIT DESCRIPTION ............................................................................. 12.6 CIRCUIT DIAGRAM ..................................................................................... 12.7 CONTROL VALVES HOIST CONTROL VALVE ........................................................................ 12.4 JOYSTICK CONTROL VALVE. SEE SERVICE MANUAL SECTION 5 STICK CONTROL VALVE ........................................................................ 12.4 FILTERS HYDRAULIC RETURN ............................................................................. 12.3 HOIST VALVE RELIEF VALVE SETTINGS ................................................. 12.8 PRESSURE SETTINGS SUMMARY ............................................................................................... 12.9 STICK VALVE RELIEF VALVE SETTINGS .................................................. 12.9

Tigercat 220C Loader BOOM SYSTEM COMPONENTS

Boom functions 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 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.

JOYSTICK CONTROL VALVE BOOM PUMPS

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.

SWING PUMP

•• •

•

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

BELL HOUSING

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.

220C-019

OUTLET DRIVEN (IDLER) GEAR

DRIVE GEAR

•

•

INLET

TYPICAL GEAR PUMP GEAR1 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.

12.2

Tigercat 220C Loader

Boom functions

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.

FILTER RESTRICTION INDICATOR

••

•• •• WATER ABSORBING RETURN FILTER (COLOUR BLUE) 220C-004

••

••

220C-003

HYDRAULIC RETURN FILTERS

HYDRAULIC RETURN 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).

OIL SAMPLING CONNECTOR

•

230C-012

HYDRAULIC OIL RETURN MANIFOLD

Return oil from each of the three control valves passes through a return manifold located in the lower front side of the pump compartment near the control valves. Stick and hoist return oil flows to the oil filters and then to tank. Swing return oil flows from the return manifold to the oil cooler and back to the return manifold to the oil filters and then to tank. An oil sampling connector is mounted on the manifold.

12.3

FILTER RESTRICTION INDICATOR

A filter restriction indicator is mounted onto the twin filter housing. 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 filter elements.

Tigercat 220C Loader

Boom functions

MAIN RELIEF 190 BAR (2750 PSI) STICK 'IN' PORT RELIEF 103.4 BAR (1500 PSI)

GAUGE TEST PORT

•• ••

•

INLET SECTION STICK 'OUT' PORT RELIEF 234.4 BAR (3400 PSI)

HOIST 'DOWN' PORT RELIEF 103.4 BAR (1500 PSI)

MAIN RELIEF 190 BAR (2750 PSI)

STICK

INLET SECTION

•• ••

•

HOIST 'UP' PORT RELIEF 234.4 BAR (3400 PSI)

GRAPPLE OPEN/CLOSE

GRAPPLE ROTATE

••

GAUGE TEST PORT

••

•

HOIST

OPTIONAL

••

OPTIONAL

••

•• OUTLET SECTION

OUTLET SECTION

AT047IL

BOOM CONTROL VALVES BOOM CONTROL VALVES 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 (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.

12.4

Tigercat 220C Loader

Boom functions

RELIEF VALVE PORT 'A'

RELIEF VALVE PORT 'B'

SEAL GROOVES

A

B

SPOOL CENTERING SPRINGS

•

• • •

•

•

•

• •

•

• PILOT END CAP

AT047IL2

•

•

•

• SPOOL TANK PASSAGE

PARALLEL PASSAGE

LOAD CHECK VALVE

THRU' NEUTRAL PASSAGE

WORK PORT BRIDGE

TANK PASSAGE

PILOT END CAP

CROSS SECTION OF SPOOL SECTIONS

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).

12.5

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.

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

Tigercat 220C Loader

Boom functions

BOOM 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 the return manifold and three filters.

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, to the return oil filters and back to tank.

12.6

Tigercat 220C Loader

220C-054

Boom functions

BOOM CIRCUIT 12.7

Tigercat 220C Loader PRESSURE SETTINGS

Boom functions

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

MAIN RELIEF 190 BAR (2750 PSI)

CAUTION

HOIST 'DOWN' PORT RELIEF 103.4 BAR (1500 PSI)

Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

GAUGE TEST PORT INLET SECTION

•• ••

•

HOIST 'UP' PORT RELIEF 234.4 BAR (3400 PSI)

GRAPPLE OPEN/CLOSE

WARNING

••

HOIST

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

•

OPTIONAL

••

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

OUTLET SECTION

................................................. 190 Bar/2750 psi

AT047IL

Hoist up port relief setting ...............................

............................................. 103.4 Bar/1500 psi

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.

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

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

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

11. Repeat steps 7 and 9 to verify settings.

............................................. 234.4 Bar/3400 psi Hoist down port relief setting ..........................

reset main relief valve:

3. Connect a 0 - 350 Bar (0 - 5000 psi) pressure gauge to the "hoist" control valve test port on the inlet section of the valve.

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

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.

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

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.

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

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

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.

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

12.8

Tigercat 220C Loader

Boom functions

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 MAIN RELIEF 190 BAR (2750 PSI)

CAUTION Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

GAUGE TEST PORT

•

STICK 'IN' PORT RELIEF 103.4 BAR (1500 PSI)

••

•

WARNING

INLET SECTION

STICK 'OUT' PORT RELIEF 234.4 BAR (3400 PSI)

GRAPPLE ROTATE

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

•

STICK

•

OPTIONAL

STICK VALVE RELIEF VALVE SETTINGS Stick main relief setting .................................... ................................................ 190 Bar/2750 psi

OUTLET SECTION

•• AT047IL

Stick out port relief setting ............................... ............................................. 234.4 Bar/3400 psi Stick in port relief setting ................................. ............................................. 103.4 Bar/1500 psi 1. Position machine on flat level ground with stabilizers down.

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.

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

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

11. Repeat steps 7 and 9 to verify setting.

3. Connect a 0 - 350 Bar (0 - 5000 psi) pressure gauge to the "stick" control valve test port on the inlet section of the valve.

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

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

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.

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.

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

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

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

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.

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

12.9

Tigercat 220C Loader

Boom functions

12.10

Tigercat 220C Loader

SECTION 15 - SWING NOVEMBER, 2007

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 SWING BEARING BACKLASH ............................................................................................. 15.12 SEAL KIT ................................................................................................ 15.11 WEAR LIMITS ........................................................................................ 15.10 SWING MOTOR ........................................................................................... 15.4 MOTOR CROSSLINE RELIEF VALVE ........................................... 15.6, 15.8 MOTOR REMOVAL NOTE ....................................................................... 15.4 SWING PUMP .............................................................................................. 15.2

Tigercat 220C 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 SWING PUMP

••

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

•

•

SWING CONTROL VALVE 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.

BELL HOUSING

GEAR PUMP 220C-019 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. FOOT PEDAL CONTROL VALVE

1

•

5

•

•

•

TANK PORT

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.

3

• 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 AW017

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 220C Loader

Swing GAUGE TEST PORT

MAIN RELIEF 179 BAR (2600 PSI)

INLET SECTION

•

SWING 'CW' PORT RELIEF 207 BAR (3000 PSI)

•

• ••

SWING 'CCW' PORT RELIEF 207 BAR (3000 PSI)

•

SWING STABILIZER

•• OUTLET SECTION

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 220C 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 69 Bar (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 220C 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 220C 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 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 220C Loader

220C-055

Swing

SWING DRIVE CIRCUIT 15.7

Tigercat 220C Loader

Swing

PRESSURE SETTINGS

MAIN RELIEF 179 BAR (2600 PSI)

CAUTION

SWING 'CW' PORT RELIEF 207 BAR (3000 PSI)

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

• SWING

GAUGE TEST PORT SWING 'CCW' PORT RELIEF 207 BAR (3000 PSI)

••

Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

6. Install a 0 - 350 Bar (0-5000 psi) pressure gauge on the test port at the inlet section of the swing valve.

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

7. Start engine and place throttle control in FULL.

SET SWING RELIEF VALVES Swing main relief valve setting ........................ .......................................... 179 Bar/2600 psi Swing left port relief setting ............................. .......................................... 207 Bar/3000 psi Swing right down port relief setting ................ .......................................... 207 Bar/3000 psi Motor crossline relief valves ............................ .......................................... 121 Bar/1750 psi

8. Lower boom assembly to the ground and restrict boom swing movement in both directions.

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.

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

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

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

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.

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.

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

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.

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

•

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

•

AQ014-2

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

•

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

MOTOR CROSSLINE RELIEF VALVE 15.8

Tigercat 220C Loader

Swing

SET SWING MOTOR CROSSLINE RELIEF VALVES

CROSS LINE 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.Loosen locknut and adjust crossline relief valves back to original position.

PRESSURE PORTS

• ••

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.

•• CASE DRAIN LINE

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

220-D53

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.

15.9

SWING MOTOR

•

Tigercat 220C Loader

Swing

SWING BEARING WEAR LIMITS

The following procedure will verify the amount of wear in the ball race:

It is important that the swing bearing be periodically inspected for wear. Any significant wear will be noticeable by observing too much "tilting" of the upper frame relative to the lower frame. A small amount of designed-in clearance in the bearing is normal and is present in a new machine.

1. Position machine with boom fully extended as in position 1.

2. Set dial indicator (A) to zero.

3. Lower boom as in position 2.

4. Note tilt reading on dial indicator.

Too much clearance will affect the backlash between the ring gear and the drive pinion and if left unchecked will cause damage to the gear teeth and ultimately the swing drive gearbox.

5. Return machine to position 1.

6. Check to see if reading on dial indicator has returned to zero, if not repeat steps 1 thru 4.

The main cause of wear in the ball race can be due to a lack of lubricant or not following the proper lubricating procedure. A damaged or missing peripheral seal will also contribute to early wear by allowing dirt particles to enter the ball race.

7. Rotate upper frame 90 deg. and repeat steps 1 thru 6.

8. The bearing is considered to be worn when the total play is 0.105" or greater.

Regular inspection of the seal should be carried out and the proper lubricating procedure should be followed. Refer to FILTER AND LUBRICATION SCHEDULE in SECTION 3 of THIS MANUAL.

15.10

Tigercat 220C Loader

Swing

SWING BEARING SEAL KIT

SEAL

••

INSTALLATION INSTRUCTIONS 1. Remove all traces of former seal and glue from the seal groove.

Groove should then be cleaned with a nonresidue commercial solvent.

2. Wipe the seal with the same solvent.

3. Apply a bead of adhesive (BN157) to the seal groove (avoid the adhesive from being extruded into the bearing cavity as the seal is installed.)

4. Insert the seal into the groove ( the length of seal provided is longer than required), trim the excess with a sharp knife or pruning shears in such a manner to smoothly meet the adjoining end. Place a drop of crazy glue (BN158) on the end so that the two ends will be joined.

5. Immediately butt the two ends together, aligning them as quickly as possible. Hold together without movement (motion weakens and may destroy the bond). After 2 minutes the joint will be strong enough.

NOTE: Read the precautions on adhesive container. Avoid getting adhesive on your fingers. It will bond them together.

6. Coat joint with grease from bearing. Moisture or high humidity may weaken bond unless protected with grease.

7. Examine seal for contact withseal surface on race ring.

8. Re-grease the bearing until grease extrudes from under the seal to remove any foreign matter.

15.11

•• SEAL 860C-0004

SWING BEARING SEAL

Tigercat 220C Loader

Swing

ADJUST SWING BEARING BACKLASH Make up adjustment tool from a 101.6x101.6mm (4" x4") piece of 6.35mm (0.25") thick steel plate.

0.25" 6.35mm

4" 101.6mm 860C-186

4" 101.6mm

ADJUSTMENT TOOL

Weld a 1" nut on the plate as shown.

Loosen swing bearing outer race bolts, and adjust the hex head bolt to decrease the backlash or swing the upper 180° and adjust the hex head bolt to reposition swing bearing to obtain acceptable backlash of 0.43mm to 0.66mm (0.017" to 0.026").

Torque four pairs of swing bearing outer race bolts located at 90° to each other to 610 Nm (450 lbs. ft.)

Position the adjustment tool up against the underside of the turntable 12.7mm (1/2") away from the bearing. Weld the tool to the turntable as shown using 6.35mm (1/4") fillet weld.

Recheck and adjust backlash every 45° of gear rotation to obtain acceptable backlash of 0.43mm to 0.66mm (0.017" to 0.026").

Install a 1" x 6" hex head bolt in the nut.

Check the backlash between the pinion gear and swing bearing gear teeth. Should be 0.43mm to 0.66mm (0.017" to 0.026").

Apply Loctite 242 to all bolts and torque swing bearing mounting bolts to 542-610 Nm ( 400-450 lbs.ft.) with sequence shown above.

15.12

Tigercat 220C Loader

SECTION 16 - STABILIZERS NOVEMBER, 2007

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

Tigercat 220C 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 STABILIZER SWING PUMP

••

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

•

•

'C' REAR RIGHT 'B' FRONT RIGHT

••

BELL HOUSING

'D' REAR LEFT 'E' FRONT LEFT

••

•

•

• GEAR PUMP 220C-019 The stabilizer pump is a fixed displacement external triple gear pump.

'A' SYSTEM PRESSURE SUPPLY

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 220C-009

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

STABILIZER PILOT MANIFOLD 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

For a detailed description of the pilot manifold refer to SECTION 5 in THIS MANUAL. 'PB' TO STABILIZER PILOT MANIFOLD

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.

STABILIZERS STABILIZERS PILOT SHUT OFF VALVE UP DOWN

• • •

PILOT RELIEF VALVE

• •

• RETURN OIL FROM STABILIZER PILOT MANIFOLD 230B-04

VIEWED FROM ABOVE

•

GAUGE TEST PORT

PILOT MANIFOLD ASSEMBLY

16.2

Tigercat 220C Loader

Stabilizers GAUGE TEST PORT

MAIN RELIEF 179 BAR (2600 PSI)

INLET SECTION

•

STABILIZER "UP" PORT RELIEF 138 BAR (2000 PSI)

STABILIZER "DOWN" PORT RELIEF 207 BAR (3000 PSI)

•

• SWING

••

••

STABILIZER

•• OUTLET SECTION

STABILIZER 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

16.3

TANK PASSAGE

PILOT END CAP

Tigercat 220C Loader

Stabilizers

STABILIZER CYLINDERS AND COUNTERBALANCE VALVES

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.

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.

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.

VERTICAL CENTERLINE

LOWER FRAME

275-15

•

COUNTERBALANCE VALVE

STABILIZER CYLINDER COUNTERBALANCE VALVE

Each counterbalance valve assembly includes a counterbalance cartridge and a "pilot-to-open" check valve cartridge.

•

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

The counterbalance cartridge relief pressure range is adjustable and factory set to 69 Bar (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 69 Bar (1000 psi) setting.

230-06A

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; 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 2 Bar (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 counterbalance valve to the 'VR' port and back to tank via the stabilizer control valve.

16.4

Tigercat 220C Loader

220-062

Stabilizers

LOWER FRAME HYDRAULIC CONNECTIONS - BASIC LOADER 16.5

Tigercat 220C Loader

220-064

Stabilizers

LOWER FRAME HYDRAULIC CONNECTIONS - SELF PROPELLED OPTION 16.6

Tigercat 220C Loader

220-034

Stabilizers

LOWER FRAME HYDRAULIC CONNECTIONS - CIRCLE SAW OPTION 16.7

Tigercat 220C Loader

Stabilizers

STABILIZER CIRCUIT DESCRIPTION

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

Refer to STABILIZER CIRCUIT DIAGRAM 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 1.7 Bar (25 psi) element bypass valve. A 4 Bar (60 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.

LOWERING STABILIZER(S) 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.

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.

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.

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

16.8

Tigercat 220C Loader

220C-056

Stabilizers

STABILIZER CIRCUIT - CIRCLE SAW SHOWN 16.9

Tigercat 220C Loader

Stabilizers

PRESSURE SETTINGS

7. Place stabilizer control switch in UP position.

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.

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

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

CAUTION Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

10. Place stabilizer control switch in DOWN position.

CAUTION SET STABILIZER RELIEF VALVES

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.

Stabilizer/"Swing" main relief valve setting .... .......................................... 179 Bar/2600 psi Stabilizer up port relief setting ......................... .......................................... 138 Bar/2000 psi Stabilizer down port relief setting .................... .......................................... 207 Bar/3000 psi Counterbalance relief valves* .......................... ............................................ 69 Bar/1000 psi *NOTE: The counterbalance valve cartridge is factory set to 69 Bar (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.

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.

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.

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.

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.

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.

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

6. Start engine and place throttle control in FULL.

16.10

Tigercat 220C Loader

SECTION 17 - GRAPPLE NOVEMBER, 2007

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

Tigercat 220C 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 sections 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.

BOOM PUMPS STABILIZER SWING PUMP

• ••

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.

BELL HOUSING

220C-019

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.

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 220C Loader GRAPPLE ROTATE 'CLOCKWISE' PORT RELIEF 207 BAR (3000 PSI)

Grapple

MAIN RELIEF 192 BAR (2750 PSI)

GAUGE TEST PORT

••

INLET SECTION

GRAPPLE 'OPEN' PORT RELIEF 207 BAR (3000 PSI)

••

• •

MAIN RELIEF GAUGE 192 BAR TEST PORT (2750 PSI)

•• ••

•

GRAPPLE ROTATE

GRAPPLE 'CLOSE' PORT RELIEF 207 BAR (3000 PSI)

••

GRAPPLE OPEN/CLOSE

•

•

INLET SECTION

HOIST

STICK OPTIONAL

OPTIONAL

••

GRAPPLE ROTATE 'COUNTERCLOCKWISE' PORT RELIEF 207 BAR (3000 PSI)

OUTLET SECTION

•• OUTLET SECTION AT047IL

GRAPPLE CONTROL VALVES

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 220C Loader

Grapple

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 open center spool sections, to the outlet section.

From there it is directed back to tank via the return manifold and filters, which are equipped with an internal 1.7 Bar (25 psi) bypass valve.

220C-002

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.

220C-002

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 return manifold and filters and back to tank.

17.4

Tigercat 220C Loader

220C-058

Grapple

GRAPPLE CIRCUIT 17.5

Tigercat 220C Loader

Grapple

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 GRAPPLE 'OPEN' PORT RELIEF 207 BAR MAIN RELIEF (3000 PSI) 192 BAR (2750 PSI)

CAUTION Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

GAUGE TEST PORT

• ••

••

GRAPPLE OPEN/CLOSE

•

WARNING

INLET SECTION

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

••

HOIST OPTIONAL

PRESSURE SETTINGS

••

GRAPPLE OPEN/CLOSE RELIEF VALVE SETTINGS Grapple open/close "Hoist" main relief setting:-

OUTLET SECTION

........................................... 190 Bar/2750 psi Grapple open port relief setting ........................

GRAPPLE 'CLOSE' PORT RELIEF 207 BAR (3000 PSI)

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

........................................... 207 Bar/3000 psi Grapple close port relief setting .......................

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.

........................................... 207 Bar/3000 psi 1. Position machine on flat 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.

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 - 350 Bar (0 - 5000 psi) pressure gauge to the "hoist" control valve test port on the inlet section of the valve.

10. Tighten locknut on adjusting screw taking care not to turn the adjusting screw. reset main relief valve: 11. Loosen locknut on "hoist" main relief and unscrew adjusting screw 3 full turns.

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.

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

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

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

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.

17.6

Tigercat 220C Loader

Grapple

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 GRAPPLE ROTATE 'CLOCKWISE' PORT RELIEF 207 BAR (3000 PSI)

CAUTION Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

MAIN RELIEF 192 BAR (2750 PSI)

GAUGE TEST PORT

••

INLET SECTION

••

•• ••

GRAPPLE ROTATE

WARNING

••

STICK

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

OPTIONAL

•

GRAPPLE ROTATE RELIEF VALVE SETTINGS Grapple rotate/"Stick" main relief setting:........................................... 190 Bar/2750 psi Rotate clockwise port relief setting .................

OUTLET SECTION

GRAPPLE ROTATE 'COUNTERCLOCKWISE' PORT RELIEF 207 BAR (3000 PSI)

.......................................... 207 Bar/3000 psi 9. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

Rotate counterclockwise port relief setting .......................................... 207 Bar/3000 psi

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

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.

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

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

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

12. Release grapple from it's secured position.

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.

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

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

6. Connect a 0 - 350 Bar (0 - 5000 psi) 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.

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.

17.7

reset main relief valve:

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.

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

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

Tigercat 220C Loader

Grapple

17.8

Tigercat 220C Loader

SECTION 18 - SLASHER NOVEMBER, 2007

CONTENTS - SECTION 18 CIRCUIT DIAGRAM ........................................................................ 18.6, 18.7 CONTROL VALVES ................................................................................. 18.2 ELECTRICAL CIRCUIT ............................................................................ 18.9 HYDRAULIC CIRCUIT LOWER FRAME .................................................. 18.7 HYDRAULIC CIRCUIT UPPER FRAME ................................................... 18.6 PILOT CIRCUIT COMPONENTS ............................................................. 18.5 PILOT MANIFOLD ................................................................................... 18.2 PRESSURE SETTINGS ........................................................................... 18.8 SLASHER CONNECTIONS ..................................................................... 18.4 SLASHER PUMP ..................................................................................... 18.2

Tigercat 220C Loader

Slasher

SLASHER CIRCUIT COMPONENTS

'PB' TO STABILIZER PILOT MANIFOLD

PUMP

TOP SAW CUT DELIMBER OPEN

•

BOOM PUMPS SWING PUMP

• ••

•

• •

PILOT SHUT OFF VALVE

•

PILOT RELIEF VALVE

•

••

•

• RETURN OIL FROM STABILIZER PILOT MANIFOLD 230B-04

BELL HOUSING

220C-019

SLASHER CUT TOP/SLASHER SAWS RETRACT

GEAR PUMP

This is a fixed displacement external triple gear pump.

The slasher circuits utilize two gear housings of this pump (boom sections) to supply hydraulic oil to the main control valve spool sections of the hoist valve and stick valve.

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

For a detailed description of the pilot manifold refer to SECTION 5 in THIS MANUAL.•

•

DELIMBER CONTROL VALVE (HOIST VALVE) The delimber arms OPEN/CLOSE functions are controlled by one of three spool sections in the 230C-025 PILOTcontrol MANIFOLD three section "hoist" valve.

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

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

18.2

GAUGE TEST PORT

PILOT MANIFOLD ASSEMBLY

•

Tigercat 220C Loader

Slasher

MAIN RELIEF 190 BAR (2750 PSI) SAWS CUT PORT RELIEF 207 BAR (3000 PSI)

•

SAWS RETRACT PORT RELIEF 103.4 BAR (1500 PSI)

•

••

MAIN RELIEF 190 BAR (2750 PSI)

INLET SECTION

GAUGE TEST PORT

SPARE PORT RELIEF 207 BAR (3000 PSI)

••

DELIMBER OPEN PORT RELIEF 207 BAR (3000 PSI)

•

••

GRAPPLE OPEN/CLOSE

GRAPPLE ROTATE

••

INLET SECTION

GAUGE TEST PORT

••

STICK

HOIST

•

SAWS CUT SAW RET

••

SPARE DEL OPEN

•

•• OUTLET SECTION

OUTLET SECTION

BOOM CONTROL VALVES

AT047IL

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 18.3

TANK PASSAGE

PILOT END CAP

Tigercat 220C Loader

Slasher

SLASHER CONNECTIONS The hydraulic connections for the slasher are located at the rear of the lower frame. They 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 the slasher. When making the hydraulic connection to the slasher, it is very important to clean around the fittings before disconnecting them to prevent dirt from entering the system.

For information on the SLASHER, please refer to the MANUFACTURERS MANUAL.

SLASHER RETRACT

TANK

•• •• 275-16

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

18.4

SLASHER CUT

••

SLASHER CONNECTIONS

Tigercat 220C Loader

220C-066 220C-065

Slasher

PILOT CIRCUIT COMPONENTS - SLASHER 18.5

Tigercat 220C Loader

220C-064

Slasher

SLASHER MAIN HYDRAULIC CIRCUIT UPPER FRAME 18.6

Tigercat 220C Loader

220C-063

Slasher

SLASHER HYDRAULIC CIRCUIT LOWER FRAME 18.7

Tigercat 220C Loader

Slasher

PRESSURE SETTINGS FOR TOP SAW CUT, SLASHER CUT AND DELIMBER

5. Connect a 0-350 Bar (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.

CAUTION

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.

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.

8. Tighten locknut on adjusting screw taking care 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.

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

NOTE: The 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 SLASHER CUT, SAW RETRACT (STICK VALVE) Slasher cut/"Stick" main relief setting:........................................ 190 Bar (2750 psi) Slasher cut port relief setting ..........................

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.

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

........................................ 207 Bar (3000 psi) Saw retract port relief setting ..........................

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

..................................... 103.4 Bar (1500 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 "stick" main relief valve and turn the relief adjusting screw all the way in, tighten locknut.

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.

18.8

Tigercat 220C Loader

230C-020

Slasher

DELIMBER/SLASHER CIRCUIT

18.9

Tigercat 220C Loader

Slasher

FUSE, RELAY AND DIODE PANEL - CAB

NOT USED

230C-021

NOT USED

FUSE AND RELAY PANEL

FUSE AND RELAY PANEL

18.10

Tigercat 220C Loader

SECTION 19 - Circle Saw NOVEMBER, 2007

CONTENTS - SECTION 19 BUTT BOARD/HOIST/ GRAPPLE CONTROL VALVE .................. 19.3, 19.11 CIRCLE SAW CIRCUIT COMPONENTS ................................................. 19.2 CIRCLE SAW CONNECTIONS ................................................................ 19.4 CIRCLE SAW MOTOR CONTROL VALVE ........................... 19.3, 19.8, 19.9 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, 19.11

Tigercat 220C Loader

Circle Saw

CIRCLE SAW CIRCUIT COMPONENTS

CIRCLE SAW MOTOR CONTROL VALVE

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.

CIRCLE SAW PUMP

SAW CUT AND SAW RETRACT CONTROL VALVE (STABILIZERS/SWING VALVE)

BOOM PUMPS SWING PUMP

••

The circle saw cutting function and the retraction of the saw are controlled by one of three spool sections in the "swing" control valve.

•• •• ••

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

••

BELL HOUSING

GEAR PUMP

220C-052

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 230B-04

•

GAUGE TEST PORT

PILOT MANIFOLD ASSEMBLY

For a detailed description of the pilot manifold refer to SECTION 5 in THIS MANUAL.

19.2

Tigercat 220C Loader MAIN RELIEF 179 BAR (2600 PSI)

•• • •

Circle Saw MAIN RELIEF 179 BAR (2600 PSI)

GAUGE TEST PORT INLET SECTION

BUTT BOARD PORT RELIEF 138 BAR (2000 PSI)

SAW 'CUT' PORT RELIEF 138 BAR (2000 PSI)

INLET SECTION

•

••

••

••

MAIN RELIEF 179 BAR (2600 PSI)

GAUGE TEST PORT

••

••

GAUGE TEST PORT INLET SECTION

•

GRAPPLE ROTATE

GRAPPLE CLOSE/OPEN

SWING

STICK

HOIST

STABILIZERS

••

LIVE HEEL OPTIONAL

BUTT BOARD DOWN UP

••

LIVE HEEL/STICK/ GRAPPLE CONTROL VALVE

SAW PRESSURE PORT RELIEF 207 BAR (3000 PSI)

•• • ••

SAW 'RETRACT' PORT RELIEF 138 BAR (2000 PSI)

OUTLET SECTION

SWING/STABLIZER/SAW CUT/ RETRACT CONTROL VALVE

BUTT BOARD/HOIST/ GRAPPLE CONTROL VALVE MAIN RELIEF 179 BAR (2600 PSI)

••

CIRCLE SAW

••

BUTT BOARD PORT RELIEF 138 BAR (2000 PSI)

OUTLET SECTION

OUTLET SECTION

••

••

GAUGE TEST PORT INLET SECTION

• ••

CIRCLE SAW MOTOR

••

SAW RETURN PORT RELIEF 207 BAR (3000 PSI)

OUTLET SECTION

CIRCLE SAW MOTOR CONTROL VALVE

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 19.3

TANK PASSAGE

PILOT END CAP

Tigercat 220C 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 220C Loader

220-035

Circle Saw

MAIN HYDRAULIC CIRCUIT - CIRCLE SAW 19.5

Tigercat 220C Loader

220-017

Circle Saw

PILOT CIRCUIT - CIRCLE SAW 19.6

Tigercat 220C Loader

220C-053

Circle Saw

CIRCLE SAW - ELECTRICAL DIAGRAM 19.7

Tigercat 220C Loader

220-D51

220-D51

Circle Saw

MAIN VALVES

CIRCLE SAW MOTOR CONTROL VALVE 19.8

Tigercat 220C Loader

Circle Saw

PRESSURE SETTINGS FOR CIRCLE SAW MOTOR, SAW CUT/ RETRACT AND BUTT BOARD

MAIN RELIEF 179 BAR (2600 PSI) SAW PRESSURE PORT RELIEF 207 BAR (3000 PSI)

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

• •• •

INLET SECTION

••

CIRCLE SAW MOTOR

•

OUTLET SECTION

CAUTION

GAUGE TEST PORT

•• SAW RETURN PORT RELIEF 207 BAR (3000 PSI)

CIRCLE SAW MOTOR CONTROL VALVE

Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

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, loosen locknut and turn port relief valve adjusting screw in to increase pressure or out to decrease pressure until set value is obtained on gauge.

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

NOTE:

The Butt Board, Saw Motor and Saw Cut/Retract 7. Tighten locknut on adjusting screw taking care not to turn the adjusting screw. Circle Saw hydraulic hoses must be disconnected at the Motor drive pressure port relief valve is now loader connections before carrying out the set. following procedure. Cap the hoses to keep clean and use the appropriate steel caps on the NOTE: The return port relief is not used, it is fittings to prevent leakage during the pressure factory set to 3000 psi and serves only as a setting procedure. plug. The pilot line connected to the spool section pilot end cap is a "vent" to allow the RELIEF VALVE SETTINGS spool to shift when pilot pressure is applied to CIRCLE SAW MOTOR VALVE the opposite end.

Circle saw motor valve main relief setting:Reset main relief valve: .................................................. 172 Bar/2500 psi 8. Loosen locknut on "Circle Saw Motor Valve" Pressure port relief setting............................... main relief and unscrew adjusting screw 3 full .......................................... 207 Bar/3000 psi turns.

Spare port relief setting ....................................

9. Depress the Circle Saw switch (on the switch .......................................... 207 Bar/3000 psi 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.

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.

4. Connect a 0 - 350 Bar (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.

19.9

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

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.

Tigercat 220C Loader

Circle Saw

RELIEF VALVE SETTINGS SAW CUT, SAW RETRACT (SWING VALVE)

MAIN RELIEF 179 BAR (2600 PSI)

Saw cut/"Swing" main relief setting:- ....................

SAW 'CUT' PORT RELIEF 138 BAR (2000 PSI)

.................................................. 179 Bar/2600 psi

•

••

Saw cut port relief setting ................................ .......................................... 138 Bar/2000 psi

GAUGE TEST PORT INLET SECTION

•

SWING

Saw retract port relief setting ..........................

STABILIZERS

••

.......................................... 138 Bar/2000 psi

CIRCLE SAW

••

1. Position machine on level ground with stabilizers down.

OUTLET SECTION

2. Ensure that the hydraulic oil is at operating temperature and that the AUTO RETRACT switch is OFF.

••

SAW 'RETRACT' PORT RELIEF 138 BAR (2000 PSI)

SWING/STABLIZER/SAW CUT/ RETRACT CONTROL VALVE

3. Connect a 0 - 350 Bar (0 - 5000 psi) pressure gauge to the "swing" control valve test port on the inlet section of the valve.

Check main relief 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, loosen 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, loosen locknut and turn port relief valve adjusting screw in to increase pressure or out to decrease pressure until set value is obtained on gauge.

9. Select stabilizer ALL and hold stabilizer DOWN switch in the DOWN position, check gauge pressure reading at "swing" valve test connection. If adjustment is required, loosen locknut and turn main relief valve adjusting screw in to increase pressure or out to decrease pressure until set value is obtained on gauge.

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

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.

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

19.10

Tigercat 220C Loader

Circle Saw

RELIEF VALVE SETTINGS BUTT BOARD UP/DOWN (HOIST VALVE)

MAIN RELIEF 179 BAR (2600 PSI)

Butt Board/"Hoist" main relief setting:- ................

BUTT BOARD PORT RELIEF 138 BAR (2000 PSI)

.................................................. 189 Bar/2750 psi Butt Board Up port relief setting .......................

••

•

.......................................... 138 Bar/2000 psi

GAUGE TEST PORT INLET SECTION

••

GRAPPLE CLOSE/OPEN

Butt Board Down port relief setting ..................

HOIST

••

.......................................... 138 Bar/2000 psi 1. Position machine on level ground with stabilizers down.

BUTT BOARD DOWN UP

•

OUTLET SECTION

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

3. Connect a 0 - 350 Bar (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, loosen 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.

•

BUTT BOARD PORT RELIEF 138 BAR (2000 PSI)

BUTT BOARD/HOIST/ GRAPPLE CONTROL VALVE Check main relief valve: 9. While holding the L.H. joystick in the HOIST UP position, check gauge pressure reading. If adjustment is required, loosen locknut and turn port relief valve adjusting screw in to increase pressure or out to decrease pressure until set value is obtained on gauge.

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

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

12. Clean hoses and fittings and re-connect Butt Board, Saw Motor and Saw Cut/Retract units to Loader.

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, loosen locknut and turn port relief valve adjusting screw in to increase pressure or out to decrease pressure until set value is obtained on gauge.

8. Tighten locknut on adjusting screw taking care not to turn the adjusting screw. BUTT BOARD DOWN port relief on "hoist" valve is now set.

19.11

Tigercat 220C Loader

Circle Saw

19.12