Tigercat 250 Loader Service Manual - PDF DOWNLOAD

SERVICE MANUAL

Tigercat 250 Loader

TABLE OF CONTENTS

Issue 1.1, MARCH 2003

SECTION INTRODUCTION .............................................................................................................. iii NON-APPROVED FIELD PRODUCT CHANGES ............................................................ iv SAFETY ............................................................................................................................ 1 CONTROLS AND OPERATION ............................. See separate OPERATOR'S MANUAL LUBRICATION AND MAINTENANCE ............................................................................... 3 HYDRAULIC SYSTEM/ LOAD SENSE CONTROL ........................................................... 4 PILOT SYSTEM ................................................................................................................ 5 ELECTRICAL, GAUGES AND ALARMS ........................................................................... 6 ENGINE START AND STOP ............................................................................................. 7 ENGINE ANTI-STALL ....................................................................................................... 9 BOOM FUNCTIONS ....................................................................................................... 12 SWING ............................................................................................................................ 15 STABILIZERS ................................................................................................................. 16 GRAPPLE ....................................................................................................................... 17 DELIMBER/SLASHER .................................................................................................... 18

250-SM00

250 Available Literature Operator's Manual ............................... Part No. 17381A Service Manual .................................... Part No. 17382A Parts Catalog ....................................... Part No. 17380A Hydraulic Adapters Book ....................... Part No. 1472A Hydraulic Hose assemblies Book ......... Part No. 3707A

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

®

Tigercat 250 Loader

Introduction

ii

Tigercat 250 Loader

Introduction

Tigercat 250 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 250 Loader.

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 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.

250-01

iii

Tigercat 250 Loader

Introduction

NON-APPROVED FIELD PRODUCT CHANGES The installation of any unauthorized attachment or changes made of any kind to this Tigercat product could affect the product's ability to perform as originally intended. The product's integrity, stability and safety could be at serious risk.

IT IS Tigercat POLICY THAT NO CHANGES ARE TO BE MADE TO ITS PRODUCTS INCLUDING DELETIONS OR ADDITIONS OTHER THAN A Tigercat APPROVED OPTION FITTED IN THE FACTORY APPROVED MANNER. Official approval to make changes or install options is only as follows: i) The relevant options for that product must be shown or listed on current Tigercat documentation or literature such as a printed specification sheet, price list, parts manual, or product literature issued by Tigercat . ii) Approved options or product changes authorized in writing by the Tigercat Engineering Manager.

Authorization by any other person is unacceptable.

Unauthorized changes made or contributed to by a person or organization may result in creating a dangerous situation and therefore the person or organization will be considered to have assumed the risk involved or be negligent in creating this situation.

Weight is an important factor when considering the addition of options or an attachment, Refer to your Tigercat distributor for information on maximum permissible operating weight and the effect the addition of various options may have on your machine.

Tigercat will not be held responsible for any situation that may arise resulting from Non-approved Field Product Changes to its product.

Should Tigercat become involved in a suit resulting from changes made to the product without proper authorization by Tigercat as stated above, Tigercat will take whatever action is appropriate to protect its interests.

The product warranty policy and the certification on any safety items installed on the modified product will become NULL and VOID if the above policy is not adhered to as specified.

Non-approved product changes also nullify warranties given to Tigercat by its component manufacturers.

Tigercat Industries Inc.

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Tigercat 250 Loader

SECTION 1 - SAFETY Read and understand this Safety section prior to operating any equipment.

Read and understand all manuals for any attachments or accessories.

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

MARCH 2003

Tigercat 250 Loader

Safety

SAFETY SYMBOLS

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

Understanding Signal Words

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

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

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

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

1.2

Tigercat 250 Loader

Safety familiar with and adhere to. More specific measures are illustrated with pictograms which may also be attached to the machine in locations pertinent to their respective message. Keep safety labels in good condition. Repair or replace damaged labels.

GENERAL SAFETY PRECAUTIONS Remember that safety is a prime responsibility of all.

To minimize the risks and promote safety at all times, this section of the operator s manual details a number of safety rules which should always be followed and obeyed.

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 500 feet (150M) 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 1.3

Tigercat 250 Loader

Safety exhaust system, safety covers, or other devices removed.

GENERAL SAFETY PRECAUTIONS CONTINUED

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.

Approach with extreme caution, any area where overhanging electrical powerlines are present.

Serious injury or death by electrocution can result if the machine or any of its attachments are not kept a safe distance from these lines.

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

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

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

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

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

Machine should be washed completely at every major service.

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

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

Read, understand and follow all general safety precautions specified by grapple, delimber and saw manufacturers.

WARNING

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

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.

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.

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

1.4

Tigercat 250 Loader

Safety

OPERATING SAFETY PRECAUTIONS

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

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

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

Ensure that the windshield guard is installed and properly secured.

During refuelling do not leave the filler nozzle unattended.

Avoid over filling and immediately clean up spilled fuel.

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

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

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

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

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

Sound the machine horn before starting the machine.

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

Start the engine according to the instructions in this manual.

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

Use only prearranged and approved signalling practices.

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

1.5

Tigercat 250 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.

DANGER

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

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

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

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.

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

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.

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 250 Loader

Safety

SERVICING SAFETY PRECAUTIONS

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

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

When servicing or repairing equipment, shut the engine down. Turn Master Disconnect switch OFF.

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.

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

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

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

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

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

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.

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.

Also, the battery negative terminal must be disconnected.

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

1.7

Tigercat 250 Loader

Safety

SERVICING SAFETY PRECAUTIONS CONTINUED SAFE REMOVAL OF STABILIZER COUNTERBALANCE AND CHECK CARTRIDGES

WARNING

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.

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.

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.

If a stabilizer cannot be moved to the vertical VERTICAL CENTERLINE

LOWER FRAME

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

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

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

•

COUNTERBALANCE VALVE

•

STABILIZER UP IN VERTICAL POSITION

• • •

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

CYLINDER

STABILIZER COUNTERBALANCE/CHECK VALVE CARTRIDGE REMOVAL 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.

230-06A

1.8

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

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

Tigercat 250 Loader

Safety

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 250 Loader

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

FIRE PREVENTION

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

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

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

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

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

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.

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

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

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

3. Remove debris and blow out dust regularly from the air intake doors, engine radiator, hydraulic oil cooler and A/C condenser core to prevent overheating of the engine and hydraulics. Refer to CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR in SECTION 2 of the OPERATOR S MANUAL. 4. Blow off all debris and dust accumulated near hot engine exhaust components (turbocharger and exhaust manifold as well as exhaust pipes and muffler) at the completion of each work shift or more frequently depending on logging conditions. Visual inspection after blow off to ensure thorough cleanliness is vital. Engine exhaust systems provide numerous small pockets where saw dust, small wood chips and other flammable forest debris can gather. Even small accumulations close to hot exhaust components can ignite and smolder. If 1.10

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

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

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

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

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

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

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

Tigercat 250 Loader

Safety WHAT TO DO IN CASE OF A MACHINE FIRE

FIRE PREVENTION continued

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

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

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

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

Shut the engine off.

Activate the fire suppression system*

Radio or call for help (as appropriate).

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

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

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.

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

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

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

Use the PASS method with most extinguishers.

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

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

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

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

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

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

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

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

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

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

Continued on page 12

*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.

1.11

Tigercat 250 Loader

Safety WHAT TO DO AFTER A FIRE

FIRE PREVENTION continued Continued from page 11

20229A

TYPICAL FIRE EXTINGUISHER ACCESS HOLE

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

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

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

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

1.12

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

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

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

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

Tigercat 250 Loader

SECTION 3 - LUBRICATION & MAINTENANCE JULY 2002

CONTENTS - SECTION 3 AIR CLEANER ............................................................................................. 3.12 AIR CLEANER MAINTENANCE ................................................................... 3.13 AIR CONDITIONING - SERVICE ................................................................. 3.14 CYCLE TIMES, FACTORY SETTINGS .............................................. 3.23, 3.25 FILTERS ENGINE AIR FILTER ................................................................................ 3.12 HYDRAULIC OIL RETURN FILTERS ....................................................... 3.10 PILOT RETURN PRESSURE FILTER ..................................................... 3.11 GENERAL MAINTENANCE ........................................................................... 3.3 HYDRAULIC OIL RETURN FILTERS .......................................................... 3.10 HYDRAULIC OILS, APPROVED .................................................................... 3.8 HYDRAULIC TANK PRESSURIZATION SYSTEM EARLIER DESIGN .................................................................................... 3.16 LATER DESIGN ....................................................................................... 3.18 LUBRICATING CYLINDER PINS AND BOOM JOINTS ................................ 3.4 LUBRICATION POINTS ................................................................................. 3.6 NEW MACHINE MAINTENANCE .................................................................. 3.2 FIRST 50-100 HOUR INSPECTION AND SERVICE REPORT .................. 3.2 INITIAL PRE-DELIVERY INSPECTION ...................................................... 3.2 TIGHTENING POINTS ............................................................................... 3.2 OIL LOST FROM LEAKAGE CHART ............................................................. 3.2 PILOT RETURN PRESSURE FILTER ......................................................... 3.11 PRESSURE SETTING PROCEDURES. SEE SERVICE MANUAL PRESSURE SETTINGS MACHINE SERIAL NUMBERS 2500111 TO 2500140 ............................. 3.22 MACHINE SERIAL NUMBERS 2500141 AND UP .................................... 3.24 PREVENTIVE MAINTENANCE SCHEDULE ................................................. 3.2 SCHEDULED MAINTENANCE EVERY 8 HOURS: ...................................................................................... 3.4 EVERY 24 HOURS: .................................................................................... 3.4 EVERY 125 HOURS ................................................................................... 3.4 EVERY 250 HOURS ................................................................................... 3.5 EVERY 500 HOURS: .................................................................................. 3.5 EVERY 1000 HOURS ................................................................................. 3.5 EVERY 2000 HOURS ................................................................................. 3.5 SERVICE AND LUBRICATION POINTS ........................................................ 3.6 TIGHTENING POINTS ................................................................................... 3.2 TORQUE CHART, GENERAL ...................................................................... 3.21 TORQUE SETTINGS, RECOMMENDED .................................................... 3.20 VACUUM PUMP (LATER DESIGN ONLY) .................................................. 3.19

Tigercat 250 Loader

Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE FOR 250 LOADER NEW MACHINE MAINTENANCE

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

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

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

Tightening points:~

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

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

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

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

OIL LOST FROM LEAKAGE

Swing motor mounting bolts Cab securing bolts

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

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

3.2

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

Tigercat 250 Loader

Lubrication and Maintenance

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

Clean around filler caps before checking or adding fluids.

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

Clean up spills as soon as possible.

Always use clean oil and containers.

Drain dirty oil while still warm.

Do not exceed recommended fluid levels.

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

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

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

Before welding on machine be sure the negative battery terminal is disconnected and the anti-stall controller is unplugged.

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

Clean away all branches, bark and chips.

Clean up all traces of oil to avoid fires.

Always have a fire extinguisher at hand.

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

3.3

Tigercat 250 Loader

Lubrication and Maintenance

SCHEDULED MAINTENANCE Condition and tension of fan belts.

EVERY 8 HOURS:~

Conduct an overall visual inspection.

Check engine coolant level

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

Check engine oil level Drain fuel/water separator Clean air cleaner unloader valve. Refer to AIR CLEANER in SECTION 2 of the OPERATOR'S MANUAL.

EVERY 24 HOURS:~ Perform 8 hour maintenance

Check hydraulic oil level

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

Lubricate:~ Swing bearing; 1-fitting - 4 shots while swinging Swing pinion; 1-fitting - 10 shots while swinging

Lubricate stabilizer cylinders; 8-fittings - purge

*Boom joint; 2-fittings - purge

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

*Stick joint; 2-fittings - purge

EVERY 125 HOURS:~

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

Perform 8 hour maintenance

*Lubricating cylinder pins and boom joints:1.

Ensure machine is on level ground

2.

Fully extend stick boom cylinder

3.

Lower main boom and rest grapple firmly on ground or stable trailer 4.

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

Perform 24 hour maintenance And in addition:~ Check air cleaner filter restriction indicator at full engine RPM Check return filter restriction indicator with engine running at high idle and oil flow Check:~ Fluid level in batteries unless maintenance free

Yoke pins; 2-fittings - purge Grapple rotate pinion; 1-fitting - 4 shots, rotate 90° after each shot

Engine RPM

Grapple arm pins; 6-fittings - purge

Hydraulic pumps and motor securing bolts

All hydraulic pressures 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

Swing bearing area Attachment

Check:~ For leakage around hydraulic components and flexible hoses

Make repairs immediately Visually inspect for:~ Frayed electrical wiring and hydraulic hoses

For loose nuts, bolts and fittings

Wear in any other components 3.4

Tigercat 250 Loader

Lubrication and Maintenance

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

Lubricate door and cover hinges; 8 fittings - 1 shot

Cab fresh air filter

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.

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

EVERY 250 HOURS:~ Perform 8 hour maintenance

EVERY 1000 HOURS:~

Perform 24 hour maintenance Perform 125 hour maintenance

Perform 8 hour maintenance

And in addition:~ Replace engine oil and filter

Perform 24 hour maintenance Perform 125 hour maintenance

Replace engine fuel filter

Perform 250 hour maintenance

Replace fuel/water separator filter

Perform 500 hour maintenance

Replace air cleaner primary element

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

Check fire extinguisher and turn it to mix contents Lubricate swing gearbox lower bearing; 2-fittings - 5 shots each ‡

Replace air cleaner unloader valve.

NOTE: Do not use a power grease gun. ‡ With gearbox at operating temperature slowly add 5 shots of lithium based EP2 grease to each side of the gearbox. Note: during cold weather applications the swing function must operate for several hours to achieve operating temperature. Caution: Do not force grease, gearbox failure may result. Do not use winter grease. Grease should purge from gearbox pinion seal.

EVERY 2000 HOURS:~

Check torque on trailer mounting studs.

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

EVERY 500 HOURS:~ Perform 8 hour maintenance

Perform 8 hour maintenance Perform 24 hour maintenance Perform 125 hour maintenance Perform 250 hour maintenance Perform 500 hour maintenance Perform 1000 hour maintenance

______________________________________________

Perform 24 hour maintenance Perform 125 hour maintenance Perform 250 hour maintenance And in addition:~ Replace air cleaner safety element Replace hydraulic oil return filters †

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

Replace hydraulic oil pilot pressure filter †

3.5

Tigercat 250 Loader

Lubrication and Maintenance

DOOR HINGES 2 FTG/500

SWING BEARING 1 FTG/8 12

4 SHOTS WHILE SWINGING

5 1

SWING PINION 1 FTG/8

4

10 SHOTS WHILE SWINGING

2 3 6 7

DOOR HINGES 2 FTG/500

*** SWING GEARBOX LOWER BEARING 2 FTG/250

8

5 SHOTS EACH FITTING (FITTINGS LOCATED UNDER BOOM)

9

STICK JOINT 2 FTG/8

9

BOOM JOINT 2 FTG/8

DOOR HINGES 4 FTG/500

YOKE PINS 2 FTG/8

10

BOOM PINS 4 FTG/8 GRAPPLE ROTATE BEARING 1 FTG/24 4 SHOTS ROTATE 90° AFTER EACH SHOT

11

GRAPPLE ROTATE PINION 1 FTG/8 4 SHOTS ROTATE 90° AFTER EACH SHOT

GRAPPLE ARM PINS 6 FTG/8

STABILIZER ARM JOINTS AND CYLINDERS 16 FTG/24

CYLINDER PINS 4 FTG/8

13682BR2.PDF

3.6

Tigercat 250 Loader

Lubrication and Maintenance

Tigercat® 250 Loader SERVICE AND LUBRICATION POINTS REFER TO Tigercat® OPERATOR’S MANUAL FOR ADDITIONAL INFORMATION

CHK

2

ENGINE OIL AND FILTER CUMMINS 'C'

CHK

3

FUEL FILTER (ENGINE)

4

FUEL/WATER SEPARATOR

5

INTANK FUEL STRAINER

REP

DRN

34

9

24

6.3

60/40 ANTIFREEZE/DISTILLEDWATER ** SEE ENGINE MANUFACTURER'S SERVICE MANUAL

REP

1

REP

1 CHK

AIR CLEANER PRIMARY ELEMENT

1

CHK REP

1

6 AIR CLEANER SAFETY ELEMENT

REP

7

AIR CLEANER UNLOADER VALVE

CHK

8

HYDRAULIC RESERVOIR

CHK

9

RETURN FILTERS † . 3 STANDARD FILTERS . 1 WATER ABSORBING FILTER ON LATER MACHINES

10

PRESSURE FILTER, PILOT †

11 12

1

DRAIN TANK, CLEAN OR REPLACE AS NECESSARY CHECK AIR CLEANER FILTER RESTRICTION INDICATOR AT FULL ENGINE RPM

1

REFER TO OPERATOR'S MANUAL SECTION 2 FOR DETAILS

1

DRAIN AND REFILL AS REQ'D BY SEASONAL OIL CHANGE. REFER TO APPROVED HYD. OILS

REP

4

CHECK FILTER RESTRICTION INDICATOR, ON HYDRAULIC OIL RETURN MANIFOLD, WITH ENGINE RUNNING AT HIGH IDLE WITH OIL FLOW

REP

1

REP

D/R 350

CHK

DESCRIPTION

QTY

2000 $

1000 $

500 $

250 $

CHANGE COOLANT EVERY 2 YEARS

US GAL

COOLING SYSTEM

CAPACITY LITER

1

125 $

ITEM

8$

SERVICE POINT NO.

SERVICE EVERY

92

GRAPPLE, Tigercat

SEE LUBRICATION POINTS DIAGRAM

GRAPPLE, OTHER MANUFACTURERS

SEE MANUFACTURER'S MAINTENANCE SCHEDULE

FIRE EXTINGUISHER

CHK

1

TURN TO MIX CONTENTS

LEGEND LUBRICATION POINT WITH A DESIGNATED NUMBER OF FITTINGS (2 FTG) AND HOURS BETWEEN SERVICING (125 $). EXCEPT WHERE SPECIFIED, PURGE WITH LITHIUM BASED EP2 GREASE CONTAINING MOLYBDENUM DISULFIDE "MOLY". ** ANTIFREEZE MUST MEET GM 6038M SPECIFICATIONS - SEE ENGINE MANUFACTURER'S MAINTENANCE MANUAL. *** DO NOT USE A POWER GREASER. REFER TO SCHEDULED MAINTENANCE: EVERY 250 HOURS IN SECTION 3 OF THE MANUAL FOR DETAILED INSTRUCTIONS. INCORRECT LUBRICATION MAY RESULT IN GEARBOX FAILURE.

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

250LUBCHART.XLS

3.7

$ …….. HOURS CHK …. CHECK REP …. REPLACE DRN …. DRAIN D/R ….. DRAIN & REFILL

Tigercat 250 Loader

Lubrication and Maintenance

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

Chevron

Mechanism LPS 68 (summer)

Citgo

Mystik HVI-68 (summer)

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

Tellus T68 (summer) Tellus T22 (winter)

Texaco

Rando HDZ 68 (summer)

3.8

Tigercat 250 Loader

Lubrication and Maintenance

3.9

Tigercat 250 Loader

Lubrication and Maintenance

RETURN MANIFOLD

DOUBLE FILTER HEADS

• •

FILTER HEAD

GASKET

•

FILTER ELEMENT

SQUARE SECTION GASKET INSTALLATION

FILTR_SEALS 2

n

1-WATER ABSORBING RETURN FILTER (COLOUR BLUE)

3-HYDRAULIC RETURN FILTERS

358-17 HYDRAULIC RETURN FILTERS HYDRAULIC OIL RETURN FILTERS

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.

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

The majority of return oil entering the hydraulic tank passes through 4 spin-on hydraulic oil filters. One of the filters is a water absorbing filter (color blue) which is in place to assist with the removal of unwanted moisture from the hydraulic oil (the filters are rated 10m abs).

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

Square Section Gasket

FILTER HEAD

• • • FILTR_SEALS 2

l

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.

3.10

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 10. Start the engine and check for leaks. any oil properly.

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.

GASKET

Tigercat 250 Loader

Lubrication and Maintenance PILOT RETURN 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. Changing the filter:

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

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.

LOCATED LOWER LEFT SIDE OF ENGINE COMPARTMENT

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

383-11

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

HYDRAULIC PILOT FILTER

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

8. Turn filter an additional 1/2 turn by hand to tighten.

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

9. Start the engine and check for leaks.

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.

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.

3.11

Tigercat 250 Loader

Lubrication and Maintenance

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

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

AIR INTAKE GRILL

AIR INTAKE TUBE

AIR FILTER

INDICATOR

1/4" HOSE CONNECTION

AIR CLEANER UNLOADER VALVE

382-12A

250-P04

AIR CLEANER

FILTER RESTRICTION INDICATOR

FILTER RESTRICTION INDICATOR A filter restriction indicator is located in the engine enclosure beside the air intake grill.

The indicator is remote mounted and is connected to the outlet side of the air filter with a 1/4" diameter hose. Service to the filter is required when the indicator shows RED. This indicator provides a continuous reading whether the engine is running or is shut down.

After servicing the filter, reset the indicator by pressing down on the reset button.

205-19AC

AIR CLEANER PRIMARY ELEMENT

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.

205-22AC

AIR CLEANER SAFETY ELEMENT

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

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

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

3.12

Tigercat 250 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.

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

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

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

4. Always clean the inside of the outlet tube.

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

6. Inspect the new filter for damage.

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

8. Check connection and ducts for air tight fit.

Ensure that all clamps, bolts and connections are tight. Leaks here send dust directly to the engine.

3.13

Tigercat 250 Loader

Lubrication and Maintenance

AIR CONDITIONING - SERVICE

CAUTION

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.

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)

R134a REFRIGERANT 2 LBS. 12 OZ.

A/C CONDENSER CORE

2 OZ.

Any service work must be performed by authorized A/C technicians. The system should be charged with 2 lbs. 12 oz. of R134a refrigerant.

At least 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 COMPRESSOR

••

381-16A

206-6A CHECK A/C CONDENSER CORE 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

LEFT FRONT ENGINE MOUNT

Perform the following checks on system: a. Check and adjust compressor drive belt tension. 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.

RECEIVER DRYER

•

UPPER FRAME

•• 383-10

A/C RECEIVER DRYER 3.14

Tigercat 250 Loader

Lubrication and Maintenance

3.15

Tigercat 250 Loader

Lubrication and Maintenance

SERVICING HYDRAULIC PRESSURIZATION SYSTEM (EARLIER DESIGN)

SET HYDRAULIC TANK REGULATOR BEFORE SETTING TANK PRESSURE 1. If a new pressure gauge has been installed excess air that may be trapped in the gauge must be relieved. With the gauge in an upright position momentarily remove the rubber nipple on top of the gauge and insert back into place.

Do not cut the rubber nipple off as is indicated on the new replacement gauge.

2. Ensure hydraulic fluid level is within specified limits. Overfilling the tank can cause hydraulic fluid to flow into the regulator disabling the unit.

3. To ensure that tank pressure is not influenced by any remaining air still circulating through the hydraulic lines allow the entrained air to escape from the hydraulic system. This can take up to one or two days.

LOCATED INSIDE REAR ACCESS DOOR 381-15A

LOCATED INSIDE FRONT ACCESS PANEL

SET UP PROCEDURE 1. Set the engine to FULL throttle. This should provide a no load boost pressure of approximately 10 psi from the turbo manifold.

2. Close the air vent ball valve. Turn the regulator adjusting handle in completely. If tank pressure exceeds 12 psi replace the relief valve.

383-4

3. Relieve all pressure from the tank by opening the ball valve.

HYDRAULIC TANK PRESSURIZATION SYSTEM (EARLIER DESIGN)

4. Turn the regulator adjusting handle out until it starts to turn freely.

Refer also to HYDRAULIC PRESSURIZATION SYSTEM (EARLIER DESIGN) in SECTION 2 of the OPERATOR'S MANUAL for more information on the system and its operation.

PRESSURE GAUGE

RUBBER NIPPLE

HYDRAULIC TANK

REGULATOR ADJUSTING HANDLE

AIR FILTER

LOCKING NUT REGULATOR

RELIEF VALVE

BALL VALVE, AIR VENT

TURBO AIR FROM ENGINE 845-41

REGULATOR SET-UP PROCEDURE (EARLIER DESIGN ONLY) 3.16

Tigercat 250 Loader

Lubrication and Maintenance

5. Close the ball valve.

6. Slowly turn the regulator adjusting handle IN, allowing the gauge reading to settle between turns until reading a of 3 to 3.5 psi is obtained.

Lock the regulator adjusting handle in place by tightening the locking nut.

7. If tank pressure exceeds 3.5 psi open the ball valve and repeat steps 4 to 7.

8. Turn the engine off.

9. Watch the tank pressure gauge for several minutes for any indications of a loss in system pressure.

10. If tank pressure falls check all fittings and connections for leaks. NPT connectors must be fastened using pipe sealant to prevent leakage. A properly installed system should be capable of maintaining constant pressure over night.

NOTE: The tank pressure can decrease without substantial leaks due to the contraction of air within the hydraulic tank. This may occur when the air and oil temperature within the tank decreases.

If gauge motion seems erratic and is difficult to adjust there may be air remaining in the hydraulic lines. Sufficient time must be allowed for the entrained air to escape from the system before the regulator can be accurately set.

3.17

Tigercat 250 Loader

Lubrication and Maintenance

SERVICING HYDRAULIC PRESSURIZATION SYSTEM (LATER DESIGN)

RELIEF VALVE

PRESSURE GAUGE AIR VENT BALL VALVE

Refer also to HYDRAULIC PRESSURIZATION SYSTEM (LATER DESIGN) in SECTION 2 of the OPERATOR'S MANUAL for more information on this system and its operation.

SET HYDRAULIC TANK RELIEF VALVE WITH AIR COMPRESSOR CHARGING SYSTEM

2. Momentarily remove the rubber nipple on top of the pressure gauge to release any trapped air and insert back into place. Do not cut the rubber nipple off as indicated on the gauge.

The gauge should now read 0 psi.

••

•

VENT FILTER

1. Open the air vent ball valve to vent air from the tank.

•

••

••

HYDRAULIC TANK

•• 250-P05

PUMP SWITCH

••

AIR COMPRESSOR/ VACUUM PUMP

HYDRAULIC PRESSURIZATION SYSTEM (LATER DESIGN)

AIR COMPRESSOR/VACUUM SOLENOID VALVE

3. Close air vent ball valve and turn relief valve adjustment fully IN.

••

4. Use the hand fill pump to pressurize the hydraulic tank. Remove hose clamp from end of suction hose, remove hose from stored position and operate hand pump until a gauge reading of 11-12 psi is obtained. Close oil fill shut-off valve, place hose in stored position and secure with the hose clamp.

VENT FILTER

AIR COMPRESSOR/ VACUUM PUMP

••

•

5. Slowly turn the relief valve OUT until the pressure gauge reading drops to 10 psi.

Tighten the relief valve locking nut.

6. Watch the tank pressure gauge for several minutes for any indications of a loss in system pressure.

250-04

RELIEF VALVE

7. If tank pressure falls check all fittings and connections for leaks. NPT connectors must be fastened using pipe sealant to prevent leakage. A properly installed system should be capable of maintaining constant pressure over night.

NOTE: The tank pressure can decrease without substantial leaks due to the contraction of air within the hydraulic tank. This may occur when the air and oil temperature within the tank decreases.

PRESSURE GAUGE

AIR COMPRESSOR/ VACUUM PUMP

AIR VENT BALL VALVE

•• •

•• VENT FILTER

•• ••

250-05

3.18

HYDRAULIC PRESSURIZATION SYSTEM (LATER DESIGN/LATER MACHINES)

Tigercat 250 Loader

Lubrication and Maintenance

VACUUM PUMP (LATER MACHINES)

5. Turn the vacuum pump switch OFF.

Later machines are equipped with a vacuum pump to "hold" the oil in the hydraulic tank when work is being done on the hydraulic system. This eliminates the need to drain the hydraulic reservoir before servicing pumps and other hydraulic components. The air compressor used for hydraulic reservoir pressurization also acts as a vacuum pump for this purpose.

6. Relieve the vacuum in the hydraulic tank by OPENING and CLOSING the air vent ball valve.

IMPORTANT It is recommended that the start key be removed while servicing the hydraulic system.

Do not attempt to START the machine or turn key to the RUN position. The vacuum pump only operates when the key switch is in the OFF position.

SERVICE NOTE: Before doing any work on the hydraulic system follow the steps below: 1. Turn the start key to the OFF position and remove the key. NOTE: The key switch must be in the OFF position to provide electrical power to the vacuum pump circuit and maintain a constant vacuum.

Do not leave machine unattended or overnight with vacuum pump on.

REMOVE KEY FROM KEY SWITCH

250-P02

REMOVE KEY

2. Relieve any pressure in the hydraulic tank by OPENING and CLOSING the air vent ball valve.

VACUUM TANK SWITCH

380-9AA

VACUUM TANK SWITCH

3. Turn the vacuum pump switch ON. NOTE: The vacuum pump will start and stop as required to maintain a constant vacuum.

4. Perform all required work on the hydraulic system.

3.19

Tigercat 250 Loader

Lubrication and Maintenance

TORQUE CHART LOCATION

THREAD DIAMETER

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 Grapple, Piston nut Grapple, Gland

TORQUE (LUBRICATED) lbf-ft Nm

2 1/2"-12 UNF (GC) 3/4"-16 UNF (G8) 2 1/2"-12 UNF (GC) 3/4"-16 UNF (G8) 2 1/4"-12 UNF (GC) 6"I/D CYLINDER 2" -12 UNF (GC) 3/4"-10 UNC (G8) 1 3/4"-12 UNF (GC) 1/2"-13 UNC (G8)

3200 315-347 3200 315-347 2100 450 2250 315-347 1750 80-88

4320 427-470 4320 427-470 2835 607 3050 427-470 2355 109-119

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)

450-500 500

610-680 680

7/8"-9 UNC (Cat bolts) 7/8"-9 UNC (Cat bolts) 5/8"-11 UNC (G8) M16 (10.9)

450-500 450-500 160-175 200

610-680 610-680 215-235 275

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)

450-500 75 90 40

610-680 100 122 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

Boom joint and cylinder pin retaining bolts Main and Stick boom pin retaining nut

*

Swing bearing bolts Swing bearing bolts, Track machine Swing gearbox mounting bolts Swing motor mounting bolts

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.

3.20

Tigercat 250 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 5 BOLTS

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

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

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

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

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

METRIC

SIZE

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

M6 M8 M10

4.8 12 23

3.5 8.5 17

6 15 29

4.5 11 21

9 22 43

6.5 16 32

11 28 55

8.5 20 40

13 32 63

9.5 24 47

17 40 80

12 30 60

15 37 75

11.5 28 55

19 47 95

14.5 35 70

M12 M14 M16

40 63 100

29 47 73

50 80 125

37 60 92

75 120 190

55 88 140

95 150 240

70 110 175

110 175 275

80 130 200

140 225 350

105 165 225

130 205 320

95 150 240

165 260 400

120 190 300

M18 M20 M22

135 190 260

100 140 190

175 240 330

125 180 250

260 375 510

195 275 375

330 475 650

250 350 475

375 530 725

275 400 540

475 675 925

350 500 675

440 625 850

325 460 625

560 800 1075

410 580 800

M24 M27 M30

330 490 675

250 360 490

425 625 850

310 450 625

650 950 1300

475 700 950

825 1200 1650

600 875 1200

925 1350 1850

675 100 1350

1150 1700 2300

850 1250 1700

1075 1600 2150

800 1150 1600

1350 2000 2700

1000 1500 2000

M33 M36

900 1150

675 850

1150 1450

850 1075

1750 2250

1300 1650

2200 2850

1650 2100

2500 3200

1850 2350

3150 4050

2350 3000

2900 3750

2150 2750

3700 4750

2750 3500

ISSUE 3 800

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

3.21

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

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

Tigercat 250 Loader

Lubrication and Maintenance

PRESSURE SETTINGS, Effective on machine serial numbers 2500111 to 2500140 Engine RPM (Cummins C ) ............................................... 2400 rpm ............................................................................................. 950 rpm Main Pump - Anti Stall Solenoid Valve Start of Anti-Stall Output ................................................... 2100 RPM Pilot Valve Main relief ...........................................................................

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

425 psi

@ Full throttle

Main Valve High Pressure Limiting Control Main Relief ................................................................ Non Adjustable Load Sense Relief P1 .... Screw in fully (Not used in this application) Load Sense Relief P2 (at P port) ...................................... 4500 psi Margin Pressure ( P - LS ) ................................................. 300 psi

@ Full throttle @ Full throttle

Main Valve Port reliefs Port relief Delimber OPEN ............................................. ***2500 psi @ Full throttle Port relief Grapple Saw (option) ..................................... ***3600 psi @ Full throttle Port relief Heel IN (option) ................................................. *4900 psi @ 1200 rpm Port relief Heel OUT (option) ............................................. *4900 psi @ 1200 rpm Port relief Grapple Rotate CCW ........................................ †1750 psi @ Full throttle Port relief Grapple Rotate CW .......................................... †1750 psi @ Full throttle Port relief Stick IN ............................................................. *4900 psi @ 1200 rpm Port relief Stick OUT ......................................................... *4900 psi @ 1200 rpm Port relief Slasher CUT ............................................... § ***2700 psi @ Full throttle Port relief Top Saw CUT ................................................. ***2500 psi @ Full throttle Port relief Hoist DOWN ..................................................... *4900 psi @ 1200 rpm Port relief Hoist UP ............................................................ *4900 psi @ 1200 rpm Port relief Swing CCW ...................................................... No port relief Port relief Swing CW ......................................................... No port relief .......................................................................................................

Swing motor Crossline Reliefs ................................................................ ***3600 psi @ Full throttle Auxilliary Pump Compensator POR ............................................................. **2900 psi @ Full throttle Compensator Standby Valve .............................................. Screw in fully (Not used in this application) Maximum Displacement ..................................................... Turn adjusting screw IN until it just touches the swashplate, then turn IN 1/2 turn more.

Minimum Displacement ...................................................... Do not adjust Auxilliary Valve Main Relief Auxilliary Valve ................................................. 3300 psi Port relief Slasher CUT ................................................... § 2500 psi Port relief Saw RETRACT .................................................. 1500 psi Port relief Stabilizer DOWN ................................................ 3500 psi Port relief Stabilizer UP ...................................................... 2000 psi Port relief Grapple OPEN ................................................... 3500 psi Port relief Grapple CLOSE ................................................. 3500 psi

@ Idle @ Full throttle @ Full throttle @ Idle @ Full throttle @ Idle @ Idle

ALL PRESSURES MUST BE SET WITH HYDRAULIC OIL AT OPERATING TEMPERATURE. NOTE: The above values are for reference purposes only, SEE SERVICE MANUAL FOR SETTING PROCEDURE. 3.22

13442B-R2.04/02/01

Tigercat 250 Loader

Lubrication and Maintenance

PRESSURE SETTINGS, Effective on machine serial numbers 2500111 to 2500140 * With Load Sense relief temporarily set at 4900 psi. Set port relief to a point just above the point when the engine stops lugging. ** Turn pump compensator POR valve all the way out to set at 2900 psi. *** Set pressure with gauge on 'LS' port † Tigercat grapple set to 1750 psi.

Hultdins grapple set to 2900 psi. § Slasher cut port relief valve on "auxiliary" valve must be turned up above 2800 psi before setting port relief on "main valve".

CYCLE TIMES, FACTORY SETTINGS Main Valve Flow Adjustment Delimber OPEN ........................................................................... 9 Grapple SAW (option) ................................................................. 11 Heel IN (option) ........................................................................... 4 Heel OUT (option) ....................................................................... 4 Grapple rotate CCW ................................................................. 7.5 Grapple rotate CW ................................................................... 7.5 Stick IN ........................................................................................ 6 Stick OUT ............................................................................... 6.75 Slasher CUT ................................................................................ 9 Top saw CUT ............................................................................... 11 Hoist DOWN ............................................................................... 8 Hoist UP ................................................................................... 8.5 Swing CCW ................................................................................. 9 Swing CW ................................................................................... 9

turns turns seconds seconds turns turns seconds seconds turns turns seconds seconds rpm rpm

To adjust, carefully turn the flow adjusting screw IN until it just touches the spool. Then turn the flow adjusting screw OUT 'x' turns. (example: To set Delimber OPEN turn the flow adjusting screw IN until it just touches the spool. Then turn the flow adjusting screw OUT 9 turns.)

NOTE:

All cycle times are set at full throttle.

Cycle time is adjusted by the flow adjusting screw opposite the work port connection.

The above chart lists factory set cycle times and settings. It should be noted that over adjusting to provide faster cycle times could increase the stress on boom components and the hydraulic system.

13442B-R2.04/02/01

3.23

Tigercat 250 Loader

Lubrication and Maintenance

PRESSURE SETTINGS, Effective on machine serial numbers 2500141 and up Engine RPM (Cummins C ) ............................................... 2400 rpm ............................................................................................. 950 rpm Main Pump - Anti Stall Solenoid Valve Start of Anti-Stall Output ................................................... 2100 RPM Pilot Valve Main relief ...........................................................................

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

425 psi

@ Full throttle

Main Valve High Pressure Limiting Control Main Relief ................................................................ Non Adjustable Load Sense Relief P1 .... Screw in fully (Not used in this application) Load Sense Relief P2 (at P port) ...................................... 4500 psi Margin Pressure ( P - LS ) ................................................. 300 psi

@ Full throttle @ Full throttle

Main Valve Port reliefs Port relief Stabilizer UP .................................................. ***2000 psi Port relief Stabilizer DOWN ............................................ ***3000 psi Port relief Heel IN (option) ................................................. *4900 psi Port relief Heel OUT (option) ............................................. *4900 psi Port relief Grapple OPEN .................................................. †2500 psi Port relief Grapple CLOSE ................................................ †2500 psi Port relief Stick IN ............................................................. *4900 psi Port relief Stick OUT ......................................................... *4900 psi Port relief Grapple saw (option) ...................................... ***3600 psi Port relief Delimber OPEN ............................................. ***2500 psi Port relief Hoist DOWN ..................................................... *4900 psi Port relief Hoist UP ............................................................ *4900 psi Port relief Slasher CUT ............................................... § ***2700 psi Port relief Top Saw CUT ................................................. ***2500 psi

@ Full throttle @ Full throttle @ 1200 rpm @ 1200 rpm @ Full throttle @ Full throttle @ 1200 rpm @ 1200 rpm @ Full throttle @ Full throttle @ 1200 rpm @ 1200 rpm @ Full throttle @ Full throttle

Swing motor Crossline Reliefs ............................................................. ***3000 psi

@ 1200 rpm

"Swing" Pump Compensator POR .............................................................. 3600 psi @ Full throttle Compensator Standby Valve .............................................. Screw in fully (Not used in this application) Maximum Displacement ..................................................... Turn adjusting screw IN until it just touches the swashplate, then turn IN 1/2 turn more.

Minimum Displacement ...................................................... Do not adjust "Swing" Valve Main Relief "Swing" Valve .................................................. 4000 psi Port relief Swing CCW .................................................. Turn fully in Port relief Swing CW ..................................................... Turn fully in Port relief Slasher CUT ................................................... § 2500 psi Port relief Saw RETRACT .................................................. 1500 psi Port relief Grapple Rotate CCW ...................................... ¶ 1750 psi Port relief Grapple Rotate CW ........................................ ¶ 1750 psi

@ Idle

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

ALL PRESSURES MUST BE SET WITH HYDRAULIC OIL AT OPERATING TEMPERATURE. NOTE: The above values are for reference purposes only, SEE SERVICE MANUAL FOR SETTING PROCEDURE. 3.24

16292B-R1.05/31/02

Tigercat 250 Loader

Lubrication and Maintenance

PRESSURE SETTINGS, Effective on machine serial numbers 2500141 and up * With Load Sense relief temporarily set at 4900 psi. Set port relief to a point just above the point when the engine stops lugging. *** Set pressure with gauge on 'LS' port † Tigercat grapple OPEN/CLOSE set to 3500 psi. ¶ Hultdins grapple ROTATE set to 2900 psi. § SLASHER CUT port relief valve on "SWING" valve must be turned up above 2800 psi before setting port relief on "main valve".

CYCLE TIMES, FACTORY SETTINGS Main Valve Flow Adjustment Stabilizer UP .................................................................................. 9 Stabilizer DOWN ........................................................................... 9 Heel IN (option) ........................................................................... 4 Heel OUT (option) ....................................................................... 4 Grapple OPEN .............................................................................. 1 Grapple CLOSE ......................................................................... 1.5 Stick IN ........................................................................................ 6 Stick OUT ............................................................................... 6.75 Grapple SAW (option) ................................................................... 9 Delimber OPEN ........................................................................ 8.5 Hoist DOWN ............................................................................... 8 Hoist UP ................................................................................... 8.5 Slasher CUT ................................................................................ 7 Top saw CUT ............................................................................... 11

turns turns seconds seconds second seconds seconds seconds turns turns seconds seconds turns turns

To adjust, carefully turn the flow adjusting screw IN until it just touches the spool. Then turn the flow adjusting screw OUT 'x' turns. (example: To set Delimber OPEN turn the flow adjusting screw IN until it just touches the spool. Then turn the flow adjusting screw OUT 8.5 turns.)

NOTE:

All cycle times are set at full throttle.

Cycle time is adjusted by the flow adjusting screw opposite the work port connection.

The above chart lists factory set cycle times and settings. It should be noted that over adjusting to provide faster cycle times could increase the stress on boom components and the hydraulic system.

16292B-R1.05/31/02

3.25

Tigercat 250 Loader

Lubrication and Maintenance

3.26

Tigercat 250 Loader

SECTION 4 - HYDRAULIC SYSTEM CONTENTS - SECTION 4

CIRCUIT DIAGRAM LOAD SENSING SYSTEM ....................................................................... 4.11 DIFFUSERS/STRAINERS CLEANING ................................................................................................. 4.4 HIGH PRESSURE LIMITING CONTROL VALVE SET LOAD SENSE RELIEF VALVE ......................................................... 4.24 HYDRAULIC OIL RESERVOIR DESCRIPTION ........................................................................................... 4.2 RESERVOIR ............................................................................................... 4.3 HYDRAULIC PUMPS AUXILIARY OR SWING PUMP .................................................................. 4.6 GENERAL DESCRIPTION ......................................................................... 4.5 MAIN PUMP ............................................................................................... 4.6 MAIN PUMP CONTROLLER ................................................................ 4.23 SWING OR AUXILIARY PUMP .................................................................. 4.6 HYDRAULIC SYSTEM OPERATION AUXILIARY OR SWING SYSTEM .............................................................. 4.2 BOOM CYLINDERS ................................................................................... 4.2 MAIN CIRCUIT DESCRIPTION ................................................................ 4.10 FLOW ON DEMAND AND LOAD COMPENSATION ........................... 4.11 MAIN HYDRAULIC CIRCUIT .................................................................... 4.10 MAIN HYDRAULIC SYSTEM ...................................................................... 4.2 MARGIN PRESSURE ................................................................................. 4.6 PILOT CIRCUIT .......................................................................................... 4.2 SWING OR AUXILIARY SYSTEM .............................................................. 4.2 LOAD SENSING BASIC DESCRIPTION CLOSED CENTRE SYSTEM .................................................................. 4.9 OPEN CENTRE SYSTEM ...................................................................... 4.8 BASIC PRINCIPALS ................................................................................... 4.7 MARGIN PRESSURE ................................................................................. 4.6 OPERATING TIPS .................................................................................... 4.10 SET LOAD SENSE RELIEF VALVE ......................................................... 4.24 SET MARGIN PRESSURE ....................................................................... 4.23 MAIN CONTROL VALVE CONTROL VALVE SECTIONS ................................................................. 4.14 CONTROL VALVE SPOOL OPERATION ................................................ 4.17 DESCRIPTION ......................................................................................... 4.12 HIGH PRESSURE LIMITING CONTROL VALVE ..................................... 4.22 PORT RELIEF AND ANTICAVITATION VALVE ....................................... 4.16 ADJUSTING PROCEDURE .................................................................. 4.16 STRAINERS/DIFFUSERS CLEANING ................................................................................................. 4.4

JULY 2002

Tigercat 250 Loader HYDRAULIC SYSTEM OPERATION The hydraulic system has three separate circuits; 1. Variable-displacement main hydraulic circuit.

2. Variable-displacement auxiliary circuit for the slasher/stabilizers/grapple open/close on earlier machines and swing/slasher/grapple rotate on later machines.

3. Closed-centre pilot circuit.

1. THE MAIN HYDRAULIC SYSTEM This a closed centre system utilizing a variabledisplacement axial-piston pump with load sensing and horsepower limiting control. The load sensing system ensures that the pump will deliver only the amount of oil that is required by an individual function or combination of functions.

This feature improves fuel economy and cuts back on heat generation because power is not wasted on excess pump flow that is not being used. Refer to LOAD SENSING HYDRAULIC SYSTEM in THIS SECTION. The horsepower limiting control is one which ensures that the engine will not lug down below the full load rpm by reducing the output from the main hydraulic pump. Refer to ENGINE ANTISTALL description in SECTION 9 of this manual.

The main control valves are pressure and flow compensated to provide load independent operation for all functions.

2. AUXILIARY OR SWING SYSTEM This open centre circuit uses a variabledisplacement pressure-compensated piston pump which delivers oil to the three section spool valve. This valve controls the Slasher, Stabilizers and Grapple Open/Close on machine serial numbers 2500111 to 2500140 and the Slasher, Swing and Grapple Rotate on machine serial numbers 2500141 and up.

The return oil from the open centre circuit is cooled by the oil cooler and then flows to the hydraulic tank via the return oil filters.

Hydraulic system Boom cylinders The main boom and stick cylinders have built-in cushions on both ends. All cylinder rods are ground, heat treated, chrome plated and polished.

Swing system On machine serial numbers 2500111 to 2500140 the swing circuit is in the main hydraulic system. On machine serial numbers 2500141 and up the swing circuit is in the auxiliary or "swing" hydraulic system.

This swing system has a piston motor with crossover relief valves and a double reduction planetary gearbox which provides variable swing speeds from 0 to 8 rpm. A rotary manifold provides hydraulic connection to the subframe of the vehicle and permits continuous 360 degree swing. A multi-disc wet brake is installed between the motor and gearbox and is controlled with a switch on the instrument panel.

The brake is spring-apply hydraulic-release and will apply whenever the pilot oil supply is shut off. Refer to SWING in SECTION 15 of THIS MANUAL.

HYDRAULIC OIL RESERVOIR Also refer to SECTION 2 of THIS MANUAL for additional service information.

Located at the left rear corner of the machine, the hydraulic reservoir (or tank) has a capacity of 80 U.S. gallons (300 l).

Hydraulic oil is drawn from the tank by the pumps through the suction manifold at the base of the tank.

The bulk of the oil returning to the tank is directed to the return manifold and the four return filters and from there to the return tubes in the hydraulic tank.

There is a bypass valve built into each filter head preset at 25 psi. which will open in the event the elements become restricted. A strainer/diffuser is attached to the end of each of the two return tubes.

The reusable return strainers with a 250 micron particle retention, screen oil prior to re-entering the tank.

Case drain oil from the main pump, swing pump & motor and stabilizer manifold return to the tank via The pilot circuit is supplied with oil from the pilot two hose connections at the base of the tank. This pump which is driven by the auxiliary drive off the return oil also flows through two strainer/diffusers left side of the engine. The pilot system is turned before re-entering the tank. on and off by the pilot shut off valve located on The hydraulic tank is pressurized to assist pump the pilot manifold which is controlled by the suction, this pressure is referred to as PUMP INLET armrest switch and the pilot reset button. Refer to PILOT SYSTEM description in SECTION 5 of PRESSURE. On later machines, the hydraulic tank is pressurized, before machine start-up, by an air this manual. compressor to 4 psi. A 10 psi. relief valve located at 4.2

3. PILOT CIRCUIT

Tigercat 250 Loader

Hydraulic system PRESS. GAUGE, HYD. TANK

AIR COMPRESSOR/ VACUUM PUMP

TANK RELIEF VALVE

•

•

•

•

•

•

•

AIR COMPRESSOR/ VACUUM SOLENOID VALVE

VACUUM SWITCH 9 INS. HG

•

FILTER/ BREATHER

PRESSURE SWITCH 6 PSI.

HYDRAULIC TANK PRESSURIZATION/ VACUUM SYSTEM BALL VALVE, AIR VENT

• VACUUM SWITCH 9 INS. HG RETURN MANIFOLD

DUAL FILTER HEADS (2)

PRESSURE SWITCH 4 PSI.

'A'

• • •

• • • •

RETURN TUBES

•

•

RETURN FILTERS (4) OIL LEVEL SIGHT GAUGE

• •

• • CROSS SECTION 'A' 'A'

•

OIL TEMP. SENDERS PUMP CONNECTIONS

•

HAND FILL PUMP

••

•

TO PILOT PUMP

RETURN STRAINERS (4)

•• ••

•

OIL LEVEL SIGHT GAUGE PILOT SHUT OFF VALVE

ACCESS COVER WITH 'O' RING SEAL

•

•

ACCESS COVER WITH 'O' RING SEAL

• •

CASE DRAIN FROM SWING PUMP & MOTOR AND STABILIZER MANIFOLD DRAIN PLUG

CASE DRAIN FROM MAIN PUMP

• •

•

• SUCTION

'A' MANIFOLD TO PUMPS HYDRAULIC RESERVOIR 250-01 the top of the hydraulic tank serves to protect the when work is being done on the hydraulic system. tank from over-pressurization.

Two sensor switches located at the top of the tank control the pressure or the vacuum in the IMPORTANT: DO NOT start the engine unless hydraulic tank. the hydraulic tank is pressurized to 4 psi. Starting the engine before pressurizing the tank will result in damage to pumps and other hydraulic components.

The air compressor/vacuum pump is used to perform two functions in the hydraulic pressurization system. First it is used as an air compressor to provide the required 4 psi pressure for the hydraulic tank. Second it is used as a vacuum pump to "hold" the oil in the hydraulic tank 4.3

Refer also to HYDRAULIC PRESSURIZATION SYSTEM in SECTION 3 and SECTION 2 of the OPERATOR'S MANUAL. IMPORTANT: Before disconnecting any hoses, release the pressure in the hydraulic tank by opening the air vent ball valve.

Tigercat 250 Loader

Hydraulic system

The hydraulic hand fill pump, located behind the front access panel, is used for adding oil to the hydraulic oil reservoir via the return filters.

On earlier machines the pump is also used to initially pressurize the hydraulic reservoir to 3 PSI. Refer to HYDRAULIC PRESSURIZATION SYSTEM, EARLIER DESIGN in SECTION 2 OF THE OPERATORS MANUAL for this procedure.

STRAINER/DIFFUSER SERVICE NOTE The strainer/diffusers should be checked whenever the hydraulic tank is drained at the intervals specified in the LUBRICATION AND MAINTENANCE SCHEDULE in SECTION 3 of THIS MANUAL. CHANGING OR CLEANING THE STRAINER/ DIFFUSERS: This should be performed in the event of a pump failure or hydraulic oil contamination.

1. Position machine on flat level ground with grapple resting on the ground.

2. Stop engine. Turn battery disconnect switch to the OFF position.

3. Release the pressure in the hydraulic tank by opening the air vent valve.

4. Drain the hydraulic tank via a drain plug in the bottom of the tank.

5. Remove the lower access cover and 'O' ring.

6. Before removing the strainers, clean any debris from bottom of the tank and wipe it clean.

7. Remove the four strainers using the hex on the end of strainer. Carefully clean the strainers (avoid damage by rough handling).

8. Check for a buildup of foreign materials at the strainer connections.

9. Reinstall the strainers using the hex on end.

10. Reinstall access cover with a NEW O ring.

11. Refill and check for leaks.

12. Ensure that the air vent valve is closed.

NOTE: Changing strainer/diffusers and replacing the hydraulic oil tends to aerate the oil. For maximum pump life, the machine should sit for 1 hour after servicing to allow entrained air to escape from the oil prior to applying working pressures to the pumps.

4.4

Tigercat 250 Loader

Hydraulic system

ENGINE BELL HOUSING

PILOT PUMP

AUXILIARY (SWING) PUMP (LINDE)

••

• MAIN PUMP

• • 240B-D23

PILOT PUMP

HYDRAULIC PUMPS All hydraulic functions are powered by three pumps. Two of the pumps, the main and the auxiliary (swing on later machines) are mounted one behind the other on the flywheel housing of the engine. The first pump (main pump) is a piston pump with load sensing and horsepower limiting controls.

HYDRAULIC PUMPS (LINDE)

250-07

AUXILIARY PUMP (PARKER)

ENGINE BELL HOUSING

Mounted and coupled to the main pump is the auxiliary pump. It is a pressure compensated piston pump.

• •

A third pump, the pilot pump, is driven off the auxiliary drive on the left side of the engine.

••

For information on the hydraulic circuits that these pumps are part of ; Refer to HYDRAULIC SYSTEM OPERATION in THIS SECTION.

MAIN PUMP

250-06

HYDRAULIC PUMPS (LINDE/PARKER)

ENGINE BELL HOUSING

••

•

MAIN PUMP

•

AUXILIARY PUMP (KAWASAKI)

250-14

HYDRAULIC PUMPS (LINDE/KAWASAKI) 4.5

Tigercat 250 Loader

Hydraulic system

MAIN PUMP

L.S. GAUGE TEST CONN.

The main pump is a Linde HPR, axial-piston, variable-displacement pump with load sensing, and horsepower limiting controls.

When all of the control valve sections on the main valve are in the neutral position the pump is destroked and the output is just sufficient to maintain a pressure of approx. 500 psi in the pump output line. The swashplate control piston is in a condition where the spring force, swashplate forces and the control pressure forces are balanced.

MARGIN PRESSURE When a function control lever is moved, i.e. joystick, to activate a function, LS pressure increases to the point where it is equal to the work port pressure and it shifts the LS control valve.

The pump then adjusts its output volume until the HORSEPOWER CALIBRATION DO NOT ADJUST

ENGINE ANTI-STALL SOLENOID VALVE

•

GAUGE TEST PORT 'X1' ANTI-STALL SIGNAL PRESSURE

•

•

'P' GAUGE TEST CONN.

103-17A

GAUGE TEST PORTS

•

LOAD SENSING RELIEF VALVE (P2)

At this point the LS control valve shifts back to its previous condition and the swashplate control piston will be balanced with the pump output remaining constant until the pressure at the LS port changes. This is a dynamic condition with the swashplate angle changing constantly in response to the load fluctuations. The LS pressure is always equal to the highest work port pressure.

The pump is protected by a high pressure limiting control which is attached to the main control valve manifold. Refer to HIGH PRESSURE LIMITING CONTROL in this section.

AUXILIARY OR SWING PUMP

MAIN PUMP

103-18A

••

Also refer to ENGINE ANTI-STALL in SECTION 9 of this manual.

•

•

••

••

NOTE: If the machine controls are not responding as they should, i.e. boom is jerky or sluggish, the margin pressure setting may be out of adjustment.

• MARGIN PRESSURE ADJUSTING SCREW

•

HIGH PRESSURE LIMITING CONTROL (HPLC)

LINDE MAIN VALVE MANIFOLD

MAIN PUMP CONTROLLER

For the operation and adjustments of this pump refer to SECTION 15 of THIS MANUAL.

(LS CONTROL)

pump output pressure exceeds the LS pressure by a small amount. This difference is known as MARGIN PRESSURE (Also known as differential pressure Delta P).

Refer to SET MARGIN PRESSURE in this section.

Also refer to VERIFY ANTI-STALL SOLENOID SETTING (H.P. CALIBRATION) in this section.

4.6

Tigercat 250 Loader

Hydraulic system

LOAD SENSING BASIC PRINCIPALS Figs. 1 & 2 Early hydraulic systems used a fixed displacement pump, with valves to control or adjust flow rates or speeds. This throttling or restricting pump flow to achieve control over the functions causes excess oil to flow over the relief valve. This results in wasting power and at the same time creating heat. SEE FIGS. 1 & 2.

FLOW

WASTED

Figs. 3 & 4 In an attempt to recover some of the wasted energy, variable volume pumps evolved. These pumps are power regulated or horsepower controlled and since they reduce the pumps output to maintain a constant system hp, oil flow over the relief valve is less, therefore reducing the wasted power losses and heat generation. SEE FIGS. 3 & 4.

W

853SM18

USED

FIG. 1

FIXED DISPLACEMENT PUMP

PRESSURE FIG. 2

HP

The power wasted in the horsepower control system is still considerable and still requires constant "throttling" by the operator if he wants the speeds to remain as selected.

853SM16

=CO NST ANT

This system combines the energy saving benefits of flow on demand with load compensation at each work port. The compensator eliminates the need for operator flow adjustments (throttling). SEE FIGS. 5 & 6.

FLOW

Figs. 5 & 6 The load control system was developed to address the problems outlined above.

WASTED

W USED

853SM19

FIG. 3

HP REGULATED PUMP

PRESSURE FIG. 4 853SM16

HP =C ON ST AN

FLOW

T

∆p LS W USED PRESSURE

853SM17

FIG.5

LOAD SENSING (FLOW ON DEMAND) 4.7

FIG.6

853SM16

Tigercat 250 Loader

Hydraulic system

LOAD SENSING BASIC DESCRIPTION OPEN CENTRE VS. CLOSE CENTRE OPEN CENTRE SYSTEM:

853SM21

If the oil flowing to the motor or cylinder meets variable loads, this will upset the balance of oil going to the tank and the load. This causes the speed of the function to change with load changes.

853SM20

With the control valve in neutral all of the oil from the pump bypasses through the open center passage directly to tank. There is no back pressure created by the control valve to force oil into the work port (the work port is actually blocked off when the spool is in neutral, and unblocked when the spool begins to move).

853SM20 853SM21

When the control valve lever is moved to actuate a cylinder or motor, the open center passage is blocked off in proportion to the amount the lever is moved. This creates back pressure forcing oil into the valve work port to move the load.

This type of system exhibits the following characteristics; 1. If the load against the cylinder or motor changes, the speed of the function will change.

2. If the load increases on a boom cylinder, the boom will slow or stop. Moving the lever further will increase the pressure against the load, and when high enough, the load will begin to move again.

3. The maximum speed of the function is determined by the maximum flow of the pump.

853SM20

When the control valve lever is fully shifted to the maximum flow position the open center passage is completely blocked, and all of the pump flow is forced against the load.

4.8

Tigercat 250 Loader

Hydraulic system

CLOSED CENTRE SYSTEM: Load sensing systems use variable flow pumps and only flow oil when required. Unlike the open centre system, the control valve does not have an open centre passage. When in neutral, no oil flows through the control valve to tank and the pump output flow is zero. The pump s output flow is controlled by a stroking piston which is connected to the pump output, and to the valve s work port or load . This sense line to the actual working load defines the system as load sensing.

The key component in the system above is the spring in the stroking piston. The pump s output pressure must be 300 psi. higher than the load pressure to compress the spring and reduce the flow of the pump. This 300 psi. is the differential or margin pressure.

adjusts the flow of the pump to find a new balance point. The stroking piston will change the pump s flow until pump pressure is 300 psi. higher than load pressure.

In the figures below note that even though the load pressure may change, (as illustrated by the extra restriction) the flow remains constant. This is because the difference in pressure, or differential pressure, between the pump and load pressures can be maintained by the stroking piston regardless of load. It is important to remember the pump is really responding to the pressure differential resulting from flow through the valve, not the actual load pressure level.

853sm22

853sm22

In the figure above the valve is closed blocking the pump from the load. With the load at zero the pump will maintain 300 psi. of stand-by pressure and pump flow is zero.

853sm22

The following are key differences from open centre systems; 1. The load sensing valve s maximum flow is not equal to the pumps maximum flow as with the open centre system. The valves maximum flow is determined by the maximum size of opening or orifice it provides.

853sm22

When the control valve lever is moved to actuate a cylinder or motor, the control valve opens the pump to the load. In this case the load is zero and the pump output pressure falls as the oil escapes through the valve. The 300 psi. that was holding the spring in the compressed state is reduced and the spring moves the pump to increase flow. Flow will increase to a level that requires 300 psi. to force the oil through the valve opening. At this point the load pressure combined with the spring force will be high enough to oppose the pump output pressure, and the stroking piston will stop moving.

Changing the control valve lever changes the size of the opening in the valve and upsets the balance of the stroking piston. The stroking piston then 4.9

2. The speed of the load does not change as the load changes. If the load increases on a boom cylinder the pump pressure will increase automatically to maintain the load s original speed. If the load stops, it is because the load is too heavy for the boom to lift.

Moving the lever further will not increase the lifting force.

3. A load sensing system provides the speed the operator selects with the lever, and automatically adjusts the pressure to match the load. The open centre system requires the operator to adjust the pressure to match the load and the speed is determined by the load.

Tigercat 250 Loader

Hydraulic system

OPERATING TIPS When using the controls on a load sensing system think of what the system is trying to do for you. If you move the lever or pedal 20% of its total angle, the system will provide whatever pressure it takes ( up to its maximum capacity if needed) to meet this speed requirement. If you move the lever past the point needed in an attempt to speed up the boom movement, you will only overshoot the speed you wanted. Open centre systems responded to larger lever angles with increased boom speeds, but this system will not. Relax and try to use the least amount of lever action you can.

Load sensing systems respond to rough operation by amplifying these movements. If you find the boom is jerky or always giving feedback , you re probably too active on the controls. If slowing down doesn t eliminate the roughness, the margin pressure setting may be too high and can be reduced to calm down the machine s response.

Refer to SET MARGIN PRESSURE in this section.

Another feature of this system is that the maximum flow of each function, in each direction, can be tuned to your requirements. This is easily done by changing the flow adjusting screws on each control valve. Take the time to set up your machine, as this greatly reduces fatigue.

Refer to PRESSURE SETTINGS, CYCLE TIMES in SECTION 3 of THIS MANUAL.

MAIN HYDRAULIC CIRCUIT CIRCUIT DESCRIPTION (S/N 2500111 T0 0140) The main hydraulic circuit controls the hoist, stick, delimber, grapple rotate, slasher and swing functions.

An axial piston, swashplate controlled pump supplies oil for the main hydraulic system. A load sensing signal is sent from the control valve manifold (LS port) to the pump regulator to control pump output pressure.

Oil flow for each function is supplied by its own control valve section. When the control valve sections are in neutral, there is no flow through the valves, therefore the system is closed-centre.

When all control valves are in neutral, the pump will only supply enough oil to make-up for leakage in the system and the pressure remains at a low level (approx. 500 psi). The swing, hoist, stick and grapple rotate control valve sections trap oil in their circuits when the spools are in neutral.

The delimber, slasher and top saw control valve sections utilize motor spools which have a 4.10

passage between the work ports and return when the spool is in neutral. The counterbalance valves in the motor circuits trap the oil in the motors. Oil returning to the tank from the control valve sections must open back pressure check valves in the control valve manifold before flowing to the reservoir. This creates a small positive pressure in the manifold to prevent cavitation in the cylinders and motors. All oil returning to the reservoir is filtered.

CIRCUIT DESCRIPTION (S/N 2500141 AND UP) The main hydraulic circuit controls the hoist, stick, delimber, grapple open/close, slasher and stabilizer functions.

An axial piston, swashplate controlled pump supplies oil for the main hydraulic system. A load sensing signal is sent from the control valve manifold (LS port) to the pump regulator to control pump output pressure.

Oil flow for each function is supplied by its own control valve section. When the control valve sections are in neutral, there is no flow through the valves, therefore the system is closed-centre.

When all control valves are in neutral, the pump will only supply enough oil to make-up for leakage in the system and the pressure remains at a low level (approx. 500 psi). The hoist, stick, delimber, and grapple open/close control valve sections trap oil in their circuits when the spools are in neutral.

The stabilizer, slasher and top saw control valve sections utilize motor spools which have a passage between the work ports and return when the spool is in neutral. The counterbalance valves in the motor circuits trap the oil in the motors. Oil returning to the tank from the control valve sections must open back pressure check valves in the control valve manifold before flowing to the reservoir. This creates a small positive pressure in the manifold to prevent cavitation in the cylinders and motors. All oil returning to the reservoir is filtered.

Tigercat 250 Loader

Hydraulic system

FLOW ON DEMAND AND LOAD COMPENSATION The combination of control valves and pump used in this system provides flow on demand and load compensation. Flow on demand means that only the required quantity of oil will be delivered to a function by the pump. This will save energy and reduce heat generation in the hydraulic system.

Load compensation means that all functions will continue to receive oil regardless of their pressure and without further movement of the control levers.

Without this system, an operator moving control levers halfway on the boom up and stick out controls would find that the lowest pressure function would move and the other would not move.

250-02

To make both functions move the operator would have to move the high load lever much more than the low load lever. In other words, the operator would have to restrict oil flow to one function while opening up the valve fully to the other. This is what the load compensation system does automatically as will be explained further below.

With the load compensation on this unit the operator does not need to continually adjust the control lever to move two or more functions because of pressure differences.

Valves inside of the main control valve spools will automatically adjust flow according to the pilot pressure applied to the spool to move functions independent of load pressure.

LOAD SENSING SYSTEM CIRCUIT DIAGRAM 4.11

Tigercat 250 Loader DELIMBER OPEN/ GRAPPLE SAW

•

Hydraulic system GRAPPLE ROTATE

SLASHER/ TOP SAW CUT

STICK CYLINDER

•

•

•

HOIST CYLINDER

•

SWING

•

• VIEWED FROM BELOW

•

HIGH PRESSURE LIMITING CONTROL

CONTROL VALVE MANIFOLD

MAIN CONTROL VALVE (S/N 2500111 TO 2500140)

250-09

GRAPPLE OPEN/CLOSE

STABILIZERS

•

DELIMBER OPEN/ STICK CYLINDER GRAPPLE SAW

•

•

•

HOIST CYLINDER

•

SLASHER/TOP SAW CUT

•

• VIEWED FROM BELOW

• 250-08

HIGH PRESSURE LIMITING CONTROL

CONTROL VALVE MANIFOLD

MAIN CONTROL VALVE (S/N 2500141 AND UP)

MAIN CONTROL VALVE DESCRIPTION The main control valve consists of six individual valve sections, a high pressure limiting relief valve and a non adjustable safety relief. Each section, including the relief valve is fastened to the control valve manifold which contains four common passages for all valves.

The four passages are: (Refer to fig. 853sm24) 1. Centre passage for pump 2. Two passages for return (connected internally) 3. One for load sensing

2 3 1

SCHEMATIC DIAGRAM, VALVE MANIFOLD/VALVE SECTION WITH H.P. RELIEF

853SM24

4.12

Tigercat 250 Loader

Hydraulic system

4.13

Tigercat 250 Loader

Hydraulic system

CONTROL VALVE SECTIONS The spools are pilot actuated and returned to neutral by centering springs. An air bleed plug is provided on the top pilot cap. If a hesitation is noticed when actuating a function, air should be bled from the pilot caps. Spool travel stop screws are fitted in the pilot end caps and are used to limit the spool travel so that maximum speed can be adjusted for each individual function. The screws can also be turned in to lower the boom or stick when the engine or pump will not operate.

All valve sections have return pilot checks in the end caps which allow pilot oil to enter quickly but restrict the flow out thus dampening the movement of the control spool for smoother control of the function.

All control valve sections have port relief and anicavitation valves installed. Except on earlier machines the swing control valve section utilizes make-up valves for anti-cavitation. See FIG. 90919.

The hoist, stick grapple and delimber functions have relief and anti-cavitation valves. See FIG. 90744.

MAKE UP OR ANTICAVITATION VALVE

MAKE UP OR ANTICAVITATION VALVE

WORK PORTS

•

•

PILOT CHECK PILOT END CAP AIR BLEED PLUG

•

•

•

• •

•

•

•

BALL AND SPRING 90919

SPOOL TRAVEL STOP (ADJUSTABLE)

LOAD SENSING 'LS'

• COMPENSATOR VALVE PUMP RETURN 'P' 'T'

RETURN 'T'

LOAD SENSING 'LS'

CONTROL VALVE SECTION "MOTOR" TYPE SPOOL - SWING FUNCTION (EARLIER MACHINES)

4.14

Tigercat 250 Loader

Hydraulic system WORK PORTS

ANTICAVITATION RELIEF VALVE

•

ANTICAVITATION RELIEF VALVE

• •

•

MAX. FLOW ADJUSTING SCREW

•

• • MAIN CONTROL SPOOL PUMP 'P'

RETURN 'T'

RETURN 'T'

COMPENSATOR

CONTROL VALVE SECTION "MOTOR" TYPE SPOOL - TYPICAL FOR STABILIZER, SLASHER AND TOP SAW CUT. ALSO DELIMBER OPEN ON EARLIER MACHINES.

98387

ANTICAVITATION RELIEF VALVE MAX. FLOW ADJUSTING SCREW

WORK PORTS

•

ANTICAVITATION RELIEF VALVE

• •

•

• • • MAIN CONTROL SPOOL RETURN 'T'

90744

90744-2

PUMP 'P'

RETURN 'T'

COMPENSATOR

CONTROL VALVE SECTION "CYLINDER" TYPE SPOOL - TYPICAL FOR HOIST, STICK, GRAPPLE AND DELIMBER FUNCTIONS (SHOWN IN NO FLOW POSITION)

CONTROL VALVE SECTION "CYLINDER" TYPE SPOOL - TYPICAL FOR HOIST, STICK, GRAPPLE AND DELIMBER FUNCTIONS (SHOWN IN FLOW POSITION) 4.15

Tigercat 250 Loader

Hydraulic system

PORT RELIEF AND ANTICAVITATION VALVE OPERATION

MEDIUM SYSTEM PRESSURE

During normal operation, oil pressure in the work circuit is less than the circuit relief valve setting and the circuit relief valve remains closed.

RELIEF AND HOLLOW ANTICAVITATION PISTON 'C' POPPET 'B' (MAIN)

PILOT POPPET 'D'

• WORK PORT

During relief operation, the relief valve will open in three steps.

(Step 1) The pilot poppet 'D' is opened; Flow restriction through the hollow piston 'C' causes the pressure in the cavity behind the main poppet 'B' to decrease.

• •

•

• RETURN

ORIFICE 'A'

NORMAL OPERATION

90744-4A

(Step 2) The piston seats against the poppet.

This further reduces oil flow into the cavity and greatly decreases the pressure against the back side of the main poppet.

MEDIUM SYSTEM PRESSURE

HIGHEST SYSTEM PRESSURE

•

(Step 3) The main poppet 'B' opens.

When the relief valve again closes, the piston and the pilot poppet move together until the pilot poppet is seated. Oil flows into the cavity through the clearance between the piston and the main poppet to move the piston away from the pilot poppet. This permits flow into the cavity through the piston to seat the main poppet.

•

WORK PORT

• RETURN

RELIEF OPERATION

90744-6A

During anticavitation operation the main poppet 'B' will retract to allow oil to flow from the return passage into the work circuit.

LOW WORK PORT PRESSURE

ADJUSTING PROCEDURE 1. Loosen locknut.

•

WORK PORT

2. Turn the adjusting screw to obtain desired pressure reading on gauge.

•

3. Tighten locknut on adjusting screw making sure adjusting screw does not turn.

RETURN 90744-5A

ANTICAVITATION OPERATION

4. Re-check pressure gauge reading.

Refer to SET MAIN BOOM, STICK AND PORT RELIEF VALVES in SECTION 12 of THIS MANUAL for more complete details.

PORT RELIEF VALVE

LOCKNUT • 17mm WRENCH

• • • • MAIN VALVE BODY

90744-4

4.16

ADJUSTING SCREW • 5mm ALLEN KEY

MAIN VALVE PORT RELIEF VALVE

Tigercat 250 Loader

Hydraulic system

CONTROL VALVE SPOOL OPERATION To achieve load sensing compensation, each control spool has two compensator valves and two L.S. check valves. These compensator valves can be either in the form of a shuttle valve or a ball, depending on the function being controlled.

PILOT END CAP

SHUTTLE COMPENSATOR CONTROL COMPENSATOR VALVE VALVE SPOOL VALVE

SHUTTLE VALVE

PILOT END CAP

•

•

•

• CENTERING SPRING

•

•

•

LOAD SENSING PASSAGE 'LS'

•

•

•

WORK PORT 'A'

RETURN PASSAGE 'T'

• •

• •

•

LOAD SENSING PASSAGE 'LS' RETURN PASSAGE 'T'

WORK PORT 'B'

SUPPLY PASSAGE 'P'

• CENTERING SPRING

(A) CONTROL VALVE SECTION ~ IN NEUTRAL

853SM25

(A) Each work port (A & B) has a compensator valve and shuttle valve. Each valve section also has two return passages (T) and two load sensing passages (LS). Each valve section has only one supply passage (P).

With the control valve spool held in neutral by the centering springs in both pilot caps, the pump discharge is blocked. Therefore, the control valves are closed centre. Pump discharge, work port, return, and load sensing passages are all blocked by the spool. Oil in the work ports is trapped.

With all control valve spools in neutral, pump discharge or "stand-by" oil pressure is approximately 400-600 psi.

PILOT OIL

LS PORT JUST OPENED

SHUTTLE VALVE

CONTROL SPOOL

• •

(B) CONTROL VALVE SECTION ~ • CONTROL SPOOL STARTING TO MOVE TO RIGHT 853SM26

• LS PORT JUST OPENED • ONLY SPOOL ACTUATED

(B) Whenever a single function is operated, pilot oil flows to a control valve end cap. Pilot oil will start to move the spool against the centering spring on the opposite end of the spool. The load sensing port (LS) is the first port to open. When the LS port is opened, the shuttle cavity is at LS pressure. Since this is the first function being operated, there is no LS pressure in the manifold and the shuttle does not move.

4.17

Tigercat 250 Loader

Hydraulic system

PILOT OIL

SHUTTLE VALVE

•

COMPENSATOR VALVE

•

CONTROL SPOOL

•

WORK PORT 'A' JUST OPENED

(C) CONTROL VALVE SECTION ~ • CONTROL SPOOL CONTINUES TO MOVE TO RIGHT • WORK PORT 'A' JUST OPENED • HIGHEST WORKING PRESSURE

853SM27

(C) The second port to open is work port A (port B if the control spool moves to the left). The left compensator valve stays to the right as in the neutral condition and the shuttle valve moves to the left directing work port pressure to the area behind the compensator valve to hold it shut until it can be opened by pressure in the P port. In this mode, the compensator valve is functioning as a load check valve would in a conventional valve.

PILOT OIL

(5) SHUTTLE (6) COMPENSATOR VALVE VALVE MOVES LEFT

CONTROL SPOOL

TANK PORT 'T' (RETURN)

(1) ANGLED VENT PORT OPENS

• •

•

•

• •

(4) OIL FLOWS TO 'LS' PASSAGE

(3) PRESSURE PORT OPENED SLIGHTLY

(2) WORK PORT 'B' OPENS

(D) CONTROL VALVE SECTION ~ • CONTROL SPOOL CONTINUES TO MOVE TO RIGHT 853SM28

• PRESSURE PORT OPENED SLIGHTLY • HIGHEST WORKING PRESSURE

(D) The next port to open is the angled vent port (1) on the right side of the control spool which connects to the tank port, T . This connects all passages in the compensator spool to return pressure. There is no movement at this time but as soon as the work port B opens (2) and oil flows, the returning oil will push the compensator valve to the right and connect B to T .

The pressure port in the control spool is the last port to open (3). When it opens, pump discharge pressure flows through the passage in the compensator spool and through the shuttle cavity to the load sense passage (4).

The load sensing pressure increases causing the pump to increase its displacement and further increase the pressure. The compensator valve keeps the work port passage closed until the pump discharge pressure is higher than the work port pressure (load check feature).

Once the pump discharge pressure is higher, the shuttle valve moves to the right (5) and connects load sensing pressure to the cavity behind the compensator valve. The compensator valve moves to the left (6) allowing oil to flow to the work port. With the compensator valve open, the cavity to the right of the compensator valve assumes approximate work port pressure and this pressure flows through the passage to the shuttle cavity allowing work port pressure to control load sensing pressure. As the control spool moves further, in response to pilot pressure, the compensator valve and shuttle valve positions remain the same.

4.18

Tigercat 250 Loader PILOT OIL

Hydraulic system

(1) COMPENSATOR VALVE

SHUTTLE CONTROL SPOOL FULLY SHIFTED TO RIGHT VALVE

•

•• •

•

•

•

•

•

•

LOAD SENSING WORK WORK PASSAGE 'LS' PORT 'A' PORT 'B' RETURN SUPPLY PASSAGE 'P' RETURN PASSAGE 'T' (PUMP DISCHARGE) PASSAGE 'T'

LOAD SENSING PASSAGE 'LS'

(E) CONTROL VALVE SECTION ~ • CONTROL SPOOL FULLY SHIFTED TO RIGHT • HIGHEST WORKING PRESSURE

853SM29

(E) In this figure, pump discharge pressure is slightly higher than work port pressure because the compensator valve (1) is open. When using just one function both the compensator valve and the shuttle valve are moved to the end of their bores.

The load sensing pressure is always the same as the highest work port pressure and as a result is always lower than pump discharge pressure. There are two factors that establish this pressure difference between pump discharge and work port pressure, the load sensing valve and the orifice effect of the passages in the control valve between the pump discharge port and the work port. There are three openings the pump discharge oil must flow through to get to the work port. Each time the oil flows through a passage there is a pressure drop, that is, there is an orifice at each passage. The smaller the opening the smaller the oil flow due to the constant load sensing pressure. There is a passage from the work port to the load sensing passage and this is the pressure sensed at the pump regulator; since the flow is very small there is virtually no pressure drop from the work port to the LS port on the pump.

Load sensing pressure is the same at both ends of all the control spools because the two passages in the control valve manifold are joined together in the manifold.

LOAD SENSING ~ TWO OR MORE FUNCTIONS IN USE Load compensation comes into effect whenever two or more functions are actuated at the same time.

The following is an explanation of the function of the valve components whenever a spool with a lower working pressure is activated when a higher working pressure spool is fully shifted.

PILOT OIL

LS PORT COMPENSATOR JUST VALVE OPENED

(2) SHUTTLE VALVE MOVES TO RIGHT

(1) CONTROL SPOOL STARTS TO MOVE

CENTERING SPRING

• ••

•

(F) CONTROL VALVE SECTION ~ • CONTROL SPOOL STARTING TO MOVE TO RIGHT 853SM30

• LS PORT JUST OPENED • LOWER WORKING PRESSURE

(F) Pilot oil will start to move the control spool against the centering spring on the opposite end of the spool. The LS port is the first to open and load sensing pressure is applied to the shuttle valve. The shuttle valve moves to the right to the end of its bore and then LS pressure flows into the cavity at the left end of the compensator valve.

4.19

Tigercat 250 Loader

Hydraulic system SHUTTLE VALVE

PILOT OIL

•

COMPENSATOR VALVE

•

CONTROL SPOOL

•

WORK PORT 'A' JUST OPENED

(G) CONTROL VALVE SECTION ~ • CONTROL SPOOL CONTINUES TO MOVE TO RIGHT • WORK PORT 'A' JUST OPENED • LOWER WORK PORT PRESSURE

853SM31

(G) As the control spool continues to move, the work port is the next to open. The work port oil pressure passes through compensator valve port and is applied to the end of the shuttle valve but since this work port pressure is lower than LS, the shuttle does not move.

PILOT OIL

SHUTTLE VALVE

(4) COMPENSATOR VALVE MOVES LEFT THEN RIGHT (5)

•

CONTROL SPOOL

•

TANK PORT 'T' (RETURN)

(1) ANGLED VENT PORT OPENS

• •

• •

OIL FLOWS TO 'LS' PASSAGE

(3) PRESSURE PORT OPENED SLIGHTLY

(2) WORK PORT 'B' OPENS

(H) CONTROL VALVE SECTION ~ • CONTROL SPOOL CONTINUES TO MOVE TO RIGHT 853SM32

• PRESSURE PORT OPENED SLIGHTLY • LOWER WORKING PRESSURE

(H) As the control spool continues to move, the angled vent port opens (1), then work port B' opens (2) allowing oil to flow and shift the right side compensator valve connecting port 'B' to 'T'. The pressure port P is next to open (3) and supply pressure passes into the cavity to the right of the compensator valve causing it to shift to the left (4) since the supply pressure is somewhat greater than LS pressure. As it shifts to the left (4) oil can travel into work port A and in doing so it causes pressure in the cavity to drop which results in LS pressure pushing the compensator valve back to the right (5). The compensator finds a position where the pressures are balanced and some oil flows into work port A .

4.20

Tigercat 250 Loader PILOT OIL

Hydraulic system

(2) COMPENSATOR VALVE SETTLES IN A BALANCE POSITION

(1) CONTROL SPOOL FULLY SHIFTED TO RIGHT

•

• •

•

•

•

•

•

•

LOAD SENSING WORK WORK PASSAGE 'LS' PORT 'A' PORT 'B' RETURN SUPPLY PASSAGE 'P' RETURN PASSAGE 'T' (PUMP DISCHARGE) PASSAGE 'T'

LOAD SENSING PASSAGE 'LS'

(I) CONTROL VALVE SECTION ~ • CONTROL SPOOL FULLY SHIFTED TO RIGHT 853SM33

• LOWER WORKING PRESSURE

(I) As the control spool continues to move (1), the compensator spool continues to move in response to the pressure variations and it settles in a position of balance (2) as shown in the figure with the spool fully shifted. As the loads vary in the work ports, the valve components continue to modulate and compensate for the load variations and maintain movement of the selected functions.

This valve system performs the functions automatically that are performed by an operator using a conventional system as explained in the third paragraph above.

If the second valve being operated had a higher work port pressure than the one already selected, the operation would be the same up to the point where the work port was opened. At this point the LS would change to the new higher work port pressure and the new valve would act in the same way as the first valve selected and described above. The first valve selected would then have the internal spool components take the same positions as the lower work port pressure valve described above.

4.21

Tigercat 250 Loader

Hydraulic system

HIGH PRESSURE LIMITING CONTROL VALVE

MAIN CONTROL VALVE MANIFOLD

The main pump is protected by a High Pressure Limiting Control which consists of three relief valve cartridges. The H.P.L. control is attached to the main control valve manifold and contains three relief valves:

•

•

The first relief valve (P2) limits L.S. pressure to approx. 4200 psi, (Gauge at 'L.S.' test port) which in turn limits the pump output pressure to 4500 psi. (Gauge at 'P' test port) The 300 psi differential is known as margin pressure. See SET MARGIN PRESSURE in THIS SECTION.

•

•

SYSTEM RELIEF VALVE NON-ADJUSTABLE P1. SCREWED FULLY IN NOT USED

Margin pressure is the difference between 'P' port pressure and L.S. port pressure, observed while a function is operating.

The second relief is a system relief valve which limits the pump output pressure to 870 psi above L.S. pressure, this relief is non-adjustable.

• HIGH PRESSURE LIMITING CONTROL

The third relief valve (P1) is screwed fully in and is not used.

PAB18-1

853SM24

P2 L.S. PRESSURE LIMIT, SET AT 4200 PSI. GAUGE ON L.S. TEST PORT • 4mm ALLEN KEY • 13mm WRENCH

HIGH PRESSURE LIMITING CONTROL VALVE

SCHEMATIC DIAGRAM OF H.P.L. CONTROL, MANIFOLD & A VALVE SECTION WITH PORT RELIEFS 4.22

Tigercat 250 Loader

Hydraulic system PILOT PRESSURE

11.3 mm

ENGINE ANTI-STALL PROPORTIONAL SOLENOID VALVE

•

•

• ANTI-STALL CALIBRATION

TANK

DO NOT ADJUST

LOAD SENSE PRESSURE

REQUIRES TEST BENCH FOR READJUSTMENT GAUGE TEST PORT 'X1'

•

•

•

•

•

8 mm

•

•

MARGIN PRESSURE ADJUSTING SCREW • 8mm WRENCH • 19mm WRENCH (Turn OUT to decrease Margin pressure)

PUMP OUTLET PRESSURE PUMP SWASH CONTROL PASSAGE

TANK

MAIN PUMP CONTROL VALVE The margin pressure adjustment is made at SET MARGIN PRESSURE the main pump controller attached to the main MARGIN PRESSURE is the difference pump. The pressure gauge connections are between the LOAD SENSE pressure and the the 'L.S.' and 'P' gauge test ports on the Linde PUMP OUTPUT pressure while a function is main valve manifold. being operated. For the load sensing system LINDE MAIN HIGH PRESSURE L.S. GAUGE VALVE LIMITING to operate correctly the differential pressure TEST CONN. MANIFOLD CONTROL (HPLC) between L.S. and 'P' should be 300 psi. 'P' being higher than L.S. • 90669

**NOTE: If the margin pressure is not set correctly, the machine controls may not respond as they should, i.e. boom is jerky or sluggish.

HORSEPOWER CALIBRATION DO NOT ADJUST

••

'P' GAUGE TEST CONN.

103-17A

• •

* MAIN PUMP

103-18A

•

1. Use a differential pressure gauge* (preferably a differential gauge with ten psi increments).

•

••

LOAD SENSING RELIEF VALVE (P2)

GAUGE TEST • PORTS The margin pressure is set at the factory to 300 psi. The margin pressure can be adjusted however the flow stops on the valves must be reset in order to maintain the same speed of the functions.

GAUGE TEST PORT 'X1' ANTI-STALL SIGNAL PRESSURE

•

••

ENGINE ANTI-STALL SOLENOID VALVE

•

MARGIN PRESSURE ADJUSTING SCREW

•

•

MAIN PUMP CONTROLLER (LS CONTROL)

4.23

If a differential pressure gauge is not available, one single 0-5000 psi gauge may be used; First placing it on the L.S. test port and noting the reading, Then on 'P' test port and noting the reading. 'P' should be 300 psi greater than 'L.S.'.

Tigercat 250 Loader

Hydraulic system SET LOAD SENSE RELIEF VALVE

2. With hydraulic oil at operating temperature, Connect one side of the differential pressure gauge to the L.S. gauge port located on the back of the main control valve manifold and the other side of the gauge to the pressure 'P' gauge test port.

NOTE: Constant loosening and tightening of the locknut (sealnut) on the adjusting screws of these relief valves will eventually cause the seal in the nut to break down and leak.

Because of this it is best to keep the adjusting procedure brief.

3. Start the engine and place throttle control in FULL position.

1. With hydraulic oil at operating temperature, Connect a 0 - 5000 psi gauge to 'P' gauge test port on back of main control valve manifold.

4. Press PILOT RESET button to activate pilot system and turn anti-stall switch OFF. 5. S/N 2500111 TO 2500140: Turn swing brake ON and place SWING joystick lever in FULL position (left or right).

L.S. GAUGE TEST CONN.

S/N 2500141 AND UP: Hold LH joystick in the GRAPPLE CLOSE position.

•

6. Loosen locknut on margin pressure adjusting screw on main pump controller and turn adjusting screw until the differential reading on gauge is 300 psi**. (Turn OUT to decrease Margin pressure).

LINDE MAIN VALVE MANIFOLD

•

••

HIGH PRESSURE LIMITING CONTROL (HPLC)

••

'P' GAUGE TEST CONN.

If only one 0-5000 psi gauge is being used; It should first be connected to the L.S. test port and the reading noted, it should then be connected to the 'P' test port and the margin pressure adjusting screw adjusted until reading on gauge is 300 psi** greater than the 'L.S.' previously noted reading.

103-17A

GAUGE TEST PORTS

••

LOAD SENSING RELIEF VALVE (P2)

2. Start engine and set throttle control to FULL position.

3. Press PILOT RESET button to activate pilot system and turn anti-stall switch OFF.

NOTE: This is a sensitive adjustment, significant changes in pressure will be noticed with only a small movement of the adjusting screw.

4. While holding R.H. joystick in the STICK OUT position (fully extended), loosen locknut on P2 relief valve cartridge and turn adjusting screw until pressure gauge reads 4500 psi. Tighten locknut on adjusting screw and re-check pressure reading on gauge.

**NOTE: If the margin pressure is not set correctly, the machine controls may not respond as they should, i.e. boom is jerky or sluggish.

5. Stop engine and remove pressure gauge.

7. Allow a short time for pressure reading to stabilize then tighten locknut on adjusting screw. Repeat above procedure to verify the differential pressure setting is still correct.

4.24

Tigercat 250 Loader

SECTION 5 - PILOT SYSTEM JULY 2002

CONTENTS - SECTION 5 CIRCUIT DIAGRAM ....................................................................................... 5.6 ELECTRICAL CIRCUIT .................................................................................. 5.5 PILOT SYSTEM COMPONENTS ................................................................... 5.2 JOYSTICKS AND FOOT PEDALS ............................................................. 5.4 PILOT MANIFOLD ...................................................................................... 5.3 PRESSURE SETTINGS ................................................................................. 5.5

Tigercat 250 Loader

Pilot system

PILOT SYSTEM COMPONENTS

A shut-off valve is installed in the pilot suction line at the hydraulic tank connection. Use this valve to isolate the pilot hydraulic system when disconnecting any hoses or fittings. A plastic tie is installed on the shut off valve at the factory to

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

LEFT SIDE OF ENGINE

HYDRAULIC TANK BALL VALVE (SHOW OPEN)

PILOT PUMP

PLASTIC TIE TO PILOT PUMP

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

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

240B-D23

PILOT SHUT-OFF BALL VALVE prevent the valve from being accidentally turned to the CLOSED position when the engine is running, this could cause serious damage to the pilot pump. The tie should be replaced whenever it is taken off to operate the shut off valve.

240B-D21

PRESSURE FILTER This filter is a cartridge filter with a built-in differential pressure relief valve, if the pressure differential at the oil filter exceeds 50 psi this

Pilot oil is also supplied to the main pump controller port 'P1' to operate the horsepower limiting control. Refer to ENGINE ANTI-STALL in THIS MANUAL.

FILTER ELEMENT

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

LOCATED BELOW PUMPS

206-5A

PILOT FILTER

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.

5.2

Tigercat 250 Loader

Pilot system

PILOT MANIFOLD

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

PILOT SHUT "IN" CONNECTION OFF VALVE FROM PILOT FILTER

"T" TANK CONNECTIONS

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

The pilot manifold distributes oil to the following circuits through the ports in the manifold listed below: • • • • • • • • • • • •

Joysticks (both) Swing control foot pedal Stabilizer pilot manifold Gauge test port Slasher saw, cut Slasher saw, retract Top saw, cut Delimber, open Stabilizers up Stabilizers down Grapple saw Swing brake

PILOT RELIEF VALVE 240B-D22 PILOT MANIFOLD pressing the pilot reset switch in cab (with the left armrest down).

The pilot shut off valve, which is an integral part of the pilot manifold, controls the flow of oil from the INLET port to the three outlet ports labelled (2/ PB and G) and to the eight solenoid operated pilot valves. The pilot shut off valve is activated by STABILIZERS STABILIZERS TOP SAW, UP CUT DOWN GRAPPLE SAW

GAUGE TEST PORT CONNECTION

(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

SWING BRAKE

PILOT MANIFOLD

Pilot oil enters the manifold through the inlet port.

'PB' TO STABILIZER PILOT MANIFOLD

240B-D20

Two outlet ports ('PB') on each end of the pilot manifold, feed the Stabilizer pilot manifold, 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.

Eight 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.

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

'PB' TO JOYSTICK AND SWING FOOT PEDAL

SLASHER SAW, CUT SLASHER SAW, RETRACT

DELIMBER OPEN

PILOT SHUT OFF VALVE GAUGE TEST PORT INLET

230B-04

PILOT RELIEF VALVE

RETURN OIL FROM STABILIZER PILOT MANIFOLD

PILOT MANIFOLD ASSEMBLY 5.3

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

Tigercat 250 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.

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.

RR-12

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

1

5

TANK PORT

3

4 8

WORK PORT

2

PRESSURE PORT

WORK PORT

FOOT PEDAL PILOT VALVE (KAWASAKI)

AW017

5.4

JOYSTICK PILOT VALVE

Tigercat 250 Loader

Pilot system

PILOT SYSTEM ELECTRICAL CIRCUIT 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 SHUT OFF VALVE

PILOT MANIFOLD GAUGE TEST PORT CONNECTION PILOT RELIEF VALVE 240B-D22

PILOT RELIEF VALVE

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

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

3. Start engine and set throttle in FULL position.

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

5. Stop engine, and remove pressure gauge.

PILOT MANIFOLD BODY

RELIEF VALVE CARTRIDGE

LOCKNUT ADJUSTING SCREW

240B-01

5.5

PILOT RELIEF VALVE

IN

OUT

Tigercat 250 Loader

250-03

Pilot system

PILOT SYSTEM CIRCUIT DIAGRAM 5.6

Tigercat 845B Feller Buncher

SECTION 6 - ELECTRICAL, GAUGES AND ALARMS

JULY 2002

CONTENTS - SECTION 6 ELECTRICAL SCHEMATIC DIAGRAM ......................................... 6.2, 6.3, 6.4 FUSE AND RELAY PANEL ............................................................................ 6.6 GAUGES AND ALARMS ................................................................................ 6.8 INSTRUMENT PANEL WIRING DIAGRAM ................................................... 6.7 SENSOR LOCATIONS .................................................................................. 6.9 WIRE COLOUR CODE CHART ..................................................................... 6.5

Tigercat 250 Loader

250-04 (13264B 02)

Electrical, gauges and alarms

MACHINE SCHEMATIC DIAGRAM SHEET 1 OF 3 6.2

Tigercat 250 Loader

250-05 (13264B 02)

Electrical, gauges and alarms

MACHINE SCHEMATIC DIAGRAM SHEET 2 OF 3 6.3

Tigercat 250 Loader

250-06 (13264B 02)

Electrical, gauges and alarms

MACHINE SCHEMATIC DIAGRAM SHEET 3 OF 3 6.4

Tigercat 250 Loader

Electrical, gauges and alarms

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

FUNCTION EXAMPLE Power ........................................ (protected and unprotected) 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)

6.5

Tigercat 250 Loader

Electrical, gauges and alarms

FUSE AND RELAY PANEL

250-D08

1

DIODE MODULE 1

DIODE MODULE 2

DIODE MODULE 3

RELAY 1

RELAY 2

RELAY 3

RELAY 4

LOW ENG. OIL PRESS.

PILOT LOCK-OUT

A/CHEATER

LOW HYD. OIL

2 3 4 5

DIODE MODULE 4

DIODE MODULE 5

DIODE MODULE 7

DIODE MODULE 6

DIODE MODULE 8

RELAY 5

RELAY 6

RELAY 7

RELAY 8

WORK LIGHTS

DELIMBER CLOSE

DELIMBER OPEN

SAW CUT

RELAY 30

RELAY 31

RELAY 32

CHARGE TANK

CHARGE TANK

VACUUM TANK

6 7

GAUGES 5A SAFETY 15A FUEL 10A JOYSTICKS 15A STABILIZERS 15A WIPER/WASH 15A ANTI-STALL 2A

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

16605B R0

250-08 (16524B R0)

6.6

Tigercat 250 Loader

250-07 (16524B R0)

Electrical, gauges and alarms

INSTRUMENT PANEL WIRING DIAGRAM 6.7

Tigercat 250 Loader GAUGES AND ALARMS

Electrical, gauges and alarms

The 250 Loader is monitored for proper operation by sensors located in the hydraulic system and on the engine. These sensors are connected to either gauges, warning lights and/or a panel buzzer.

The operator may sound the safety alert horn at any time.

For operation of the gauges 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

GAUGE RANGE

LIGHT

0 - 100 psi

YES

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

Engine coolant temp.

100°F - 280°F

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

0 - 9999.9

NONE

Total running hours

8v - 18v

NONE

Normal operating range 12 - 13.5 volts

Hydraulic oil temp.

100°F - 240°F

YES

RED light comes ON above 205°F *

Hydraulic oil level LOW

SIGHT GLASS

YES

RED light comes ON indicates 13 gallons below FULL *

Pump inlet pressure

NONE

YES

RED light comes ON below 2 psi.

Hyd. tank charge press.

NONE

YES

GREEN light turns ON when tank charge press.reaches 4 psi. with key switch in OFF position.

Light goes OFF when key in RUN position.

Safety alert HORN

NONE

NONE

Engine oil pressure

Engine hours Volts

*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.

6.8

INFORMATION

Switch on control panel

Tigercat 250 Loader

SWITCH- HYDRAULIC OIL TEMPERATURE (RED LIGHT)

Electrical, gauges and alarms

SENDER- HYDRAULIC OIL TEMPERATURE (GAUGE)

SIGHT GAUGE/SWITCHHYDRAULIC OIL LEVEL (RED LIGHT)

START SOLENOID RELAYS

BATTERIES

BATTERY DISCONNECT SWITCH SWITCHCOOLANT ENGINE TEMP. (RED SPEED LIGHT) SENSOR

SWITCH- PUMP INLET PRESSURE (RED LIGHT) SWITCH, TOPTANK VACUUM

DELIMBER 'OPEN' SOLENOID STABILIZER PILOT MANIFOLD

SWITCH, BTM.TANK PRESSURE

TANK AIR COMPRESSOR/ VACUUM PUMP

+

BOOM LIGHTS

_

_ +

SWITCH - ENGINE OIL PRESSURE (ENGINE HOURS METER) (RED WARNING LIGHT)

LIMIT SWITCH, PILOT SHUT OFF

SAFETY ALERT HORN (SWITCH ON CONTROL PANEL)

COOLANT LEVEL PROXIMITY SWITCH (RED LIGHT)

HARNESS, ENGINE HARNESS, ENGINE LOAD CONTROL

HARNESS, PILOT

HARNESS, TANK/ PRESS. VACUUM

SENDER COOLANT TEMPERATURE (GAUGE)

250-09

PILOT MANIFOLD

SENSOR LOCATIONS 6.9

SENDER ENGINE OIL PRESSURE (GAUGE) JOYSTICKS

HARNESS, JOYSTICK

Tigercat 250 Loader

Electrical, gauges and alarms

6.10

Tigercat 250 Loader

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

JULY 02

Tigercat 250 Loader

Engine start and stop

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

FUEL CONTROL VALVE SOLENOID

The engine normally installed on these Tigercat Loaders is a Cummins Diesel 6CT8.3C.

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.

THROTTLE ARM

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.

FUEL CONTROL VALVE

CIRCUIT DESCRIPTION

ENGINE FUEL CONTROL VALVE Turn the ignition switch to the OFF position and current is removed from the RELAY contact and wire (13) to the fuel solenoid, to close the fuel control valve and stop the engine.

279-11A

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

When the key switch is turned to the START position, the BATTERY contact is connected to the RELAY and START contacts. Current (voltage) then flows through wires (16) and (17) via the vacuum switch to energize the coils of the fuel solenoid relay and the start solenoid relay.

The fuel solenoid relay contacts close and current flows from the alternator + RED wire (1) through wire (54) to the fuel solenoid PULL IN contact.

Current also flow along the excite wire to the 'D' terminal on the alternator, a diode is in the excite wire to prevent current flowing back from the alternator once the engine is running. The start solenoid relay contacts also close and current flows from the alternator + RED wire (1) through wire (12) to the start solenoid coil to close the contacts and operate the start motor to start the engine. Current also flows through wire (20) to wire (13) to the fuel solenoid HOLD contact.

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

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

When the ignition key is turned to the RUN position, the BATTERY remains connected to the RELAY contact allowing current to continue to flow through wire (13) to the fuel solenoid HOLD contact and HOLD the fuel control valve OPEN to RUN the engine.

7.2

Tigercat 250 Loader

Engine start and stop

START CIRCUIT - AT REST

250-28

START CIRCUIT - AT REST BATTERY DISCONNECT SWITCH - ON

250-29

7.3

Tigercat 250 Loader

Engine start and stop

START CIRCUIT - START IGNITION KEY - START POSITION

250-30

START CIRCUIT - RUN IGNITION KEY - RUN POSITION

250-31

7.4

Tigercat 250 Loader

Engine start and stop

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

250-32

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

250-33

7.5

Tigercat 250 Loader

Engine start and stop

7.6

Tigercat 250 Loader

SECTION 9 - ENGINE ANTI-STALL

JUly 2002

CONTENTS - SECTION 9 CIRCUIT SCHEMATICS ................................................................................ 9.4 CONTROL MODULE IN CAB ........................................................................ 9.2 FAULT FINDING PROCEDURE ~ ANTI-STALL QUICK CHECK .................. 9.4 FAULT FINDING PROCEDURES, ADDITIONAL .......................................... 9.5 HORSEPOWER LIMITING CONTROL ......................................................... 9.2 GENERAL DESCRIPTION ......................................................................... 9.2 4 LOAD SENSE; SET MARGIN PRESSURE ............................ SEE SECTION 4 SET PILOT PRESSURE ......................................................... SEE SECTION 5 SOLENOID VALVE ........................................................................................ 9.2 SPEED SENSOR ADJUSTING ...................................................................... 9.3 SPEED SENSOR ON ENGINE ...................................................................... 9.2 VERIFY ANTI-STALL SETTING ............................................. SEE SECTION 4

SEE ALSO SECTION

Tigercat 250 Loader

Engine anti-stall

HORSEPOWER LIMITING CONTROL

HPR REGULATOR VALVE

GENERAL DESCRIPTION In the past it was common to lug an engine down when several functions with high loads were used at the same time and engine stalling was avoided only by the operator. In order to prevent engine over loading, the Tigercat machine is equipped with an electronic system which detects any drop in engine speed and destrokes the main pump to reduce engine load and thus maintain engine speed. This is done without any input from the operator and in most cases he will be unaware of the operation of this system.

TANK PORT

LOAD SENSE PRESS. PORT

A control module mounted on the rear side wall of the cab interior.

A speed sensor mounted on the back of the engine above the flywheel (Cummins).

A solenoid valve mounted on the main pump.

A wiring harness.

MAIN PUMP

WIRING HARNESS WITH 25 PIN CONNECTOR

••

SOLENOID VALVE

••

•• •• WIRING HARNESS

The control module in the cab receives and distributes signals through a 25 pin connector which is attached to the wiring harness.

•

CONTROL MODULE IN CAB SPEED SENSOR

••

105-2

•

SOLENOID VALVE ON MAIN PUMP The standard Linde system also uses a throttle position sensor but since this machine is intended to be operated with the engine at full RPM, the throttle position sensor is not needed. The horsepower control can be turned OFF when required for maintenance work by switching the anti-stall switch in the cab to the off position; the engine may then be used at less than full throttle.

During normal operation of this machine the engine should be running at MAXIMUM RPM with the throttle control pulled out completely and the anti-stall switch should be ON.

••

250-10

••

103-18A

CONTROL MODULE

•

PILOT PRESS.PORT

•

••

A Linde system is used and incorporates the following components:

GAUGE TEST PORT 'X1'

SPEED SENSOR ON ENGINE 9.2

Tigercat 250 Loader

Engine anti-stall ADJUSTING SPEED SENSOR

The pins on the 25 pin connector are connected as follows:

1. Stop engine.

Refer to Horsepower limiting control diagrams;

Pin 1 is connected to "power" through the 2 amp fuse.

Pin 13 is connected to ground.

Pin 6 is jumpered to Pin 17.

Pin 18 is jumpered to Pin 20.

Pin 14 is connected to the speed sensor on the flywheel housing.

Pin 16 is connected to the solenoid on the main pump.

Pin 11 is connected to the solenoid through the ON/OFF switch in the instrument panel.

2. Loosen locknut on speed sensor.

3. Screw speed sensor IN until it touches fly wheel.

4. Turn speed sensor OUT one full turn.

5. Tighten locknut.

NOTE : Before welding anywhere on the machine the 25 pin connector should be disconnected from the control module.

The system control module constantly monitors the engine speed and any drop in RPM from 2100 will result in a signal being sent to the main pump solenoid via wires 91, 92 and 82 from pins 11 and 16. This signal causes the solenoid valve to shift which directs pressure from the pilot system to shift the displacement control valve causing the pump to destroke. This electical signal is a pulse width modulated signal which provides for precise modulation of the hydraulic valve and the resulting smooth control of the main pump displacement.

9.3

Tigercat 250 Loader

Engine anti-stall

FAULT FINDING ~ ANTI-STALL QUICK CHECK

B. ANTI-STALL OFF 1. Connect a 0-1000 psi gauge to the X1 gauge test port on the main pump regulator.

The following is a quick procedure to detemine if the anti-stall is functioning properly. If the machine fails any of these tests, then a more detailed diagnosis is necessary. However, there can still be other problems that are not related to the anti-stall system which are being masked.

2. Start engine.

3. Place anti-stall switch in the OFF position.

4. Activate each function 1 at a time.

Expected Results:

IMPORTANT: Always ensure that the hydraulic oil is at operating temperature when performing all of the following diagnosis.

Does the problem occur with the anti-stall ON or OFF? ANSWERS:

All functions should operate normally.

X1 pressure should be less than 20 psi.

C. ANTI-STALL ON, THROTTLE MINIMUM 1. Connect a 0-1000 psi gauge to the X1 gauge test port on the main pump regulator.

A. WHEN DOES THE PROBLEM OCCUR ?

2. Start engine and place throttle in minimum position.

Occurs with the system ON or OFF The problem is likely hydraulic related. This also includes the anti-stall (VD3) solenoid valve on the main pump.

3. Place anti-stall switch in the ON position.

Occurs only with the system ON.

Expected Results:

The problem is either related to the hydraulic system, the engine, or the anti-stall system.

Boom up function should be inactive (boom will not lift)

X1 pressure should be greater than 320 psi.

845-43

4. Fully activate MAIN BOOM UP function.

HORSEPOWER LIMITING CONTROL CIRCUIT 9.4

Tigercat 250 Loader

Engine anti-stall ADDITIONAL FAULT FINDING PROCEDURES

D. ANTI-STALL ON, THROTTLE MAXIMUM 1. Connect a 0-1000 psi gauge to the X1 gauge test port on the main pump regulator.

The following procedures can be used to diagnose the anti-stall system. They are not in any particular order and should be done if addition diagnoses is required.

2. Start engine and place throttle in maximum position.

A. PILOT PRESSURE. 1. Ensure pilot pressure is correct.

3. Place anti-stall switch in the ON position.

4. Fully activate MAIN BOOM UP function.

To verify PILOT PRESSURE refer to PILOT SYSTEM in SECTION 5 of THIS MANUAL.

Expected Results:

Boom up function should operate normally.

X1 pressure should be less than 20 psi.

B. MARGIN PRESSURE 1. Ensure margin pressure is correct.

E. BEGIN OF MOVEMENT 1. Start engine and place throttle in minimum position.

To verify MARGIN PRESSURE refer to HYDRAULIC SYSTEM in SECTION 4 of THIS MANUAL.

2. Place anti-stall switch in the ON position.

C. ELECTRICAL POWER TO ANTI-STALL CONTROL MODULE. 1. Remove connector from anti-stall control module.

3. Fully activate MAIN BOOM UP function.

(Initially, the boom should not move) 4. Increase the throttle until the boom begins to lift.

2. Start engine.

3. Measure DC voltage across pins 1 and 13 on connector.

5. Measure the engine speed when the boom starts to lift. The transition state of the anti-stall system from fully active to completely inactive is very narrow. It is necessary to approach this point very slowly.

The electrical power should be 13 ±2VDC D. SOLENOID VALVE WIRES. 1. Remove connector from anti-stall control module.

Expected Results:

The boom should not move initially.

As the engine speed approaches full speed, the boom should begin to move.

The point where the boom begins to move should be 2100 rpm.

2. Measure resistance between pins 11 and 16 on connector.

The resistance should be 6.6 ±2 ohms 3. Check for shorts to chassis.

E. SOLENOID VALVE COIL 1. Remove DIN connector from anti-stall (VD3) solenoid valve.

2. Measure resistance of solenoid coil.

The resistance should be 6.6 ±2 ohms.

Continued on page 6

9.5

Tigercat 250 Loader

Engine anti-stall

Continued from page 5

F.

SPEED SENSOR OUTPUT 1. Remove connector from anti-stall control module.

2. Start engine and place throttle in maximum position.

3. Measure the AC voltage across pins 12 and 14 or pins 13 and 14 on connector.

The speed sensor output should be >5VAC. The speed sensor is non adjustable on the John Deere 6076 and 6081 engines (853 and 860). The speed sensor on the Cummins C engine (845/845B/250) should be a fixed distance from the flywheel. Do not use the voltage to adjust this distance. Refer to INSTALL OR ADJUST SPEED SENSOR in THIS SECTION.

G. SPEED SENSOR WIRES 1. Remove connector from anti-stall control module.

2. Measure resistance between pins 12 and 14 or pins 13 and 14 on connector The resistance should be: 960 ±150ohms ...... Tigercat model ........................ 845/845B/250; Cummins 'C' engine.

3000 ±300 ohms ... Tigercat model 853; 860; John Deere 6076, 6081.

3. Check for shorts from pin 14 to chassis.

(Pin 12 or 13 is connected to ground) H. SPEED SENSOR COIL 1. Remove connector from anti-stall control module.

2. Measure resistance of speed sensor coil.

The resistance should be: 960 ±150 ohms ..... Tigercat mode ........................ 845/845B/250; Cummins 'C' engine.

3000 ±300 ohms ... Tigercat model 853; 860; John Deere 6076, 6081.

9.6

Tigercat 250 Loader

SECTION 12 - BOOM FUNCTIONS

JULY 2002

CONTENTS - SECTION 12 ADJUST OIL FLOW TO CYLINDERS (CYLINDER CYCLE TIMES ............ 12.6 BOOM CONTROL VALVE ........................................................................... 12.2 BOOM SYSTEM DESCRIPTION ................................................................. 12.2

SEE ALSO SECTON 4

CIRCUIT SCHEMATIC ................................................................................ 12.3 CYLINDER CYCLE TIMES, TYPICAL ......................................................... 12.6 ENGINE ANTI-STALL .................................................................................. 12.2

SEE ALSO SECTON 4

LOAD SENSING .......................................................................................... 12.2

SEE ALSO SECTION 9

PRESSURE SETTINGS .............................................................................. 12.4 PRESSURE SETTINGS, SUMMARY .......................................................... 12.6

Tigercat 250 Loader

Boom functions

BOOM SYSTEM DESCRIPTION Single cylinders are used in each location to raise and lower the hoist boom and stick boom.

These cylinders receive oil from the main pump via two spool sections on the main hydraulic valve.

Two joystick handles in the cab control the movement of each cylinder by directing pilot oil to the pilot end caps on each end of the appropriate spool sections to shift the spool and move the cylinder(s).

BOOM CONTROL VALVE The boom and stick spool sections each have port relief valves with anticavitation features.

These protect the circuit from abnormally high pressures induced by the load.

Adjustable spool travel stops on each pilot end cap of the spool sections can be adjusted to limit spool travel and control the flow of oil to the cylinder. Controlling the flow of oil to the cylinders also controls the operating speed.

To adjust the relief valves, Refer to SET HOIST BOOM AND STICK PORT RELIEF VALVES in THIS SECTION. To adjust oil flow, Refer to ADJUST OIL FLOW TO CYLINDERS in THIS SECTION. LOAD SENSING\ENGINE ANTI-STALL The boom hydraulics along with the other circuits operated from the main control valve are all under the control of the load sensing system incorporated into the main hydraulic circuit.

For a full description of the main hydraulic system including load sensing, the main pump and the main control valve, Refer to SECTION 4 in THIS MANUAL. For a full description of the engine anti-stall, Refer to SECTION 9 in THIS MANUAL. For a full description of the pilot system including the joystick handles, Refer to SECTION 5 in THIS MANUAL.

12.2

Tigercat 250 Loader

250-10

Boom functions

BOOM HYDRAULIC CIRCUIT 12.3

Tigercat 250 Loader

Boom functions

PRESSURE SETTINGS

4.

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

Turn port relief valve adjusting screws for functions being set fully IN (clockwise). Do not overtighten or breakage will result.

SPOOL TRAVEL STOP 19mm WRENCH 6mm ALLEN KEY

•

•

ADJUSTING SCREW 5mm ALLEN KEY

•

CAUTION Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

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

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

5.

SET HOIST AND STICK PORT RELIEF VALVES ON "MAIN" VALVE NOTE: Constant loosening and tightening of the locknut (sealnut) on the port relief valve adjusting screws will eventually cause the seal in the nut to break down and leak. Because of this it is best to keep the adjusting procedure brief.

L.S. GAUGE TEST CONN.

•

LINDE MAIN VALVE MANIFOLD

••

••

HIGH PRESSURE LIMITING CONTROL (HPLC)

••

'P' GAUGE TEST CONN.

103-17A

GAUGE TEST PORTS

•

LOAD SENSING RELIEF VALVE (P2)

1.

With hydraulic oil at operating temperature,

2.

Connect a 0-5000 PSI pressure gauge on 'P' test port of Linde main valve manifold.

3.

Start engine and set throttle to 1200 rpm.

NOTE; It may be necessary to increase the engine RPM sufficiently to prevent the engine from stalling.

•

PORT RELIEF VALVE

90744-3

IMPORTANT

•

LOCKNUT 17mm WRENCH

MAIN VALVE BODY

12.4

PILOT END CAP

•

MAIN VALVE PORT RELIEF VALVE

With the aid of an assistant, bottom out the cylinder of the function being set and adjust L.S. pressure relief valve on Linde main valve manifold to 4900 psi on pressure gauge at 'P' port. Tighten locknut on adjusting screw.

Tigercat 250 Loader 6.

Boom functions

HOIST BOOM PORT RELIEFS: With an assistant holding L.H. joystick in HOIST BOOM UP position (fully extended), loosen locknut on the hoist boom UP port relief valve cartridge and slowly unscrew adjusting screw (counterclockwise) until oil can be heard (hissing noise) flowing through the relief valve or engine begins to lug slightly.

be heard (hissing noise) flowing through the relief valve or engine begins to lug slightly.

11. Slowly raise setting (clockwise) until hissing noise stops or until engine stops lugging.

NOTE: Observe the pressure gauge at 'P' port when making these adjustments, it will fall and rise as the adjusting screw is being turned and should show 4900 psi as the hissing sound begins to subside or until engine stops lugging.

WARNING

12. Tighten locknut on adjusting screw taking care NOT to turn the adjusting screw at the same time.

When adjusting the port relief valves, the boom will fall if the relief adjusting screw is unscrewed (counterclockwise) out too far.

7.

13. Check the setting again by ensuring that the hissing noise is still absent after tightening the locknut.

Slowly raise setting (clockwise) until hissing noise stops or until engine stops lugging.

NOTE: Observe the pressure gauge at 'P' port when making these adjustments, it will fall and rise as the adjusting screw is being turned and should show 4900 psi as the hissing sound begins to subside or until engine stops lugging.

8.

Tighten locknut on adjusting screw taking care NOT to turn the adjusting screw at the same time.

9.

Check the setting again by ensuring that the hissing noise is still absent after tightening the locknut.

STICK PORT RELIEFS 14. Repeat steps 5 thru' 12 to set the port relief valves for the STICK 'IN' and 'OUT' functions.

15. Readjust L.S. pressure relief valve on Linde main valve manifold to read 4500 psi on pressure gauge at 'P' port (4200 psi at 'LS' port). Refer to SET LOAD SENSE RELIEF VALVE in SECTION 4 of THIS MANUAL. 16. Stop engine, remove all gauges and reinstall plugs and caps.

10. With an assistant holding L.H. joystick in HOIST BOOM DOWN position (fully retracted), loosen locknut on the hoist boom DOWN port relief valve cartridge and slowly unscrew adjusting screw (counterclockwise) until oil can STICK 'IN' PORT RELIEF

FLOW ADJUSTING SCREW FOR PORT 'A' (TYPICAL)

HOIST 'DOWN' PORT RELIEF

• • •

B B B B

A

B A

B

A A A

A

• VIEWED FROM BELOW CONTROL VALVE MANIFOLD 250-09

•

• HIGH PRESSURE LIMITING CONTROL

•

•

MAIN CONTROL 12.5

STICK 'OUT' PORT RELIEF FLOW ADJUSTING SCREW FOR PORT 'B' (TYPICAL) VALVE

HOIST 'UP' PORT RELIEF

Tigercat 250 Loader

Boom functions SUMMARY:

ADJUST OIL FLOW TO CYLINDERS (CYLINDER CYCLE TIMES) NOTE: Constant loosening and tightening of the locknut (sealnut) on the adjusting screws will eventually cause the seal in the nut to break down and leak. Because of this it is best to keep the adjusting procedure brief.

1.

Hydraulic oil must be at operating temperature.

2.

Start engine and place engine throttle control in FULL position.

3.

4.

5.

6.

1. Ensure hydraulic oil is at operating temperature.

2. Connect gauge to 'LS' port.

3. Start engine, throttle to 1200 rpm..

4. Turn hoist and stick port reliefs in.

5. Set L.S. pressure relief valve to 4900 psi.

6. Set HOIST UP port relief.

7. Set HOIST DOWN port relief.

HOIST BOOM CYLINDER; Fully retract cylinder.

8. Set STICK UP port relief.

9. Set STICK DOWN port relief.

Place HOIST BOOM joystick lever in 'FULL UP' position and fully ** extend cylinder. Record cycle time from start until cylinder hits cushion.

10. Set L.S. pressure relief valve back to 4500 psi.

Place HOIST BOOM joystick lever in 'FULL DOWN' position and fully ** retract cylinder.

Record cycle time from start until cylinder hits cushion.

11. Set cylinder cycle times.

12. Stop engine.

STICK BOOM CYLINDER; Repeat steps (4) and (5) using STICK BOOM joystick lever. ** When extending or retracting the cylinders to record the time, it is better to stop the cylinder just before it gets to the end of it's stroke rather than let it bottom out and impose unnecessary loads on the cylinder parts and boom structures.

TYPICAL CYLINDER CYCLE TIMES Refer to CYCLE TIME - FACTORY SETTINGS in SECTION 3 of this manual for typical cylinder cycle times. It should be noted that over adjusting to provide faster cycle times could increase the stress on boom components and the hydraulic system.

To adjust cycle times; Loosen locknut on spool adjusting screw on main control valve and turn adjusting screw IN (clockwise) to slow down and OUT (counterclockwise) speed up. Tighten locknut on adjusting screw and re-check times.

NOTE: The 'A' ports (bottom ports) are connected to the base end of the cylinders and the 'B' ports (top ports) are connected to the rod end of the cylinders.

To adjust the flow rate at 'A' PORTS, adjust spool travel stop adjusting screw located at TOP of valve and vice-versa for 'B' ports. See figure 250-09 on previous page.

12.6

Tigercat 250 Loader

SECTION 15 - SWING CONTENTS - SECTION 15 FOOT PEDAL CONTROL VALVE ..................................................... 15.2, 15.9 GEARBOX, SWING DRIVE ....................................................................... 15.14 PILOT MANIFOLD ............................................................................. 15.2, 15.9 SERIAL NUMBER 2500111 TO 2500140 ADJUST SWING MOTOR SPEED MOTOR SPEED ................................ 15.5 CIRCUIT DESCRIPTION .......................................................................... 15.4 CIRCUIT DIAGRAM.................................................................................. 15.6 CROSSLINE RELIEF VALVE SETTINGS ................................................ 15.4 PRESSURE SETTINGS ........................................................................... 15.4 SUMMARY, PESSURE SETTINGS .......................................................... 15.5 SWING CONTROL VALVE ...................................................................... 15.2 SWING DRIVE COMPONENTS ............................................................... 15.2 SWING MOTOR ....................................................................................... 15.3 SERIAL NUMBER 2500141 AND UP CIRCUIT DESCRIPTION ........................................................................ 15.12 CIRCUIT DIAGRAM.................................................................................. 15.8 PRESSURE SETTINGS ......................................................................... 15.12 SUMMARY, PRESSURE SETTINGS ..................................................... 15.14 SWING CIRCUIT DESCRIPTION ........................................................... 15.12 SWING CONTROL VALVE .................................................................... 15.10 SWING DRIVE COMPONENTS ............................................................... 15.9 SWING MOTOR ..................................................................................... 15.11

JULY 2002

Tigercat 250 Loader

Swing

SWING DRIVE COMPONENTS

PILOT MANIFOLD

SERIAL NUMBER 2500111 TO 2500140

'PB' TO STABILIZER PILOT MANIFOLD

SWING PUMP MAIN (SWING) PUMP

230B-04

RETURN OIL FROM STABILIZER PILOT MANIFOLD

AUXILIARY PUMP

PILOT RELIEF VALVE

BELL HOUSING

PILOT SHUT OFF VALVE

SWING BRAKE

GAUGE TEST PORT

PILOT MANIFOLD ASSEMBLY

One solenoid operated pilot valve (position 8) on the pilot manifold controls the flow of pilot oil to operate the swing brake function.

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

250-07

MAIN PUMP (SWING) S/N 2500111 T0 2500140

The hydraulic pump used for the swing system in this serial number range is the main pump. For a more detailed description of this pump, refer to MAIN PUMP in SECTION 4 of THIS MANUAL. FOOT PEDAL CONTROL VALVE The swing function is controlled by the center foot pedal valve which sends proportional pilot signals to the swing valve to supply oil to the swing motor.

SWING CONTROL VALVE SERIAL NUMBER 2500111 TO 2500140 The swing control valve is a spool section on the main control valve which is described in detail in SECTION 4 of THIS MANUAL. The speed of rotation or swing speed can be increased or decreased by adjusting the spool travel stop screws in the end caps of each spool section. See ADJUST SWING MOTOR SPEED in THIS SECTION.

For a detailed description of the foot pedal control valve refer to SECTION 5 in THIS MANUAL. FLOW ADJUSTING SCREW FOR PORT 'A' (TYPICAL)

CONTROL VALVE MANIFOLD

SWING SPOOL SECTION

•

CCW ROTATION

B

•

A CW ROTATION

• VIEWED FROM BELOW

• 250-09

HIGH PRESSURE LIMITING CONTROL

MAIN CONTROL VALVE (S/N 2500111 TO 2500140) 15.2

FLOW ADJUSTING SCREW FOR PORT 'B' (TYPICAL)

Tigercat 250 Loader

Swing MOTOR

The swing motor is a fixed displacement piston motor with crossline relief valves mounted on the input end. The crossline relief valves provide a cushion to the high forces that occur during start and stop of the boom swing.

CROSSLINE RELIEF VALVES R.H ROTATION

•• ••

SWING MOTOR SERIAL NUMBER 2500111 TO 2500140

L.H. ROTATION

•• ••

SWING BRAKE

• ORIFICE CONNECTOR PORT 'U'

GEARBOX

••

•

• SWING MOTOR

111-6X

FROM BRAKE RELEASE PILOT

ORIFICE

SWING BRAKE

GEARBOX FLUSHING OIL SUPPLY FROM SWING VALVE ''PB' PORT

•

•

• CROSS LINE RELIEF VALVES

PRESSURE LINES FROM MAIN CONTROL VALVE 845-16

SWING DRIVE MOTOR SCHEMATIC

15.3

Tigercat 250 Loader SWING CIRCUIT DESCRIPTION SERIAL NUMBER 2500111 TO 2500140 A spool section on the main control valve receives oil from the main pump. When the foot pedal in the cab is pressed either to the left or right, pilot pressure acts on the end of the spool in the swing spool section of the main valve and shifts the spool to direct oil to the swing motor and cause rotation.

The swing circuit is not part of the load sensing system due to the cross line relief valves on the motor being set at a lower value than the load sensing relief valve (P2) on the main valve HPLC valve.

Swing PRESSURE SETTINGS SET SWING RELIEF VALVES ON "MAIN" VALVE SERIAL NUMBER 2500111 TO 2500140 Main valve CW port relief setting ................... No relief Main valve CCW port relief setting ................. No relief Motor crossline relief valves (low setting) ...... 3000 psi SET CROSSLINE RELIEF VALVES 1. Machine must be on level ground with stabilizers properly in place, lower grapple to the ground and stop engine.

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

Adjustable spool travel stops on each pilot end cap of the spool sections can be adjusted to limit spool travel and control the flow of oil to the swing motor.

Controlling the flow of oil to the motor also controls the swing rotation speed.

The swing brake, located in the top of the gearbox acts on the swing motor input shaft, placing the swing brake switch, located in the operator's cab in the ON position removes power from the swing brake solenoid pilot valve on the pilot manifold to apply the brake. The brake is spring applied/ hydraulic release.

L.S. GAUGE TEST CONN.

LINDE MAIN VALVE MANIFOLD

•

•

••

HIGH PRESSURE LIMITING CONTROL (HPLC)

•

'P' GAUGE TEST CONN.

•

LOAD SENSING RELIEF VALVE (P2)

• GAUGE TEST PORTS 3. Install a 0-5000 psi pressure gauge in the 'L.S.' test port on the back of the main valve manifold.

103-17A

4. Start engine and place throttle control in FULL. 5. Turn anti-stall switch OFF and the swing brake ON. 6. While operating the foot pedal fully in both the LEFT and RIGHT directions, loosen locknut on each crossline relief adjusting screw and turn adjusting screw until the reading on pressure gauge in 'L.S.' test port is 3600 psi for each direction.

CROSSLINE RELIEF VALVES R.H. ROTATION

ADJUSTING SCREWS 111-6

L.H. ROTATION

CROSSLINE RELIEF

If pressure gauge is installed in 'P' test port, reading on gauge would be 3900 psi.

15.4

Tigercat 250 Loader

Swing

7. Retighten locknut on each adjusting screw taking care not to disturb adjusting screw and recheck pressure setting before removing pressure gauge.

8

FLOW ADJUSTING SCREW FOR PORT 'A' (TYPICAL)

SWING SPOOL SECTION

•

CCW ROTATION

Stop engine, remove gauge and reinstall plug.

B

ADJUST OIL FLOW TO SWING MOTOR (SWING MOTOR SPEED)

A

SERIAL NUMBER 2500111 TO 2500140

CW ROTATION

NOTE: Constant loosening and tightening of the locknut (sealnut) on the adjusting screws will eventually cause the seal in the nut to break down and leak. Because of this it is best to keep the adjusting procedure brief.

•

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

2. Start engine and place engine throttle control in FULL position.

3. Raise the grapple off ground and operate the foot pedal in 'FULL LEFT' position and rotate the upper. Record time for one complete revolution.

SPOOL TRAVEL STOP 19MM WRENCH 6MM ALLEN KEY

•

MAKE UP VALVE

•

• FLOW ADJUSTING SCREW FOR PORT 'B' (TYPICAL)

MAIN CONTROL VALVE (S/N 2500111 TO 2500140) 5. To adjust swing speed; 250-09

VIEWED FROM BELOW

(Refer to fig. 250-09 above and fig. 90919-1) Loosen locknut on spool travel stop adjusting screw and turn adjusting screw IN (clockwise) to slow down and OUT (counterclockwise) speed up. Tighten locknut on adjusting screw and re-check times.

SUMMARY: 1. Position machine on level ground.

2. Ensure hydraulic oil is at operating temperature.

3. Connect gauge to "LS" port.

MAIN VALVE BODY

4. Start engine, FULL rpm.

• 90919-1

CONTROL VALVE MANIFOLD HIGH PRESSURE LIMITING CONTROL

•

•

PILOT END CAP

MAIN VALVE SPOOL TRAVEL STOP

4. Repeat step (3) with foot pedal in 'FULL RIGHT' position.

The recommended factory setting is 9 RPM. It should be noted that over adjusting to provide a faster swing speed could increase the stress on boom components and increase the heat load in the hydraulic system.

5. Turn anti-stall switch OFF. 6. Turn swing brake ON Set swing motor crossline reliefs:7. Set SWING LEFT crossline relief.

8. Set SWING RIGHT crossline relief.

9. Set swing speed (spool travel stops)

15.5

Tigercat 250 Loader

250-11

Swing

SWING DRIVE CIRCUIT SERIAL NUMBER 2500111 TO 2500140 15.6

Tigercat 250 Loader

Swing

15.7

Tigercat 250 Loader

250-12

Swing

SWING DRIVE CIRCUIT SERIAL NUMBER 2500141 AND UP 15.8

Tigercat 250 Loader

Swing

SWING DRIVE COMPONENTS

FOOT PEDAL CONTROL VALVE

SERIAL NUMBER 2500141 AND UP

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.

SWING PUMP On these later machines the swing pump manufacturer may vary but they are all axial-piston variable displacement pumps controlled by a pressure compensator.

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

MAIN PUMP

PILOT MANIFOLD 'PB' TO STABILIZER PILOT MANIFOLD

BELL HOUSING

250-07

250-13

SWING BRAKE

PILOT SHUT OFF VALVE

PRESSURE COMPENSATOR

RETURN OIL FROM STABILIZER PILOT MANIFOLD

SWING PUMP (LINDE SHOWN)

230B-04

PILOT RELIEF VALVE

GAUGE TEST PORT

PILOT MANIFOLD ASSEMBLY

One solenoid operated pilot valve (position 8) on the pilot manifold controls the flow of pilot oil to operate the swing brake function.

SWING PUMP S/N 2500141 AND UP

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

SWING PUMP SCHEMATIC

The pressure compensator is mounted directly onto the pump and has a STANDBY pressure adjustment and a P.O.R. adjustment.

The STANDBY adjusting screw is screwed completely in and is NOT used for this application.

The P.O.R. is adjusted to operate at 3600 psi.

Until system pressure reaches 3600 psi, the compensator valve will be in the "return" position blocking oil flow to the swashplate control piston leaving the pump at maximum displacement.

The pump is mounted and driven off the main pump PTO, which is mounted to the engine bell housing.

15.9

Tigercat 250 Loader

Swing

SWING CONTROL VALVE SERIAL NUMBER 2500141 AND UP

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).

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.

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.

OUTLET SECTION

• SWING 'CCW' PORT RELIEF (TURN FULLY IN)

SWING 'CW' PORT RELIEF (TURN FULLY IN)

•

SWING

•

•

•

INLET SECTION

AT041ZIL

RELIEF VALVE PORT 'A'

RELIEF VALVE PORT 'B'

SEAL GROOVES

A

B

AT041YIL

SPOOL CENTERING SPRINGS

PILOT END CAP

MAIN RELIEF (4000 PSI)

GAUGE TEST PORT

•

SPOOL TANK PASSAGE

PARALLEL PASSAGE

LOAD CHECK VALVE

THRU' NEUTRAL PASSAGE

WORK PORT BRIDGE

TANK PASSAGE

SWING CONTROL VALVE SERIAL NUMBER 2500141 AND UP 15.10

PILOT END CAP

Tigercat 250 Loader

Swing

SWING MOTOR SERIAL NUMBER 2500141 AND UP The swing motor is a fixed displacement piston motor with two, 2-stage crossline relief valves mounted on the port end cover. The crossline CROSS LINE RELIEF VALVES

PRESSURE PORTS

ORIFICE CONNECTOR PORT 'U'

CASE DRAIN LINE

SWING BRAKE SYSTEM PRESSURE LINES

SWING MOTOR

250-13

ORIFICE FROM BRAKE RELEASE PILOT

SWING BRAKE GEARBOX FLUSHING OIL SUPPLY FROM SWING VALVE ''PB" PORT

•

SYSTEM PRESSURE LINES

•

• 2 - STAGE CROSS LINE RELIEF VALVES

PRESSURE LINES FROM CONTROL VALVE 250-14 SWING DRIVE MOTOR SCHEMATIC relief valves provide a cushion to the high forces that occur during start and stop of the boom swing. There are two separate pressure settings for swing acceleration and deceleration. When coasting to a stop, the relief valve opens at a lower pressure resulting in a soft stop.

15.11

Tigercat 250 Loader SWING CIRCUIT DESCRIPTION SERIAL NUMBER 2500141 AND UP

The swing circuit is supplied with hydraulic oil by a variable displacement piston 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, a check valve to the return manifold and four dual element filters. A 50 psi. relief valve is installed in the oil cooler line to bypass the oil around the oil cooler, usually on cold start ups when the oil is cold and thicker.

Swing PRESSURE SETTINGS SET SWING RELIEFS ON "SWING" VALVE SERIAL NUMBER 2500141 AND UP Swing main relief valve setting .............. 4000 psi C/Clockwise port relief setting ...... Turned fully IN Clockwise port relief setting ......... Turned fully IN Motor crossline relief valves (low setting) ......................................... Non adjustable 2000 psi Pump compensator setting .................... 3600 psi Pump standby setting .................... Turned fully IN

CAUTION

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.

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 valve 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.

NOTE: At the time of printing, the type of 2-stage cross line relief valves in use are factory set and require no adjustment.

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.

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

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

1. Machine must be on level ground with stabilizers properly in place, lower grapple to the ground and stop engine.

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

3. On the swing pump compensator valve:

Slacken jamnut on compensator adjusting screw, and turn adjusting screw all the way IN. CAUTION: Do not use excessive force; stop when the resistance increases sharply.

Tighten the jamnut.

The STANDBY valve adjusting screw is screwed fully IN (factory set) and must remain this way. This portion of the compensator is NOT USED.

4. Make sure that both port relief valve adjusting screws on the swing spool section of the swing valve are screwed all the way in, this is a factory setting as they are not used in this swing circuit.

15.12

Tigercat 250 Loader

Swing

COMPENSATOR ADJUSTING SCREW

STANDBY ADJUSTING SCREW

STANDBY ADJUSTING SCREW

COMPENSATOR ADJUSTING SCREW

••

PRESSURE COMPENSATOR

•• 217-21

PUMP PRESSURE COMPENSATOR (LINDE) MAIN PUMP

SWING PUMP

BELL HOUSING

SWING PUMP (PARKER)

250-12

250-07

PRESSURE COMPENSATOR

SWING PUMP

COMPENSATOR ADJUSTING SCREW

STANDBY ADJUSTING SCREW

PRESSURE COMPENSATOR

SWING PUMP (LINDE)

5. Turn main relief valve adjusting screw on swing valve out until spring pressure is relieved and then turn the adjusting screw one full turn in.

SWING PUMP

6. Install a 0-5000 psi pressure gauge on swing valve gauge test port.

250-11

7. Place swing brake in ON position.

8. Start the engine** and put throttle control to the IDLE position. **CAUTION: Before starting engine, ensure relief valve is unscrewed as stated in step 6, otherwise damage could occur to the piston pump.

SWING PUMP (KAWASAKI)

13. Set compensator adjustment on pump compensator to 3600 psi. by slowly screwing the relief valve adjusting screw OUT until the required pressure reading is obtained.

14. Re-tighten jamnut, making sure adjusting screw does not turn.

15. The adjusting screw on the STANDBY valve must remain screwed fully IN.

9. Reset pilot system.

10. With the aid of an assistant, press the swing foot pedal in either direction and set the swing control valve main relief to 4000 PSI. Do this by loosening the jamnut and slowly screwing the relief valve adjusting screw in until the required pressure reading on the gauge is obtained.

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

11. Re-tighten jamnut, making sure adjusting screw does not turn.

12. Set throttle to FULL rpm.

15.13

Tigercat 250 Loader

Swing

SUMMARY:

SWING DRIVE GEARBOX

1. Position machine on level ground.

Power is transmitted from the motor to a double reduction planetary gearbox which has a springapplied, hydraulic-release, multi-disc brake on the input shaft. This brake is normally ON. Placing the swing brake switch in the OFF position energizes the swing brake solenoid pilot valve on the pilot manifold and allows pilot oil pressure to flow to the swing brake via an orifice in port 'Z', to place the swing brake OFF.

2. Ensure hydraulic oil is at operating temperature.

3. Turn compensator adjusting screw fully in.

4. Ensure STANDBY adjusting screw is fully in.

5. Ensure port reliefs on swing valve are fully in.

6. Turn main relief on swing valve out.

7. Connect gauge to "swing" valve.

BRAKE RELEASE PORT 'Z'

8. Place swing brake ON.

STEEL DISC

FLUSHING PORT 'T'

FLUSHING PORT 'U'

FRICTION DISC

9. Start engine, IDLE position.

10. Set SWING MAIN relief.

•

11. Place throttle in FULL position.

12. Set Pump COMPENSATOR.

•

•

•

• • BRAKE RELEASE PORT 'Y'

13. Stop engine.

BK005-3

CROSS SECTION OF SWING BRAKE

Port 'Y' (with the orifice) may also be used for this purpose with port 'Z' plugged.

In the event that electrical power is lost to the solenoid pilot valve or hydraulic pressure to the pilot valve is lost, the swing brake will engage (ON) automatically.

The swing gearbox upper gearing is lubricated by hydraulic oil which flows from the drain port on the swing valve into the 'U' port on the swing drive gearbox. A 1/16 inch orifice installed in the 'U' port regulates the flow of oil through the gearbox at approx. 1 GPM. Oil is returned to tank via flushing port 'T'. This flow of 'return oil' through the gearbox is caused by back pressure created by the oil cooler in one of the other return to tank lines from the auxiliary valve.

15.14

Tigercat 250 Loader

SECTION 16 - STABILIZERS CONTENTS - SECTION 16 COUNTERBALANCE AND CHECK CARTRIDGES, REMOVAL ................. 16.5 COUNTERBALANCE VALVES .................................................................... 16.5 CYLINDERS AND COUNTERBALANCE VALVES ...................................... 16.5 PILOT MANIFOLD ....................................................................................... 16.2 PILOT MANIFOLD, STABILIZER ................................................................. 16.2 SERIAL NUMBER 2500111 TO 2500140 CIRCUIT DESCRIPTION .......................................................................... 16.6 CIRCUIT DIAGRAM.................................................................................. 16.7 CONTROL VALVE .................................................................................... 16.3 PRESSURE SETTINGS, SUMMARY ....................................................... 16.9 PUMP ....................................................................................................... 16.2 SERIAL NUMBER 2500141 AND UP CIRCUIT DESCRIPTION .......................................................................... 16.6 CIRCUIT DIAGRAM................................................................................ 16.10 CONTROL VALVE .......................................................................... 16.3, 16.4 FLOW ADJUSTMENT ............................................................................ 16.12 PRESSURE SETTINGS, SUMMARY ..................................................... 16.12 STABILIZER CIRCUIT COMPONENTS ...................................................... 16.2 STABILIZER PILOT MANIFOLD .................................................................. 16.2

JULY 2002

Tigercat 250 Loader

Stabilizers

STABILIZER CIRCUIT COMPONENTS PUMP MAIN PUMP

For a more detailed description of this pump, refer to MAIN PUMP in SECTION 4 of THIS SERVICE MANUAL. PILOT MANIFOLD

BELL HOUSING

number range is provided by the main pump.

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

'PB' TO STABILIZER PILOT MANIFOLD

PRESSURE COMPENSATOR

STABILIZERS STABILIZERS PILOT SHUT OFF VALVE UP DOWN

AUXILIARY PUMP

PILOT RELIEF VALVE

250-07

RETURN OIL FROM STABILIZER PILOT MANIFOLD

AUXILIARY PUMP S/N 2500111 TO 2500140

230B-04

AUXILIARY/STABILIZER PUMP SERIAL NUMBER 2500111 TO 2500140 Supply oil for the stabilizer circuit for this serial number range is provided by the auxiliary pump which is an axial-piston variable displacement pump controlled by a pressure compensator.

For a more detailed description of this pump, refer to SWING PUMP in SECTION 15 of THIS SERVICE MANUAL.

GAUGE TEST PORT

PILOT MANIFOLD ASSEMBLY

For a detailed description of the pilot manifold refer to SECTION 5 in THIS MANUAL. STABILIZER PILOT MANIFOLD This stabilizer pilot manifold consists of an aluminum housing containing four solenoid operated pilot valves and four pilot operated

MAIN/STABILIZER PUMP SERIAL NUMBER 2500141 AND UP

'E' FRONT RIGHT

Supply oil for the stabilizer circuit for this serial

MAIN/ STABILIZER PUMP

'D' REAR RIGHT

'C' FRONT LEFT

BELL HOUSING

'B' REAR LEFT

PRESSURE COMPENSATOR

4-SOLENOID OPERATED PILOT VALVES 'T' TANK PORT

SWING PUMP (LINDE SHOWN)

'P' PILOT SUPPLY

4- PILOT OPERATED DIRECTIONAL VALVES

'A' SYSTEM PRESSURE SUPPLY

STABILIZER PILOT MANIFOLD

250-07

MAIN/STABILIZER PUMP S/N 2500141 AND UP

269-22

16.2

VIEWED FROM BELOW

Tigercat 250 Loader

Stabilizers

directional control valves. Pilot port 'P' is connected to the pilot manifold and supplies pilot oil to the four solenoid operated pilot valves. Port 'A' is connected to the stabilizer control valve and supplies oil at system pressure to the four directional valves. Port 'T' is a tank return line, and ports 'B', 'C', 'D' and 'E' supply oil at system pressure to the stabilizer cylinders.

the stabilizer. When the stabilizers are stationary, the spools in the directional control valves are in the closed position.

STABILIZER CONTROL VALVE SERIAL NUMBER 2500111 TO 2500140 The stabilizer UP/DOWN/OFF functions are controlled by one of three spool sections in the three section "auxiliary" control valve.

OPERATING DESCRIPTION When any (or ALL) of the four solenoid operated pilot valves are energized (by pressing a switch in the operator's cab), pilot oil via port 'P' is diverted by internal porting to shift a spool in the appropriate directional valve. Shifting one of these spools connects either port 'B', 'C', 'D' or 'E' with a counterbalance valve mounted to the base end of one of the stabilizer cylinders to raise or lower

For a detailed description of the auxiliary/stabilizer control valve, refer to SWING CONTROL VALVE S/N 2500141 AND UP in SECTION 15 of THIS MANUAL. STABILIZER CONTROL VALVE SERIAL NUMBER 2500141 AND UP The stabilizer UP/DOWN/OFF functions are controlled by one of six (optional seven) spool Continued on page 4

OUTLET SECTION STABILIZER 'UP' PORT RELIEF 2000 PSI

•

STABILIZER 'DOWN' PORT RELIEF 3500 PSI

•

STABILIZERS

•

•

•

INLET SECTION

AT041ZIL

GAUGE TEST PORT

RELIEF VALVE PORT 'A'

SEAL GROOVES

A

RELIEF VALVE PORT 'B'

B

AT041YIL

SPOOL CENTERING SPRINGS

PILOT END CAP

MAIN RELIEF (3300 PSI)

•

SPOOL TANK PASSAGE

PARALLEL PASSAGE

LOAD CHECK VALVE

THRU' NEUTRAL PASSAGE

WORK PORT BRIDGE

TANK PASSAGE

PILOT END CAP

AUXILIARY/STABILIZER CONTROL VALVE SERIAL NUMBER 2500111 TO 2500140 16.3

Tigercat 250 Loader

Stabilizers

Continued from page 3

sections on the "main" control valve.

For a detailed description of the main/stabilizer control valve, refer to SECTION 4 in THIS MANUAL.

FLOW ADJUSTING SCREW FOR PORT 'A' (TYPICAL)

STABILIZER 'UP' PORT RELIEF

STABILIZER SPOOL SECTION

•

UP

B

A DOWN

• FLOW ADJUSTING STABILIZER 'DOWN' SCREW FOR PORT PORT RELIEF 'B' (TYPICAL) 250-08

• VIEWED FROM BELOW

•

HIGH PRESSURE LIMITING CONTROL

MAIN/STABILIZER CONTROL VALVE SERIAL NUMBER 2500141 AND UP

16.4

CONTROL VALVE MANIFOLD

Tigercat 250 Loader

Stabilizers

STABILIZER CYLINDERS AND COUNTERBALANCE VALVES

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

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

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

CHECK CARTRIDGE

COUNTERBALANCE CARTRIDGE

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

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

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

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

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.

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

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

VERTICAL CENTERLINE

LOWER FRAME

275-15

CYLINDER

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 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.

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.

16.5

Tigercat 250 Loader

Stabilizers

STABILIZER CIRCUIT DESCRIPTION Refer to appropriate CIRCUIT DIAGRAM SERIAL NUMBER 2500111 TO 2500140 The stabilizer circuit is supplied with hydraulic oil by the auxiliary pump. The auxiliary/stabilizer valve receives oil at the inlet section and directs it through the three open center spool sections, to the outlet section of the valve.

From there it is directed back to tank via the oil cooler, a check valve to the return manifold and two dual element filters, which are equipped with an internal 25 psi element bypass valve. A 50 psi. relief valve is installed in the oil cooler line to bypass the oil around the oil cooler, usually on cold start ups when the oil is cold and thicker.

SERIAL NUMBER 2500141 AND UP The stabilizer circuit is supplied with hydraulic oil by the main pump. The main/stabilizer control valve manifold receives oil at the 'P' ports and directs it through the manifold to the six spool sections.

When no function is being operated the pump will de-stroke and provide a stand by pressure of 500 psi and zero flow.

The stabilizer circuit is not part of the load sensing system due to the port relief valves on the main valve being set at a lower value than the load sensing relief valve (P2) on the main valve HPLC valve.

Adjustable spool travel stops on each pilot end cap of the spool sections can be adjusted to limit spool travel and control the flow of oil to the stabilizer cylinders. Controlling the flow of oil to the cylinders also controls the speed.

For a detailed description of this system, refer to LOAD SENSING in SECTION 4 of THIS MANUAL. ALL MACHINES Six switches on the instrument panel control the stabilizers, One 3-position switch OFF/UP/DOWN and five more switches to operate the stabilizers either ALL at the same time or each one INDIVIDUALLY. For a detailed description of these switches, refer to SECTION 2 in the OPERATOR'S MANUAL. Placing the 3-position stabilizer direction switch in the OFF position removes all current from the stabilizer circuit to prevent the stabilizers from operating. The switch should remain in this position when the stabilizers are in the stationary position, either UP or DOWN.

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 pilot valve(s) on the stabilizer pilot manifold and allow pilot oil, via internal porting, to shift a spool in a directional valve in the manifold.

In this condition, hydraulic oil will flow from the UP side of stabilizer control valve to the rotary manifold and on to the cylinder counterbalance valve where it will be directed to the rod end of all selected cylinders. Return oil from the base end of the cylinders will be directed to the counterbalance valve, through the rotary manifold,through the stabilizer pilot manifold, to the stabilizer control valve and back to tank.

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.

Current will also flow to energize a solenoid pilot valve(s) on the stabilizer pilot manifold to allow pilot oil, via internal porting, to shift a spool in a directional valve in the manifold.

In this condition, hydraulic oil will flow from the DOWN side of stabilizer control valve, through the stabilizer pilot manifold, through the 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 to the counterbalance valve, through the rotary manifold to the stabilizer control valve and back to tank.

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 16.6

Tigercat 250 Loader

Stabilizers

through all of the diodes to supply electrical current to all four solenoid operated pilot valves on the stabilizer pilot manifold and also through the direction switch and energize the solenoid

250-15

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.

STABILIZER CIRCUIT SERIAL NUMBER 2500111 T0 2500140 16.7

Tigercat 250 Loader PRESSURE SETTINGS 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

CAUTION Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

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

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

5. 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.

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

7. Start engine and place throttle control in FULL. 8. Place stabilizer control switch in UP position.

9. 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.

IMPORTANT

SET STABILIZER RELIEFS ON "AUXILIARY" VALVE SERIAL NUMBER 2500111 TO 2500140 Main relief valve setting ........................... 3300 psi Stabilizer up port relief setting ............... 2000 psi Stabilizer down port relief setting .......... 3500 psi Counterbalance relief valves* ................. 1000 psi Pump compensator setting ..................... 2900 psi Pump standby setting .................. Turned fully IN *NOTE: The counterbalance valve cartridge is factory set to 1000 psi, it cannot be set in the field without removing it from the cylinder and using special test equipment. If this valve is suspect, example; stabilizers will not stay in UP position, it should be replaced with a new one.

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

1. Machine must be on level ground with stabilizers properly in place.

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

3. On the auxiliary pump compensator valve:

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

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

11. Place stabilizer control switch in DOWN position.

12. 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.

CAUTION 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.

Slacken jamnut on compensator adjusting screw, and turn adjusting screw all the way IN. CAUTION: Do not use excessive force; stop when the resistance increases sharply.

Tighten the jamnut.

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

The STANDBY valve adjusting screw is screwed fully IN (factory set) and must remain this way. This portion of the compensator is NOT USED.

15. Set engine throttle control to IDLE position.

14. Repeat steps 8 and 11 to verify settings. reset main relief valve: 16. Loosen locknut on auxiliary main relief and unscrew adjusting screw 3 full turns.

16.8

Tigercat 250 Loader

Stabilizers

17. 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.

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

Reset auxiliary pump compensator:19. Set throttle to FULL rpm.

20. Set compensator adjustment on pump compensator to 3600 psi. by slowly screwing the relief valve adjusting screw OUT until the required pressure reading is obtained.

21. Re-tighten jamnut, making sure adjusting screw does not turn.

22. Stop engine, remove pressure gauge and wipe up any spills from around gauge test port.

SUMMARY:

SERIAL NUMBER 2500111 TO 2500140 1. Position machine on level ground.

2. Ensure hydraulic oil is at operating temperature.

3. Turn compensator adjusting screw fully in.

4. Turn main relief on "auxiliary" valve fully in.

5. Turn both "stabilizer" port reliefs out.

6. Connect gauge to "auxiliary" valve.

7. Start engine, FULL rpm.

8. Set STABILIZER UP port relief.

9. Set STABILIZER DOWN port relief.

10. Set engine throttle to IDLE. 11. Reset main relief.

12. Set engine throttle to FULL. 13. Set pump COMPENSATOR. 14. Stop engine

16.9

Tigercat 250 Loader

250-16

Stabilizers

STABILIZER CIRCUIT SERIAL NUMBER 2500141 AND UP 16.10

Tigercat 250 Loader

Stabilizers 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

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

CAUTION Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

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

10. Place stabilizer control switch in DOWN position.

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

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.

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

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

13. Repeat steps 8 and 11 to verify settings.

SET STABILIZER RELIEFS ON "MAIN" VALVE SERIAL NUMBER 2500141 AND UP

14. Stop engine, remove pressure gauge and wipe up any spills from around gauge test port.

Stabilizer up port relief setting ............ 2000 psi Stabilizer down port relief setting ....... 3000 psi 1. Machine must be on level ground with stabilizers properly in place.

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

3. 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.

4. Install a 0-5000 psi pressure gauge in the 'L.S.' test port on the back of the main valve manifold.

5. Start engine and place throttle control in FULL. 6. Turn anti-stall switch OFF. 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

16.11

Tigercat 250 Loader

Stabilizers

ADJUST OIL FLOW TO STABILIZERS SERIAL NUMBER 2500141 AND UP NOTE: Constant loosening and tightening of the locknut (sealnut) on the adjusting screws will eventually cause the seal in the nut to break down and leak. Because of this it is best to keep the adjusting procedure brief.

FLOW ADJUSTING SCREW FOR PORT 'A' (TYPICAL)

STABILIZER 'UP' PORT RELIEF

STABILIZER SPOOL SECTION

•

UP

B

A DOWN

• FLOW ADJUSTING STABILIZER 'DOWN' SCREW FOR PORT PORT RELIEF 'B' (TYPICAL)

VIEWED FROM BELOW

250-08 OIL FLOW ADJUSTMENT To adjust speed;

(Refer to fig. 250-08) Loosen locknut on spool travel stop adjusting screw and turn adjusting screw IN (clockwise) until end of adjusting screw lightly touches end of spool. Do not screw adjusting screw beyond point of contact with spool or spool will begin to move. Back out adjusting screw 9 full turns and tighten locknut on adjusting screw. Repeat this procedure on opposite end of spool section.

SUMMARY:

SERIAL NUMBER 2500141 AND UP 1. Position machine on level ground.

2. Ensure hydraulic oil is at operating temperature.

3. Turn both "stabilizer" port reliefs out.

4. Connect gauge to 'LS' port.

5. Start engine, full throttle.

6. Turn anti-stall switch off.

7. Set STABILIZER UP port relief.

8. Set STABILIZER DOWN port relief.

9. Adjust oil flow.

10. Stop engine.

16.12

Tigercat 250 Loader

SECTION 17 - GRAPPLE CONTENTS - SECTION 17 BOOM CONNECTIONS ............................................................................... 17.4 CONTROL VALVE, JOYSTICK .................................................................... 17.2 CONTROL VALVES, MAIN .......................................................................... 17.2 GRAPPLE CONNECTIONS TO BOOM ....................................................... 17.4 GRAPPLE SYSTEM COMPONENTS .......................................................... 17.2 JOYSTICK CONTROL VALVE ..................................................................... 17.2 SERIAL NUMBER 2500111 TO 2500140 CIRCUIT DESCRIPTION .......................................................................... 17.4 CIRCUIT DIAGRAM.................................................................................. 17.5 OIL FLOW ADJUSTMENTS TO ROTATE MOTOR ................................. 17.7 PRESSURE SETTINGS ........................................................................... 17.6 SUMMARY, PRESSURE SETTINGS ....................................................... 17.8 SERIAL NUMBER 2500141 AND UP CIRCUIT DESCRIPTION ........................................................................ 17.11 CIRCUIT DIAGRAM................................................................................ 17.10 CYLINDER CYCLE TIMES ..................................................................... 17.12 OIL FLOW ADJUSTMENTS TO CYLINDERS (CYLINDER CYCLE ....... 17.12 PRESSURE SETTINGS ......................................................................... 17.11 SUMMARY, PRESSURE SETTINGS ..................................................... 17.13

JULY 2002

Tigercat 250 Loader

Grapple

GRAPPLE SYSTEM COMPONENTS

MAIN PUMP, GRAPPLE ROTATE

BELL HOUSING

BELL HOUSING

PRESSURE COMPENSATOR

AUXILIARY PUMP, GRAPPLE OPENCLOSE

250-07 250-07

GRAPPLE PUMPS S/N 2500111 TO 2500140

Supply oil for the grapple OPEN-CLOSE circuit is provided by the AUXILIARY PUMP which is an axialpiston variable displacement pump controlled by a pressure compensator.

For a more detailed description of this pump, refer to SWING PUMP in SECTION 15 of THIS SERVICE MANUAL. Supply oil for the grapple ROTATE circuit is provided by the MAIN PUMP. For a more detailed description of this pump, refer to MAIN PUMP in SECTION 4 of THIS MANUAL. SERIAL NUMBER 2500141 AND UP Supply oil for the grapple ROTATE circuit is provided by the SWING PUMP which is an axial-piston variable displacement pump controlled by a pressure compensator.

For a more detailed description of this pump, refer to SWING PUMP in SECTION 15 of THIS SERVICE MANUAL. Supply oil for the grapple OPEN-CLOSE circuit is provided by the MAIN PUMP. For a more detailed description of this pump, refer to MAIN PUMP in SECTION 4 of THIS MANUAL.

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 two "spool section" control valves to shift a spool(s) and supply system oil to the grapple open/close

PRESSURE COMPENSATOR

SWING PUMP, GRAPPLE ROTATE (LINDE SHOWN)

GRAPPLE PUMPS S/N 2500141 AND UP

cylinders and the grapple rotate motor.

PUMPS SERIAL NUMBER 2500111 TO 2500140

JOYSTICK CONTROL VALVE

MAIN PUMP, GRAPPLE OPENCLOSE

For a detailed description of the joystick control valve refer to SECTION 5 in THIS MANUAL. GRAPPLE CONTROL VALVES SERIAL NUMBER 2500111 TO 2500140 The grapple open/close function is controlled by one of three spool sections in the "auxiliary" valve and the grapple rotate motor is controlled by one of six (optional 7) spool sections in the "main" valve. The control valves are located in the upper frame below the floor plates inside the valve compartment.

For a detailed description of the auxiliary/grapple open-close control valve, refer to SWING CONTROL VALVE S/N 2500141 AND UP in SECTION 15 of THIS MANUAL. For a detailed description of the main/grapple rotate control valve, refer to SECTION 4 in THIS MANUAL. GRAPPLE CONTROL VALVES SERIAL NUMBER 2500141 AND UP The grapple rotate function is controlled by one of three spool sections in the "swing" valve and the grapple open-close functions are controlled by one of six (optional 7) spool sections in the "main" valve.

The control valves are located in the upper frame below the floor plates inside the valve compartment.

For a detailed description of the swing/grapple rotate control valve, refer to SWING CONTROL VALVE S/N 2500141 AND UP in SECTION 15 of THIS MANUAL. For a detailed description of the main/grapple open-close control valve, refer to SECTION 4 in THIS MANUAL.

17.2

Tigercat 250 Loader

Grapple

OUTLET SECTION

S/N 2500111 TO 2500140 GRAPPLE 'CLOSE' PORT RELIEF 3500 PSI

•

S/N 2500111 TO 2500140 GRAPPLE 'OPEN' PORT RELIEF 3500 PSI

GRAPPLE

•

S/N 2500141 AND UP GRAPPLE ROTATE 'CCW' PORT RELIEF 1750 PSI (TIGERCAT)

S/N 2500141 AND UP GRAPPLE ROTATE 'CW' PORT RELIEF 1750 PSI (TIGERCAT)

•

•

•

INLET SECTION AT041ZIL

RELIEF VALVE PORT 'A'

GAUGE TEST PORT

SEAL GROOVES

A

RELIEF VALVE PORT 'B'

B

PILOT END CAP

MAIN RELIEF (4000 PSI)

•

SPOOL CENTERING SPRINGS

SPOOL TANK PASSAGE

LOAD CHECK VALVE

PARALLEL PASSAGE

THRU' NEUTRAL PASSAGE

WORK PORT BRIDGE

TANK PASSAGE

PILOT END CAP

AUXILIARY/GRAPPLE OPEN-CLOSE CONTROL VALVE SERIAL NUMBER 2500111 TO 2500140 SWING/GRAPPLE ROTATE CONTROL VALVE SERIAL NUMBER 2500141 AND UP

AT041YIL

S/N 2500111 TO 2500140 GRAPPLE ROTATE 'CCW' PORT RELIEF 1750 PSI (TIGERCAT)

S/N 2500141 AND UP GRAPPLE 'OPEN' PORT RELIEF 3500 PSI

GRAPPLE SPOOL SECTION

FLOW ADJUSTING SCREW FOR PORT 'A' (TYPICAL)

B

A

• FLOW ADJUSTING SCREW FOR PORT S/N 2500111 TO 2500140 S/N 2500141 AND UP 'B' (TYPICAL) GRAPPLE ROTATE 'CW' GRAPPLE 'CLOSE' PORT PORT RELIEF 1750 PSI RELIEF 3500 PSI (TIGERCAT) 250-09

VIEWED FROM BELOW

•

HIGH PRESSURE LIMITING CONTROL

CONTROL VALVE MANIFOLD

MAIN/GRAPPLE ROTATE CONTROL VALVE SERIAL NUMBER 2500111 TO 2500140 MAIN/OPEN-CLOSE CONTROL VALVE SERIAL NUMBER 2500141 AND UP 17.3

Tigercat 250 Loader GRAPPLE CONNECTIONS TO BOOM

277-8 GRAPPLE CONNECTIONS 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.

CIRCUIT DESCRIPTION SERIAL NUMBER 2500111 TO 2500140 The grapple OPEN-CLOSE circuit is supplied with oil by the auxiliary pump. The "auxiliary" valve receives oil at the inlet section and directs the oil through the three open center spool sections to the outlet section. From there it is directed back to tank via a check valve to the return manifold and two dual element filters, which are equipped with an internal 25 psi element bypass valve.

Grapple The grapple ROTATE circuit is supplied with hydraulic oil by the main pump. The main/grapple ROTATE control valve manifold receives oil at the 'P' ports and directs it through the manifold to the six spool sections. When no function is being operated the pump will de-stroke and provide a stand by pressure of 500 psi and zero flow.

The ROTATE circuit is not part of the load sensing system due to the port relief valves on the main valve being set at a lower value than the load sensing relief valve (P2) on the main valve HPLC valve.

Adjustable spool travel stops on each pilot end cap of the spool sections can be adjusted to limit spool travel and control the flow of oil to the rotate motor. Controlling the flow of oil to the motor also controls the speed of rotation of the grapple.

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

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

Return oil from the cylinders is directed back through the spool section, to the outlet section and back to tank via a check valve to the return manifold and two dual element filters.

17.4

Tigercat 250 Loader

250-17

Grapple

GRAPPLE CIRCUIT SERIAL NUMBER 2500111 TO 2500140 17.5

Tigercat 250 Loader 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

CAUTION Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

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

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

PRESSURE SETTINGS SET GRAPPLE OPEN-CLOSE RELIEFS ON "AUXILIARY" VALVE SERIAL NUMBER 2500111 TO 2500140 Main relief setting .................................... 3300 psi Grapple open port relief setting ............. 3500 psi Grapple close port relief setting ............ 3500 psi Pump compensator setting .................... 2900 psi Pump standby setting .................... Turned fully IN 1. Machine must be on level ground with stabilizers properly in place.

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

3. On the auxiliary pump compensator valve:

Slacken jamnut on compensator adjusting screw, and turn adjusting screw all the way IN. CAUTION: Do not use excessive force; stop when the resistance increases sharply.

Tighten the jamnut.

The STANDBY valve adjusting screw is screwed fully IN (factory set) and must remain this way. This portion of the compensator is NOT USED.

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

5. Loosen the locknuts on both port relief valve adjusting screws for the GRAPPLE OPEN AND GRAPPLE CLOSE spool section of the

Grapple "auxiliary" valve and turn the adjusting screws out until spring pressure is relieved then turn adjusting screws one full turn in.

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

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

8. 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.

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

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

10. 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.

11. Tighten locknut on adjusting screw taking care not to turn the adjusting screw. reset main relief valve: 12. Loosen locknut on "auxiliary" main relief and unscrew adjusting screw 3 full turns.

13. 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.

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

Reset auxiliary pump compensator:15. Set throttle to FULL rpm.

16. Set compensator adjustment on pump compensator to 3600 psi. by slowly screwing the relief valve adjusting screw OUT until the required pressure reading is obtained.

17. Re-tighten jamnut, making sure adjusting screw does not turn.

18. If no further adjustments are necessary, Stop engine. Remove pressure gauge and wipe up any excess oil from test port area.

17.6

Tigercat 250 Loader SET GRAPPLE ROTATE RELIEFS ON "MAIN" VALVE. SERIAL NUMBER 2500111 TO 2500140

Grapple ADJUST OIL FLOW TO ROTATE MOTOR NOTE: Constant loosening and tightening of the locknut (sealnut) on the adjusting screws will eventually cause the seal in the nut to break down and leak. Because of this it is best to keep the adjusting procedure brief.

Grapple rotate CW and CCW port relief settings .............................. 1750 psi 1. Machine must be on level ground with stabilizers properly in place.

GRAPPLE ROTATE 'CCW' PORT RELIEF

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

GRAPPLE ROTATE SPOOL SECTION

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

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

•

CCW

B

A CW

5. Install a 0-5000 psi pressure gauge in the 'L.S.' test port on the back of the main valve manifold.

6. Start engine and place throttle control in FULL.

• FLOW ADJUSTING GRAPPLE ROTATE SCREW FOR PORT 'CW' PORT RELIEF 'B' (TYPICAL)

7. Turn anti-stall switch OFF. 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.

FLOW ADJUSTING SCREW FOR PORT 'A' (TYPICAL)

250-09

VIEWED FROM BELOW

OIL FLOW ADJUSTMENT S/N 2500111 TO 2500140

To adjust speed; (Refer to fig. 250-09) Loosen locknut on spool travel stop adjusting screw and turn adjusting screw IN (clockwise) until end of adjusting screw lightly touches end of spool. Do not screw adjusting screw beyond point of contact with spool or spool will begin to move. Back out adjusting screw 7 ½ turns and tighten locknut on adjusting screw. Repeat this procedure on opposite end of spool section.

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

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.

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

12. Release grapple from it's secured position.

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

17.7

Tigercat 250 Loader

Grapple

SUMMARY:

SERIAL NUMBER 2500111 TO 2500140 Grapple open-close on "auxiliary" valve:1. Position machine on level ground.

2. Ensure that hydraulic oil is at operating temperature.

3. Turn compensator adjusting screw fully in.

4. Turn main relief on "auxiliary" valve fully in.

5. Turn GRAPPLE OPEN and CLOSE port reliefs on "auxiliary" valve out.

6. Connect gauge to "auxiliary" valve.

7. Start engine, idle throttle.

8. Set GRAPPLE OPEN port relief on "auxiliary" valve.

9. Set GRAPPLE CLOSE port relief on "auxiliary" valve.

10. Reset main relief.

11. Set engine throttle control to full position.

12. Set pump compensator.

13. Stop engine Grapple rotate on "main" valve:1. Position machine on level ground.

2. Ensure that hydraulic oil is at operating temperature.

3. Secure grapple to prevent from rotating.

4. Turn GRAPPLE ROTATE CW and CCW port reliefs on "main" valve out.

5. Connect gauge to L.S. port on "main" valve.

6. Place engine throttle control at full rpm.

7. Turn anti-stall switch off.

8. Set GRAPPLE ROTATE CW port relief on "main" valve.

9. Set GRAPPLE ROTATE CCW port relief on "main" valve.

10. Release grapple.

11. Set oil flow adjusting screws 12. Stop engine.

17.8

Tigercat 250 Loader

Grapple

17.9

Tigercat 250 Loader

250-18

Grapple

GRAPPLE CIRCUIT SERIAL NUMBER 2500141 AND UP 17.10

Tigercat 250 Loader

Grapple

CIRCUIT DESCRIPTION SERIAL NUMBER 2500141 AND UP

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

The grapple OPEN-CLOSE circuit is supplied with hydraulic oil by the main pump. The main/ grapple OPEN-CLOSE control valve manifold receives oil at the 'P' ports and directs it through the manifold to the six spool sections. When no function is being operated the pump will de-stroke and provide a stand by pressure of 500 psi and zero flow.

CAUTION Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

The OPEN-CLOSE circuit is not part of the load sensing system due to the port relief valves on the main valve being set at a lower value than the load sensing relief valve (P2) on the main valve HPLC valve.

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

Adjustable spool travel stops on each pilot end cap of the spool sections can be adjusted to limit spool travel and control the flow of oil to the two grapple cylinders. Controlling the flow of oil to the cylinders also controls the speed of the grapple arms.

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

The grapple ROTATE circuit is supplied with oil by the swing pump. The "swing" valve receives oil at the inlet section and directs the oil through the three open center spool sections to the outlet section. From there it is directed back to tank via a check valve to the return manifold and two dual element filters, which are equipped with an internal 25 psi element bypass valve.

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

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

PRESSURE SETTINGS

SET GRAPPLE OPEN-CLOSE RELIEFS ON "MAIN" VALVE SERIAL NUMBER 2500141 AND UP Grapple open-close port relief settings ....... 3500 psi 1. Machine must be on level ground with stabilizers properly in place.

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

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

4. Install a 0-5000 psi pressure gauge in the 'L.S.' test port on the back of the main valve manifold.

5. Start engine and place throttle control in full.

6. Turn anti-stall switch off.

17.11

Tigercat 250 Loader

Grapple

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

IMPORTANT

4.

Place L.H. joystick lever in 'FULL GRAPPLE CLOSE' position and fully ** extend cylinder.

Record cycle time from stop to stop.

5.

Place L.H. joystick lever in 'FULL GRAPPLE OPEN' position and fully ** retract cylinder. Record cycle time from stop to stop.

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

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

** When extending or retracting the cylinders to record the time, it is better to stop the cylinder just before it gets to the end of it's stroke rather than let it bottom out and impose unnecessary loads on the cylinder parts and boom structures.

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

Refer to CYCLE TIME - FACTORY SETTINGS in SECTION 3 of this manual for typical cylinder cycle times. It should be noted that over adjusting to provide faster cycle times could increase the stress on grapple components and the hydraulic system.

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

11. If no further adjustments are necessary, Stop engine. Remove pressure gauge and wipe up any excess oil from test port area.

ADJUST OIL FLOW TO CYLINDERS (CYLINDER CYCLE TIMES) NOTE: Constant loosening and tightening of the locknut (sealnut) on the adjusting screws will eventually cause the seal in the nut to break down and leak. Because of this it is best to keep the adjusting procedure brief.

FLOW ADJUSTING SCREW FOR PORT 'A' (TYPICAL)

GRAPPLE 'OPEN' PORT RELIEF GRAPPLE OPENCLOSE SPOOL SECTION

•

OPEN

To adjust cycle times; Loosen locknut on spool adjusting screw on main control valve and turn adjusting screw IN (clockwise) to slow down and OUT (counterclockwise) speed up. Tighten locknut on adjusting screw and re-check times.

NOTE: The 'A' ports (bottom ports) are connected to the base end of the cylinders and the 'B' ports (top ports) are connected to the rod end of the cylinders.

To adjust the flow rate at 'A' PORTS, adjust spool travel stop adjusting screw located at TOP of valve and vice-versa for 'B' ports. See figure 250-09.

SET GRAPPLE ROTATE RELIEFS ON "SWING" VALVE SERIAL NUMBER 2500141 AND UP Main relief setting ....................................................... 4000 psi Grapple rotate CW and CCW port relief settings .... 1750 psi Pump compensator setting ....................................... 3600 psi Pump standby setting ...................................... Turned fully IN

B

A

1. Machine must be on level ground with stabilizers properly in place.

CLOSE

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

•

3. Position and secure grapple to prevent rotation in either direction.

FLOW ADJUSTING GRAPPLE 'CLOSE' SCREW FOR PORT PORT RELIEF 'B' (TYPICAL) 250-09

TYPICAL CYLINDER CYCLE TIMES

VIEWED FROM BELOW

OIL FLOW ADJUSTMENT S/N 2500141 AND UP

1.

Hydraulic oil must be at operating temperature.

2.

Start engine and place engine throttle control in FULL position.

3.

Fully retract cylinders (grapple open).

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

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

17.12

Tigercat 250 Loader

Grapple

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

SUMMARY:

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

Grapple open-close on "main" valve:-

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

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

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

4. Connect gauge to "L.S." port on "main" valve.

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

SERIAL NUMBER 2500141 AND UP 1. Position machine on level ground.

2. Ensure that hydraulic oil is at operating temperature.

5. Start engine, full rpm.

6. Turn anti-stall swich off.

7. Set GRAPPLE OPEN port relief on "main" valve.

11. Release grapple from it's secured position.

8. Set GRAPPLE CLOSE port relief on "main" valve.

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

9. Set cylinder cycle times (oil flow adjusting screws).

10. Stop engine.

Grapple rotate on "swing" valve:1. Position machine on level ground.

2. Ensure that hydraulic oil is at operating temperature.

3. Secure grapple to prevent from rotating.

4. Turn GRAPPLE ROTATE CW and CCW port reliefs on "swing" valve out.

5. Connect gauge to "swing" valve.

6. Place engine throttle control at full rpm.

7. Set GRAPPLE ROTATE CW port relief on "swing" valve.

8. Set GRAPPLE ROTATE CCW port relief on "swing" valve.

9. Release grapple.

10. Stop engine.

17.13

Tigercat 250 Loader

Grapple

17.14

Tigercat 250 Loader

SECTION 18 - DELIMBER/SLASHER CONTENTS - SECTION 18 CIRCUIT DESCRIPTION ............................................................................. 18.6 CIRCUIT DIAGRAM S/N 2500111 T0 2500140 ........................................... 18.7 CIRCUIT DIAGRAM S/N 2500141 AND UP ................................................ 18.8 CONTROL VALVE, DELIMBER AND TOP SAW CONTROL VALVE ......... 18.4 CONTROL VALVE, DELIMBER OPEN/DUMP VALVE ................................ 18.5 CONTROL VALVE, SLASHER SAW CUT AND SAWS RETRACT ............ 18.2 DELIMBER/SLASHER CONNECTIONS ...................................................... 18.5 FUSE AND RELAY PANEL ........................................................................ 18.10 OIL FLOW ADJUSTMENT ......................................................................... 18.16 PILOT MANIFOLD ....................................................................................... 18.2 PRESSURE SETTINGS ............................................................................ 18.14 PRESSURE SETTINGS, SUMMARY ........................................................ 18.16 PUMPS ........................................................................................................ 18.2 RELAY AND FUSE PANEL ........................................................................ 18.10 TROUBLESHOOTING DELIMBER RELAY CIRCUIT ............................... 18.10

JULY 2002

Tigercat 250 Loader

Delimber/Slasher

DELIMBER/SLASHER CIRCUIT COMPONENTS

'PB' TO STABILIZER PILOT MANIFOLD

MAIN PUMP, DELIMBER AND SLASHER

TOP SAW CUT DELIMBER OPEN

BELL HOUSING

PILOT SHUT OFF VALVE

RETURN OIL FROM STABILIZER PILOT MANIFOLD

PRESSURE COMPENSATOR

PILOT RELIEF VALVE

GAUGE TEST PORT

PILOT MANIFOLD ASSEMBLY PILOT MANIFOLD

230B-04

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, slasher saw and top saw functions.

AUXILIARY PUMP, (LINDE SHOWN) SLASHER CUT AND RETRACT 250-07

SLASHER CUT TOP/SLASHER SAWS RETRACT

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

DELIMBER/SLASHER PUMPS

PUMPS Supply oil for the slasher CUT and RETRACT circuit is provided by the AUXILIARY PUMP which is an axial-piston variable displacement pump controlled by a pressure compensator.

For a more detailed description of this pump, refer to SWING PUMP in SECTION 15 of THIS MANUAL. Supply oil for the delimber OPEN, slasher CUT and TOP SAW CUT circuit is provided by the MAIN PUMP. For a more detailed description of this pump, refer to MAIN PUMP in SECTION 4 of THIS MANUAL.

SLASHER SAW CUT AND SAWS RETRACT CONTROL VALVE (AUXILIARY VALVE RENAMED SWING VALVE ON LATER MACHINES) 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 "auxiliary" control valve. A spool section on the "main" valve also supplies a proportion of the oil required for the SLASHER CUT function.

For a detailed description of the slasher control valve, "slasher/auxiliary (swing)" control valve, refer to SWING CONTROL VALVE S/N 2500141 AND UP in SECTION 15 of THIS MANUAL.

18.2

Tigercat 250 Loader

Delimber/Slasher

OUTLET SECTION

•

S/N 2500141 AND UP SLASHER 'CUT' PORT RELIEF 2500 PSI

•

S/N 2500111 TO 2500140 SLASHER 'CUT' PORT RELIEF 2500 PSI

•

SLASHER

S/N 2500141 AND UP

•

SLASHER S/N 2500111 TO 2500140

•

S/N 2500141 AND UP SLASHER SAW 'RETRACT' PORT RELIEF 1500 PSI S/N 2500111 TO 2500140 SLASHER SAW 'RETRACT' PORT RELIEF 1500 PSI

•

•

INLET SECTION AT041ZIL

RELIEF VALVE PORT 'A'

GAUGE TEST PORT

SEAL GROOVES

A

AT041YIL

RELIEF VALVE PORT 'B'

B

PILOT END CAP

MAIN RELIEF (4000 PSI)

•

SPOOL CENTERING SPRINGS

SPOOL TANK PASSAGE

PARALLEL PASSAGE

LOAD CHECK VALVE

THRU' NEUTRAL PASSAGE

WORK PORT BRIDGE

TANK PASSAGE

AUXILIARY/SLASHER CONTROL VALVE SERIAL NUMBER 2500111 TO 2500140 SWING/SLASHER CONTROL VALVE SERIAL NUMBER 2500141 AND UP

18.3

PILOT END CAP

Tigercat 250 Loader

Delimber/Slasher

DELIMBER 'OPEN' PORT RELIEF 2500 PSI

FLOW ADJUSTING SCREW FOR PORT 'B'

SLASHER 'CUT' PORT RELIEF 2700 PSI

B

B

A

A

VIEWED FROM BELOW CONTROL VALVE MANIFOLD

250-09

•

FLOW ADJUSTING SCREW FOR PORT 'A'

S/N 2500111 TO 2500140 TOP SAW 'CUT' PORT RELIEF 2600 PSI

HIGH PRESSURE LIMITING CONTROL

MAIN/DELIMBER-SLASHER-TOP SAW CONTROL VALVE SERIAL NUMBER 2500111 TO 2500140 FLOW ADJUSTING SCREW FOR PORT 'B'

SLASHER 'CUT' PORT RELIEF 2700 PSI

VIEWED FROM BELOW CONTROL VALVE MANIFOLD

250-08

HIGH PRESSURE LIMITING CONTROL

B

B

A

A

FLOW ADJUSTING SCREW FOR PORT 'A'

•

DELIMBER 'OPEN' PORT RELIEF 2500 PSI

TOP SAW 'CUT' PORT RELIEF 2600 PSI

MAIN/DELIMBER-SLASHER-TOP SAW CONTROL VALVE SERIAL NUMBER 2500141 AND UP DELIMBER, SLASHER AND TOP SAW CONTROL VALVE (MAIN VALVE) The delimber arms OPEN/CLOSE functions, the top saw CUT and the slasher CUT functions are controlled by two of six spool sections in the "main" control valve.

For a detailed description of the delimber/"main" control valve, refer to SECTION 4 of THIS MANUAL.

18.4

Tigercat 250 Loader

Delimber/Slasher

DELIMBER OPEN/DUMP VALVE

DELIMBER/SLASHER CONNECTIONS

The delimber open/dump valve is a solenoid operated three way directional valve consisting of an aluminum valve body, a screw-in poppet type solenoid operated valve cartridge and a screw-in check valve cartridge.

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

CHECK VALVE

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

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

"V" SUPPLY FROM DELIMBER VALVE (SWING VALVE) "T" TANK LINE TO STICK VALVE OUTLET SECTION 240B-D25

IMPORTANT

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

DELIMBER OPEN/DUMP VALVE

DELIMBER OPEN

TANK

TOP SAW CUT

TOP SAW RETRACT

250-27

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

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

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

DELIMBER CONNECTIONS

277-3

SLASHER RETRACT

TANK

SLASHER CUT

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

18.5

Tigercat 250 Loader DELIMBER/TOP SAW/SLASHER CIRCUIT DESCRIPTION SERIAL NUMBER 2500111 AND UP Refer to appropriate CIRCUIT DIAGRAM The delimber/slasher circuit is supplied with hydraulic oil by both the "main" and "auxiliary" (renamed "swing" on later machines) pumps. Two spool sections in the "main" control valve and one spool section in the "auxiliary" valve hydraulically control all of the delimber or slasher functions.

The "main" control valve receives oil at the two 'P' ports on the back of the "main" control valve manifold and directs it through the manifold to the six spool sections. When no function is being operated the pump will de-stroke and provide a stand by pressure of 500 psi and zero flow.

The delimber/slasher circuit is not part of the load sensing system due to the port relief valves on the main valve being set at a lower value than the load sensing relief valve (P2) on the main valve HPLC valve.

Adjustable spool travel stops on each pilot end cap of the spool sections can be adjusted to limit spool travel and control the flow of oil to the delimber arms cylinders and both the slasher and top saw motors and bar cylinders. Controlling the flow of oil to the cylinders also controls the speed.

The "auxiliary/"swing" valve receives oil at the inlet section, from there it is directed through the three open center spool sections, to the outlet sections. From there it is directed back to tank via a check valve to the return manifold and two dual element filters, which are equipped with an internal 25 psi element bypass valve.

Two push button switches on each of the two joystick handles and three relays (numbers 6, 7 and 8) electrically control the delimber and slasher functions:-

Delimber/Slasher Current also flows via the contacts of DELIMBER CLOSE RELAY (6) through wire 94 and jumper wire 19 to "latch" RELAY (7) in the energized position so that the joystick switch may be released to the spring return center position while the delimber arms remain in the OPEN position. A diode in diode module #1 in wire 18 prevents the current from traveling back to the joystick switch and also the DELIMBER OPEN SOLENOID valve on the pilot manifold, which was de-energized when the joystick switch was released.

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

Close delimber arms; Push BOTTOM RIGHT L.H. Joystick switch, Current flows through wire 86 and energizes DELIMBER CLOSE RELAY (6).

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

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

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

Open delimber arms; Push BOTTOM LEFT L.H. Joystick switch, Current flows through wires 18 to energize the DELIMBER OPEN SOLENOID valve on the pilot manifold and allow pilot oil to shift the spool in the delimber spool section of the "main" valve and direct system oil to the delimber arms cylinders. Current also flows through wire 18 to energize the DELIMBER OPEN RELAY (7) and allow current to energize the DELIMBER OPEN/ DUMP VALVE SOLENOID. This will allow system oil from the delimber spool section of the "main" valve to flow through the ROTARY MANIFOLD to the base end of the DELIMBER ARM CYLINDERS to open the arms.

18.6

Tigercat 250 Loader

250-19

Delimber/Slasher

DELIMBER/TOP SAW/SLASHER CIRCUIT SERIAL NUMBER 2500111 T0 2500140 18.7

Tigercat 250 Loader

250-20

Delimber/Slasher

DELIMBER/SLASHER CIRCUIT SERIAL NUMBER 2500141 AND UP 18.8

Tigercat 250 Loader

Delimber/Slasher

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

Pilot oil flows through the SLASHER CUT solenoid pilot valve on the pilot manifold to shift the spool in the SAW RETRACT/SLASHER CUT spool section of the "auxiliary" valve and also shift the spool in the SLASHER CUT spool section of the "main" valve. This will allow an increased volume of system oil to flow through the ROTARY MANIFOLD to the SLASHER SAW MOTOR and the rod end of the BAR CYLINDER to run the saw motor and cut with the saw bar.

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

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

18.9

Tigercat 250 Loader

Delimber/Slasher

FUSE AND RELAY PANEL

250-D08

1

DIODE MODULE 1

DIODE MODULE 2

DIODE MODULE 3

RELAY 1

RELAY 2

RELAY 3

RELAY 4

LOW ENG. OIL PRESS.

PILOT LOCK-OUT

A/CHEATER

LOW HYD. OIL

2 3 4 5

DIODE MODULE 4

DIODE MODULE 5

DIODE MODULE 7

DIODE MODULE 6

DIODE MODULE 8

RELAY 5

RELAY 6

RELAY 7

RELAY 8

WORK LIGHTS

DELIMBER CLOSE

DELIMBER OPEN

SAW CUT

RELAY 30

RELAY 31

RELAY 32

CHARGE TANK

CHARGE TANK

VACUUM TANK

6 7

GAUGES 5A SAFETY 15A FUEL 10A JOYSTICKS 15A STABILIZERS 15A WIPER/WASH 15A ANTI-STALL 2A

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

16605B R0

DELIMB ARMS OPEN

voltage is present at wire 18, check diode module no. 1. If voltage is not present at wire 19, check relays 6 & 7.

DELIMB ARMS CLOSE

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

TOP/SLASHER SAW(S) RETRACT TOP/SLASHER SAW(S) CUT

380-1 380-2 LH JOYSTICK RH JOYSTICK TROUBLESHOOTING DELIMBER RELAY CIRCUIT If an electrical problem is suspected, the operation of the joystick switches and the delimber relays can be verified with the following procedure.

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

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

2. With the delimber arms switch RELEASED, voltage should still be present at wire 19 but not at wire 18. If this is the case go to step 3. If

5. With the CLOSE delimber arms switch pressed and the CUT saw switch pressed, voltage should be present at wire 41. If this is not the case, recheck voltage in wire 19 and, if it is not present, check relay 8 for proper operation.

6. With the OPEN delimber arms switch pressed and the CUT saw switch pressed, voltage should be present in wire 39. If voltage is not present in wire 39, check wire 19 which should have voltage, if this is the case check relay 8 for proper operation.

7. When the RETRACT saw switch is pressed, voltage should be present in wire 40 regardless of the delimber arms position.

18.10

Tigercat 250 Loader

Delimber/Slasher

DELIMBER/SLASHER CIRCUIT AT REST 250-21

OPEN DELIMBER ARMS 250-22

18.11

Tigercat 250 Loader

Delimber/Slasher

CLOSE DELIMBER ARMS

250-23

CUT WITH DELIMBER TOP SAW

250-24

18.12

Tigercat 250 Loader

Delimber/Slasher

CUT WITH SLASHER SAW 250-25

RETRACT DELIMBER TOP SAW AND SLASHER SAW 250-26

18.13

Tigercat 250 Loader PRESSURE SETTINGS

SET TOP SAW CUT, SLASHER CUT AND DELIMBER

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

CAUTION Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

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

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

NOTE: The procedure to set the relief valves for the TOP SAW and SLASHER SAW involve setting both the "auxiliary*" valve, "swing*" on later machines and the "main" valve at the same time. This is due to the SLASHER CUT function receiving oil simultaneousely from the two valves.

SET TOP SAW CUT, SLASHER CUT AND DELIMBER OPEN RELIEFS ON "MAIN" VALVE

Delimber/Slasher 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.

NOTE: "Main" and "auxiliary*" valves being set at same time.

1. Machine must be on level ground with stabilizers properly in place.

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

3. Loosen the locknut on port relief valve adjusting screws for the SLASHER CUT spool section of the "auxiliary*" valve and turn the adjusting screw all the way in, tighten locknut..

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

5. Loosen the locknut on port relief valve adjusting screw for the DELIMBER OPEN spool section of the "main" valve and turn the adjusting screw out until spring pressure is relieved then turn adjusting screw one full turn in.

6. Connect a 0 - 5000 psi.. pressure gauge to the "auxiliary*" control valve test port on the inlet section of the valve.

6.

Connect a 0 - 5000 psi.. pressure gauge to the 'L.S.' test port on the back of the "main" valve.

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

8.

Turn anti-stall switch OFF.

Top saw cut port relief setting .............. 2500 psi Slasher cut port relief setting ............... 2700 psi Delimber open port relief setting .......... 2500 psi SET TOP SAW CUT AND SAW RETRACT RELIEFS ON AUXILIARY* OR SWING* VALVE S/N 2500111 to 2500140 Main relief setting (auxiliary valve) ....... 3300 psi S/N 2500141 and UP Main relief setting (swing valve) ........... 4000 psi Slasher saw cut port relief setting ........ 2500 psi Saw retract port relief setting ............... 1500 psi NOTE: The Delimber and/or Slasher hydraulic hoses must be disconnected at the loader bulkhead connections before carrying out the following

*NOTE VALVE DESCRIPTION: This valve is labelled "auxiliary" valve on S/N 2500111 TO 2500140 and "swing" valve on S/N 2500141 AND UP. 18.14

Tigercat 250 Loader

Delimber/Slasher

10. While holding the L.H. joystick DELIMBER 19. While holding the L.H. joystick DELIMBER OPEN switch pressed and the R.H. joystick OPEN switch pressed, check gauge pressure SAW EXTEND switch pressed, check gauge reading at "main" valve 'L.S.' test connection. If pressure reading at "main" valve 'L.S.' test less than set value, turn DELIMBER port relief connection. If less than set value, turn valve adjusting screw in until set value is SLASHER CUT port relief valve adjusting screw obtained on gauge. in until set value is obtained on gauge.

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

Approach the gauge reading slowly and 21. Remove pressure gauges and wipe up any deliberately by turning the adjusting screw in excess oil from test port area. a little at a time. The pressure setting must not exceed the above value.

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

11. Tighten locknut on adjusting screw taking care not to turn the adjusting screw. SLASHER CUT port relief on "main" valve is now set.

12. Loosen the locknut on the SLASHER CUT port relief valve on the "auxiliay*" valve and turn the relief adjusting screw out until spring pressure is relieved then turn adjusting screws one full turn in. tighten locknuts.

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

14. Tighten locknut on adjusting screw taking care not to turn the adjusting screw. SLASHER CUT port relief on "auxiliary*" valve is now set.

15. While holding the L.H. joystick DELIMBER CLOSE switch pressed and the R.H. joystick SAW EXTEND switch pressed, check gauge pressure reading at "main" valve 'L.S.' test connection. If less than set value, turn TOP SAW CUT port 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. TOP SAW CUT port relief on "main" valve is now set.

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

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

18.15

Tigercat 250 Loader

Delimber/Slasher SUMMARY:

ADJUST OIL FLOW NOTE: Constant loosening and tightening of the locknut (sealnut) on the adjusting screws will eventually cause the seal in the nut to break down and leak. Because of this it is best to keep the adjusting procedure brief.

FLOW ADJUSTING SCREW FOR PORT 'A' (TYPICAL)

Set top saw cut, slasher cut and delimber open reliefs on "main" valve and slasher cut and saws retract on "auxiliary" valve:1. Disconnect Delimber and Slasher hoses from Loader.

2. Ensure hydraulic oil is at operating temperature.

•

3. Turn SLASHER CUT port relief on "auxiliary" valve fully in.

B

4. Turn SLASHER CUT and TOP SAW CUT port reliefs on "main" valve out.

A

5. Turn DELIMBER OPEN port relief on"main" valve out.

6. Connect gauges to "main" and "auxiliary" valves.

7. Start engine, FULL rpm.

8. Turn anti-stall switch OFF.

• FLOW ADJUSTING SCREW FOR PORT 'B' (TYPICAL) 250-09

9. Set SLASHER CUT port relief on "main" valve.

VIEWED FROM BELOW

10. Turn SLASHER CUT port relief on "auxiliary" valve fully out.

OIL FLOW ADJUSTMENT

11. Set SLASHER CUT port relief on "auxiliary" valve.

To adjust speed; (Refer to fig. 250-09) Loosen locknut on spool travel stop adjusting screw and turn adjusting screw IN (clockwise) until end of adjusting screw lightly touches end of spool. Do not screw adjusting screw beyond point of contact with spool or spool will begin to move. Back out adjusting screw X turns* and tighten locknut on adjusting screw. Repeat this procedure on opposite end of spool section. *Refer to CYCLE TIMES, FACTORY SETTINGS in SECTION 3 of THIS MANUAL.

12. Set TOP SAW CUT port relief on "main" valve.

13. Set SAW RETRACT port relief on "auxiliary" valve.

14. Set throttle to IDLE. 15. Set DELIMBER OPEN port relief on "main" valve.

16. Remove all gauges.

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

18.16