Tigercat 250C LOADER SERVICE MANUAL Sn 2502001-2502100 - PDF DOWNLOAD

250C LOADER

SERVICE MANUAL

SERIAL NUMBER 2502001 TO 2502100

ISSUE 1.0, JUNE 2014 Tigercat Industries Inc. P.O. Box 637 Brantford, Ontario Canada N3T 5P9 Tel: (519) 753-2000 Fax: (519) 753-8272

Tigercat 250C Loader

Introduction

ii

Tigercat 250C Loader

Introduction

Tigercat 250C LOADER TABLE OF CONTENTS SECTION INTRODUCTION........................................................................................................................................... v NON-APPROVED FIELD PRODUCT CHANGES........................................................................................ vi SAFETY.........................................................................................................................................................1 CONTROLS AND OPERATION.................................................(SEE SEPARATE OPERATOR'S MANUAL) LUBRICATION AND MAINTENANCE........................................................................................................... 3 HYDRAULIC SYSTEM.................................................................................................................................. 4 PILOT SYSTEM............................................................................................................................................ 5 ELECTRICAL SYSTEM & COMPUTER........................................................................................................ 6 ENGINE START & STOP.............................................................................................................................. 7 ENGINE ANTI-STALL.................................................................................................................................... 9 OIL COOLER, RADIATOR, AND FAN......................................................................................................... 10 BOOM..........................................................................................................................................................12 SWING........................................................................................................................................................15 STABILIZERS..............................................................................................................................................16 GRAPPLE...................................................................................................................................................17 DELIMBER/SLASHER................................................................................................................................ 18

CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.

250C Loader Available Literature Operator's Manual, English................................................................................................. Part No. 37674AENG Service Manual English (this manual)................................................................................. Part No. 37675AENG Parts Catalog....................................................................................................................... Part No. 37676A iii

Tigercat 250C Loader

Introduction

iv

Tigercat 250C250C Loader Loader Tigercat

Introduction

INTRODUCTION An Operator's manual, Service manual and a Parts catalog are made available by Tigercat to assist the dealer, customer and operator in becoming familiar with the features of the 250C Loaders Serial numbers:2502001 to 2502100 The 250C Loader is designed for log processing, sorting, log transferring and loading.

The operator's manual will assist the operator with the techniques of proper and safe operation of the 250C Loader. There is also important information regarding the safe operation of the attachment. The service manual contains safety and servicing procedures and a preventive maintenance schedule to ensure optimum machine performance. ,,,,

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

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

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

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

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

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

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

Tigercat Industries Inc.

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Tigercat 250C 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 it's ability to perform safely 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 to be undertaken 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 having created 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 dispute 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.

vi

Tigercat 250C Loader SECTION 1 – SAFETY CONTENTS – SECTION 1

MARCH 2012

ARTICULATION LOCK............................................................................................................................1.28 BATTERY DISCONNECT SWITCH..........................................................................................................1.9 BATTERY SAFETY...................................................................................................................................1.6 CAB EXITS................................................................................................................................................1.7 COOLING SYSTEM................................................................................................................................1.13 EMERGENCY CAB EXITS........................................................................................................................1.7 ENGINE DOORS.....................................................................................................................................1.14 EXHAUST FUMES..................................................................................................................................1.14 FIRE PREVENTION................................................................................................................................1.20 DRY CHEMICAL CLEANUP PROCEDURES.......................................................................................1.24 FIRE PREVENTION GUIDELINES.......................................................................................................1.20 WHAT TO DO AFTER A MACHINE FIRE HAS OCCURRED...............................................................1.23 WHAT TO DO TO PREPARE FOR A MACHINE FIRE.........................................................................1.21 WHAT TO DO WHEN A MACHINE FIRE OCCURS.............................................................................1.22 FLUID INJECTION INJURY....................................................................................................................1.15 FLUID LEAKS......................................................................................................................................... 1.11 GREASE INJECTION INJURY................................................................................................................1.16 HYDRAULIC PRESSURE HAZARD....................................................................................................... 1.11 LIGHTNING SAFETY AWARENESS LIGHTNING SAFETY...........................................................................................................................1.17 WHAT IS A LIGHTNING STRIKE?........................................................................................................1.17 LOOSE CLOTHING HAZARD.................................................................................................................1.14 PARKING THE MACHINE.......................................................................................................................1.10 PROTECTIVE CLOTHING........................................................................................................................1.2 SAFETY INTERLOCK SWITCH................................................................................................................1.8 SAFETY LABELS....................................................................................................................................1.25 SAFETY PRECAUTIONS, GENERAL......................................................................................................1.2 SAFETY PRECAUTIONS, OPERATING...................................................................................................1.7 SAFETY PRECAUTIONS, SERVICING.................................................................................................. 1.11 SAFETY SYMBOLS..................................................................................................................................1.2 SIGNAL WORDS.......................................................................................................................................1.2 WELDING, PRIOR TO............................................................................................................................1.12 WORKING WITH OIL................................................................................................................................1.4

Tigercat 250C Loader

Safety

GENERAL SAFETY PRECAUTIONS

SAFETY SYMBOLS

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.

This safety alert symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

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

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

Follow all instructions from safety inspector and supervisors.

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

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

WARNING

Do not let untrained persons operate the machine.

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

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

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

These safety rules highlight both general and specific measures that the operator should be familiar with and adhere to. More specific measures are illustrated with pictograms which may also be attached to the machine in locations pertinent to their respective message. Keep safety labels in good condition. Repair or replace damaged labels.

1.2

Tigercat 250C Loader

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

KEEP CLEAR

All personnel should be made AWARE of the HAZARD ZONE and be kept clear of this zone and it should be considered off limits to all individuals while the machine is operating.

Do not use the seat armrest or joystick as handle when entering or leaving the cab.

Do not use the machine foot controls as steps.

The HAZARD ZONE is the area around the machine when the machine is being operated.

When approaching an operating machine on foot, stay at least 150M/500 feet 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 the attachment resting securely on stable ground before advancing to the machine.

Always avoid the discharge path of all saws.

When mounting or dismounting the machine always use the 3 point technique; use 1 hand with 2 feet or 2 hands with 1 foot.

WARNING

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.

Avoid mounting or dismounting the machine in areas with slippery surfaces. Dry, deice, clean up or cover slippery surfaces with an anti-slip material before mounting or dismounting the machine.

Always use the handrails and steps provided when mounting and dismounting from the machine.

Do not jump off the machine at any time.

1.3

Tigercat 250C Loader

Safety Check protective windows for cracks, a damaged window has reduced strength to stop flying objects. All damaged windows must be replaced with original equipment.

GENERAL SAFETY PRECAUTIONS continued

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

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

Check all fluid levels.

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

WARNING Do not walk on machine surfaces with steel cleated foot wear. Steel cleats on steel surfaces are slippery and do not provide a safe foot hold.

WARNING It is not recommended to walk on machine surfaces that are not designated walking areas.

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

No attempt should be made to walk on angled steel surfaces or surfaces that are irregular in shape.

Working with oil Direct contact with oil implies a risk of skin complaints (example: eczema). Strict hygiene should always be observed.

Walking surfaces on the machine must be covered with anti-slip materials to provide a safe foot hold and prevent slipping.

Some advice which should be observed:

These anti-slip surfaces should be maintained on a regular basis. If the surface shows signs of wear, the anti-slip material must be replaced immediately.

• • •

To reduce risk of fire, 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, always shut off engine before cleaning machine.

•

• •

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

•

Machine should be washed completely at every major service.

•

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

• •

Check for fluid leaks, or faulty operation. Repair or replace malfunctioning parts and systems immediately.

Check windows and door guards for damage.

1.4

Oils used in this machine may be hot enough to cause serious burns.

Avoid contact with oil, particularly heated oil.

Oil on the skin should be washed off immediately with soap and water.

Wear protective gloves. Hands should be clean before putting on gloves. Apply protective cream to the hands to make washing easier.

Don't put oily rags in your pockets.

Oil soiled clothing should be changed as soon as possible.

Always keep an extra overall handy, but not in the machine where it can become dirty.

Cuts and abrasions must be attended to immediately. Clean them and apply first-aid.

Avoid breathing in oil fumes.

Wash hands and arms frequently (example: at each meal break or as often as possible).

Tigercat 250C Loader

Safety Approach with extreme caution any area where overhanging electrical power lines 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.

GENERAL SAFETY PRECAUTIONS continued Safety Hazards – Viton Seals O-rings and other seals manufactured of Viton material (fluorine rubber) produce a highly corrosive acid (Hydrofluoric) when subjected to temperatures above 600°F (315°C).

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

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

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.

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

Visually inspect any seals or gaskets which have suffered from heat; they will appear black and sticky.

•

If these are found, Do Not Touch!!!

•

Determine the material composition of any seals or gaskets, If fluoro-elastomer seals (Viton, fluorel, or tecmoflon) have been used, the affected area must be decontaminated before undertaking further work. Natural rubber and nitrile materials are not hazardous.

•

Disposable heavy duty gloves (neoprene) must be worn and the affected area decontaminated by washing thoroughly with limewater (Calcium Hydroxide solution).

•

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

If the machine must be transported, make sure that it is adequately secured to the transporting vehicle. Refer to transporting instructions in SECTION 2 of the OPERATOR'S MANUAL. Stopping the engine immediately after it has been working under load can result in overheating and premature wear of the engine components.

Reduce engine speed to LOW IDLE and let run for approximately 5 minutes to allow gradual dissipation of heat and also to reduce turbo speed. This will also prevent loss of coolant by after boil and possible hot spot damage to the engine.

Be aware when performing service and maintenance tasks that surfaces and grab handles in and around the engine and cooling system may become very hot when the engine has been running. Contact with hot surfaces may cause injury.

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

Safety Hazards – Operating Maintain a charged fire extinguisher on the vehicle at all times and KNOW HOW TO USE IT.

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

Do not carry passengers either in the cab or anywhere else on the machine. The vehicle is provided and approved with seating for the operator only.

Read, understand and follow all general safety precautions specified by attachment manufacturer.

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.

When moving the machine, watch that enough 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.

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

1.5

Tigercat 250C Loader

Safety

GENERAL SAFETY PRECAUTIONS continued

Avoid Injury from Backover Accidents Before moving machine, be sure all persons are clear of the area.

Always be alert for bystanders moving into the work area. Use horn to warn bystanders before moving the machine.

WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Wash hands after handling.

When using a signal person, keep the person in view at all times. Always be sure the signal person is clear before backing up.

To avoid backover accidents:

If acid is accidentally splashed into your eyes, flush immediately with clean water and get medical attention.

• •

Do not attempt to charge a frozen battery; it can explode.

Disconnect battery before working on electrical systems as follows: –

Turn off master switch in cab

–

Disconnect negative starter motor cable from both battery posts

–

Disconnect positive master solenoid cable from both battery posts

• • •

Connect ground terminal last when reconnecting.

•

Do not short out battery terminals for any reason.

Serious burns or an explosion can result.

CAUTION Lead-acid batteries contain sulfuric acid which can severely damage eyes or skin on contact. Always wear a safety face shield, rubber gloves and protective clothing to reduce risk of accidents.

Lead-acid batteries produce flammable and explosive gasses. Keep arcs, sparks, open flames and lighted tobacco a safe distance from the batteries.

1.6

Always look around before you back up. Be sure that everyone is clear.

Keep motion warning alarm in working condition. The motion warning alarm must sound when the machine is moving in forward or reverse.

Use a signal person when backing up if view is obstructed. Always keep the signal person in view.

Learn the meaning of all flags, signs and markings on the job site and who is responsible for signaling.

Keep windows, mirrors and lights in good condition.

Dust, heavy rain, fog, snow etc. can reduce visibility. As visibility decreases, reduce speed and use proper lighting.

Tigercat 250C Loader

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

CAB EXITS There are two ways to exit the cab in case of an emergency.

1. Side Door, this is the main point of entry used under normal operating conditions to enter or leave the cab. This door is not equipped with a safety interlock switch and therefore when left open will not deactivate the pilot controls in the cab. The left armrest is equipped with a safety interlock switch that prevents machine operation when the armrest is raised. See SAFETY INTERLOCK SWITCH ON LEFT ARMREST later in this section for more details. ALWAYS shut OFF engine before using the side door exit.

2. Side Window, this is a second cab exit for use if the side door exit becomes blocked.

This window is not equipped with a safety interlock switch and therefore when left open will not deactivate the pilot controls in the cab.

ALWAYS shut OFF engine before using the side window as an escape hatch exit.

It is important that the operator of the machine be familiar with these emergency exits and how to use them.

All operators should practice using all the cab exits to become familiar with escape procedures should they need to perform them in the dark, when the machine is in a rolled position, or other possible adverse condition.

The exits should be checked to make sure that they are operational and will function in an emergency.

For additional information, refer to EMERGENCY EXITS in SECTION 3 of the OPERATOR'S MANUAL.

OPERATING SAFETY PRECAUTIONS

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

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

Sound the machine horn before starting the machine.

The operator’s seat is equipped with lap and shoulder harness belts. Use both of these restraint systems at all times when operating the machine.

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

WARNING

Never use a liquid staring aid to start an engine.

THIS MACHINE IS EQUIPPED WITH A COMPUTER CONTROLLED HEATING ELEMENT IN THE ENGINE INTAKE SYSTEM. STARTING FLUIDS WILL EXPLODE ON CONTACT WITH THE HEATING ELEMENT. 1.7

Tigercat 250C Loader

Safety

OPERATING SAFETY PRECAUTIONS continued

WARNING

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

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

Sound the machine horn before starting the machine.

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

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

ARMREST

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

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.

1 LIMIT SWITCH ACTUATING LEVER ON SEAT BASE

247-25

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.

PILOT SYSTEM SHUT OFF

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

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

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

WARNING

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

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

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

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

Use only prearranged and approved signalling practices.

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

1.8

Tigercat 250C Loader

Safety

OPERATING SAFETY PRECAUTIONS continued

WARNING DO NOT operate this machine to lift or move any objects other than what it is designed to lift or move.

• Do not use the boom to service other equipment.

• Do not use the boom to lift items such as tires, engines, cylinders, boom components, etc.

• Do not modify the boom system.

• Do not add hooks or lugs to the boom for the purpose of attaching lifting rigging.

• Do not use the attachment for any purpose other than the intended function.

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

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

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

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

Maintain a safe operating distance between the machine and workers and all other personnel. It is the duty of the operator to ensure that no person approach the machine while in use.

Failure to follow the above instructions could result in serious injury or death.

250BTH-002

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

Before transporting the machine: • Secure the grapple to the trailer and raise the stabilizers.

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

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

1.9

Tigercat 250C Loader

Safety

OPERATING SAFETY PRECAUTIONS continued When parking a machine with self-propelled option: •

Park on level ground.

•

Do not park on a hillside or incline.

•

Take the machine out of DRIVE MODE. This will automatically engage the park brake.

•

Lower the stabilizers to the ground.

•

Park the grapple in it's proper location on the carrier or rest on the ground.

•

Stop the engine.

•

NOTE: As a safety precaution before working on or around the machine, release brake system pressure by fully applying the brake foot pedal 40 times or more.

The pedal should have a 'soft' feeling when the pressure has been released Pressure may remain in the system after completing the above. Use caution when loosening hydraulic connections.

•

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

NOTE: Wait for 30 seconds after turning key

250BTH-002

switch off before turning the battery disconnect switch off. The engine ECM requires time after the engine is turned off to record the engine data and log the information for the current operating session. If the battery disconnect is turned off too soon, the data will not be recorded and an error message will be displayed when the battery power is turned back on and the key switch is turned on.

When travelling on public roads, use accessory lights (when installed) and other cautionary devices to provide operators of other vehicles warning of your approach. Ensure your machine meets all regulatory requirements.

1.10

Tigercat 250C 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 THIS MANUAL. 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.

250BTH-002

When servicing or repairing equipment, shut the engine down. Turn Battery Disconnect switch OFF and lock out the switch in accordance with local regulations. This machine is equipped with a remotely operated battery disconnect relay.

Some wiring on the machine is live even when the battery disconnect switch is off. When servicing the electrical system, remove the battery cables from the batteries disconnecting the negative cables first.

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

Install a 'DO NOT START ENGINE' sign on the operator’s cab door and in the engine compartment 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.

1.11

Tigercat 250C Loader

Safety Prior to welding on any part of the machine, the repair area should be cleaned and a fire extinguisher should be made available at the welding location.

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

Care must be taken in attaching the welding machine grounding clamp so current does not pass through bearings, especially the swing bearing.

WARNING

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

This machine is equipped with sensitive electronic control equipment, prior to welding:Disconnect the engine ECM (Engine Control WARNING, HOT FLUIDS AND HOT MACHINE SURFACES CAN CAUSE SERIOUS BURNS! •

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

•

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

•

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

1

2

250C-001

ENGINE CONTROL MODULE

Module) by unplugging the engine power connector (1) and multi-pin connector (2).

IMPORTANT

PRESSURIZED HYDRAULIC TANK.

34.5 kpa (5 psi) MAXIMUM. Before servicing hydraulic system, wearing eye protection, release air pressure from tank using air vent valve.

FILTER BREATHER MANIFOLD

250CT-002

AIR VENT VALVE HANDLE

COMPUTER CONNECTOR

PRESSURE GAUGE

S855C-001A H855C-001

AIR VENT EXHAUST

SCHRADER VALVE 250CT-001

After service is completed, close air vent valve and add air pressure from a clean air source to the hydraulic tank via the schrader valve. Do not exceed 34.5 kPa (5 psi). Refer to HYDRAULIC TANK PRESSURIZATION INSTRUCTIONS in section 3 of this manual for details.

COMPUTER CONTROL MODULE

Disconnect the computer connector (in cab) and the control module connector (under platform).

1.12

Tigercat 250C Loader

Safety

SERVICING SAFETY PRECAUTIONS continued 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.

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

CARTRIDGES If it becomes necessary to remove either the stabilizer counterbalance or check cartridge from the housing, or cylinder base end; Raise the stabilizer until it is in the 'overcenter' position and stop the engine. In this position, the weight of the stabilizer will not influence pressures in either end of the cylinder.

LOWER FRAME

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

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

VERTICAL CENTERLINE COUNTERBALANCE VALVE

STABILIZER UP IN VERTICAL POSITION

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

WARNING CYLINDER

DO NOT operate this machine to lift or move any objects other than what it is designed to lift or move.

• Do not use the boom to service other equipment.

• Do not use the boom to lift items such as tires, engines, cylinders, boom components, etc.

• Do not modify the boom system.

• Do not add hooks or lugs to the boom for the purpose of attaching lifting rigging.

• Do not use the attachment for any purpose other than the intended function.

STABILIZER COUNTERBALANCE/CHECK VALVE CARTRIDGE REMOVAL

230-06A

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

Maintain a safe operating distance between the machine and workers and all other personnel. It is the duty of the operator to ensure that no person approach the machine while in use.

Failure to follow the above instructions could result in serious injury or death.

1.13

Tigercat 250C Loader

Safety

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

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.

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

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

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.

FRONT CHASSIS

RETAINING PIN

Dispose of fluids properly. Do not pour fluids into the ground, stream, pond or lake. Before draining any fluids, know the proper way to dispose of them.

REAR CHASSIS

LYNCH PIN SPAC-002

Read, understand and follow all operating safety precautions specified by the attachment manufacturer.

LOCK BAR

LOCK BAR IN LOCKED POSITION

WARNING

To prevent accidental articulation of a selfpropelled machine and to avoid injury when working in the center joint area, install the frame articulation lock bar between the frames and hold in place with the lynch pins provided.

Always follow attachment manufacturer's instructions and safety warnings before approaching attachment head to make adjustments.

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

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

Before performing work under the boom system ensure it is firmly supported.

When opening or closing power operated engine door, watch for personnel in door areas.

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

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

1.14

Tigercat 250C Loader

Safety

SERVICING SAFETY PRECAUTIONS continued

WARNING Diesel fuel or hydraulic fluid under pressure can penetrate the skin and could result in death or serious injury. If any fluid is injected under the skin, a medical doctor familiar with the treatment of this type of injury must surgically remove it within a few hours.

FLUID INJECTION INJURY Hydraulic and diesel fuel systems on forestry machines operate at very high pressures, often 207 bar (3000 psi) and above. If a loose connection or a defect in a hose should occur, a fine, high velocity stream of fluid will result. Even for systems pressurized to as little as 7 bar (100 psi), this fluid stream can penetrate human skin as if it were a hypodermic needle.

In the event of any suspected fluid injection injury • Report the injury to your supervisor immediately.

• Seek professional medical attention immediately.

As always the best defence against suffering the effects of fluid injection is to prevent the accident from occurring in the first place.

When searching for possible fluid leaks • Never search for leaks with your bare hands.

Always wear thick protective gloves.

• Be sure to wear safety goggles for eye protection.

• Keep all body parts well away from the area being investigated for leaks.

• Use the end of a long piece of wood to move hoses or other obstacles.

Initially, an accidental fluid injection beneath the skin may only produce a slight stinging sensation.

There is a danger that you will tend to ignore this, thinking that it will get better with time. Most often, it does not! Within a very short time the wound may begin to throb painfully, indicating that tissue damage has already begun.

Similarly fluid injected directly into a blood vessel can spread rapidly through your circulatory system. The human body has little ability to purge injected fluid.

Diesel fuel or hydraulic fluid under pressure can penetrate the skin and could result in death or serious injury. If any fluid is injected under the skin, a medical doctor familiar with the treatment of this type of injury must surgically remove it within a few hours.

•

Place the end of a long piece of wood in the suspected path of any fluid stream. Never use any part of your body.

• Recognize that the source of the leak and the fluid streaming from it may be very small and not easily visible. You may only be able to see the fluid that accumulates as a result of the fluid stream.

When performing any service work • Stop the engine and relieve all diesel fuel or hydraulic pressure before disconnecting any lines or otherwise working on the system.

• Never grab any hydraulic or diesel fuel connectors or hoses when they are subjected to pressure.

• Always ensure that hoses are rated for the pressures to which they will be subjected.

• Never use any hoses that you suspect could be defective.

Time becomes critical as tissue damage progresses rapidly. The longer you delay getting professional medical attention, the more damage can occur.

Although fluid injection accidents are rare, the resulting injury has on occasion required the amputation of a finger, a hand or in some cases the entire limb. The longer the delay in getting professional medical aid, the further up the limb the tissue damage can spread. An injury of this type can become very serious or even fatal if not dealt with promptly and properly.

1.15

Tigercat 250C Loader

Safety

SERVICING SAFETY PRECAUTIONS continued GREASE INJECTION INJURY WHEN USING PNEUMATIC GREASE GUNS Pneumatic grease guns can deliver grease at pressures from 17 – 400 Bar (246 – 5801 psi).

It takes less than 7 Bar (100 psi) to inject a substance through human skin.

ALWAYS get professional medical treatment immediately after any type of injection injury.

Provide the physician with information on the type of grease, the pressure setting of the gun, and similar details.

The amount of fluid injected, type of fluid (or material), pressure at which it was injected, and the elapsed time between injection and surgery all influence the chances of successful treatment for this type of serious injury.

Prior to using a high pressure pneumatic grease gun perform the following: •

All operators of high pressure pneumatic grease guns MUST be trained in the hazards of its operations and the treatment for such injuries.

•

DO NOT OPERATE a high pressure pneumatic grease gun unless you have been trained in the proper operation and are aware of all safety precautions of such a tool.

•

Wear protective clothing such as gloves, safety hat and safety glasses.

•

Inspect all parts of the grease gun for wear and tear and replace all worn or damaged parts.

•

Ensure that protective shrouds are installed on all grease gun nozzles as safety devices.

•

Remove dirt and grease from grease fittings prior to greasing.

•

Replace any defective grease fittings on equipment with new fittings immediately.

•

When badly positioned fittings are identified, replace them with angled or swivel fittings for easier access.

1.16

Tigercat 250C Loader

Safety LIGHTNING SAFETY

LIGHTNING SAFETY AWARENESS

In spite of the popular myth that being struck by lightning is an unlikely event, the facts show that lightning strikes occur frequently. As a result loggers are at high risk because their work is outdoors and close to known strike points such as tall trees and heavy equipment.

Loggers can increase their chances of avoiding a lightning strike by following a few simple safety practices.

1.

WHAT IS A LIGHTNING STRIKE? Lightning is a discharge of the electricity produced by a thunderstorm. As the thunderstorm develops, many small particles of ice within the storm clouds bump together. These collisions create a positive charge at the top of a cloud and a negative charge at the bottom. As this continues a second positive charge builds up on the ground beneath the cloud, concentrated around high objects such as hills, trees, buildings, equipment and even people.

Designate a member of your crew to

•

Monitor daily weather forecasts

•

Observe local weather conditions

•

Alert all other members of the crew when a possible lightning threat develops.

2.

Don’t start or continue any work that cannot be stopped immediately, when a storm moves nearby.

3.

Anticipate a high-risk situation and take action early by moving to a low-risk location.

Do not hesitate. If there is lightning, you are in danger.

4.

The electrical potential in a lightning strike can be as much as 100 million volts. Lightning strikes can occur over very large distances, even as much as 60 km (37 miles). Lightning travels both in front of and behind a thunderstorm and so strikes happen even when rain has not started or has stopped.

Lightning can hit in the same place, many times and often spreads out over 18 m (60 feet) within the soil around the strike point.

Obey the rule – If you see lightning, Flee. If you hear thunder, Clear.

5.

Do not follow the now obsolete guideline to take shelter when the time between seeing lightning and hearing thunder is 30 seconds or less. This does not provide sufficient time to ensure safety. Always follow step 4.

6.

Remain in your safe location for 30 minutes after the last sight of lightning or the last sound of thunder.

Thunder always accompanies lightning. When lightning occurs, the air through which it travels is instantaneously heated to a temperature more than 28,000°C (50,000°F). The air expands rapidly due to this heating, then quickly contracts as it cools. It is this contracting shock wave that we hear as thunder.

The safest location during lightning activity is inside a fully enclosed, substantially constructed building, a house, office, school, shopping area, etc. These are the safest because of the electrical wiring and plumbing that they contain. Should lightning strike, the electrical current will travel through the wiring or plumbing into the ground.

When such a building is nearby, always seek shelter there first.

When the difference between the electrical charge in the cloud and on the ground becomes great enough to overcome the resistance of the insulating air between them, an electrical current flows instantly. This is a lightning strike.

In many areas of the world, lightning strikes are second only to flooding as the greatest cause of storm related deaths and injuries. Although only 10% of lightning strike victims are killed, virtually all from cardiac or respiratory arrest, over 70% of those that survive suffer severe, life-long injury and disability. The symptoms of a lightning strike include memory loss, fatigue, chronic pain, dizziness, sleeping difficulty and the inability to complete several tasks at one time.

1.17

Tigercat 250C Loader

Safety WHAT TO DO IF YOU ARE OUTSIDE AND SEE LIGHTNING OR HEAR THUNDER. If you can, get inside.

1.

Run to the nearest building, motor vehicle or fully enclosed ROPS equipment cab immediately. Being anywhere outside is not safe.

2.

If inside a building:

Unfortunately loggers do not often work close to buildings and therefore other alternatives need to be considered.

Sheds, weather shelters, hunting blinds, tents and other partially open or small structures are not safe against lightning strikes as they lack the electrically grounded components of larger buildings. They are intended for sun or rain protection only. Do not seek shelter from lightning strikes inside these structures.

•

Don’t watch the lightning storm from open windows or doorways. Stay in inner rooms.

•

Stay well away from corded telephones, electrical appliances, lighting fixtures, radio microphones, electrical sockets and plumbing pipes and fixtures.

3.

If inside a motor vehicle or fully enclosed ROPS equipment cab: •

The second safest location during lightning activity is inside a fully enclosed car, van, truck or bus with a metal roof and metal sides. The electrical energy of a lightning strike to these vehicles is carried to ground by the conducting outer metal surfaces. This is called the skin effect.

Under no circumstances whatsoever step outside of the vehicle or off the equipment to move to another shelter. Very dangerous electrical pathways to ground may go through you.

•

Shut down all operation, turn off the engine, close all doors and raise all windows.

Do not seek safety from lightning strikes in vehicles with fiberglass or plastic body shells or in convertible top vehicles. None of these are safe, as they do not offer skin effect lightning protection.

•

Sit squarely in the seat with your hands in your lap and your feet flat on the floor mat.

•

Do not touch any metallic objects referenced to the outside of the vehicle.

Do not touch any door and window handles, control levers, foot pedals, steering wheels, cab interior walls and any other inside to outside metal objects.

•

Do not touch any radio or telephone connected to an outside antenna.

Heavy forestry equipment such as a skidder, loader, feller buncher, forwarder, etc. with a fully enclosed rollover protective structure (ROPS) cab take advantage of the skin effect and are therefore safe in electrical storms.

However machines with a rollover canopy only are not safe against lightning strikes as they are open to electrically conductive rainwater and do not benefit from the skin effect. Operators of this equipment must abandon their machines and get to a safer location before lightning strikes.

Note that the rubber tires on motor vehicles and heavy equipment do not increase safety from lightning strikes. Lightning has already travelled a great distance through the air to strike the vehicle.

In comparison a few inches of rubber in a tire offers absolutely no additional insulation.

1.18

Tigercat 250C Loader

Safety What to do if you feel your skin tingling, your hair stands on end, light metal objects vibrate or you hear a crackling sound.

If you are caught outside and have no where else to go.

1.

Lightning is probably about to strike. You only have a few seconds to act.

2.

Put your feet together. Crouch down like in a baseball catcher’s position. Hold your head down. Cover your ears to protect them against the noise of the thunder.

3.

Do not lie flat on the ground. By touching as little of the ground as possible, the lightning may not move across the ground to you.

1.

Avoid wide-open areas where you project above the surrounding landscape.

2.

Seek shelter in a low place, such as a ditch, ravine, valley, canyon or cave.

What to do if a co-worker has been struck by lightning.

3.

Get away from open water such as ponds or streams.

1.

4.

Do not take shelter under any isolated tall trees or small groups of trees.

The victim does not carry any electrical charge. There is no danger to anyone helping this person. You can touch him or her immediately.

5.

Seek shelter amongst the dense, thick growth of the shortest trees.

2.

Call your local emergency response telephone number immediately.

6.

Avoid entering any small enclosures or shelters.

3.

7.

Do not seek shelter under any motor vehicle or heavy equipment.

If the victim has no pulse, their heart has stopped or they have stopped breathing, start cardiopulmonary resuscitation (CPR) or mouth-to-mouth resuscitation immediately.

Use a portable defibrillator if one is available.

8.

Keep clear of any materials that can conduct electricity such as wire fences and gates, metal pipes, poles, rails and tools.

4.

9.

Stay at least 15 m (50 ft) away from metal objects such as a fuel tank, a vehicle or machinery without a cab, motorcycle, ATV, etc.

Be careful about staying in the storm to take care of the victim. You can get hit by lightning too. If you can, move the victim to a building as soon as possible.

To further increase your awareness about lightning safety, see the following web sites.

National Weather Service Lightning Safety http://www.lightningsafety.noaa.gov

10. Stay at least 5 m (16 ft) apart from any other members of a group so that lightning won’t travel between you.

National Lightning Safety Institute http://www.lightningsafety.com

11. Do not use the telephone except for emergencies.

1.19

Tigercat 250C Loader

Safety

FIRE PREVENTION

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

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

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

1. Maintain a CHARGED fire extinguisher on the machine at all times and KNOW HOW TO USE IT. 2. Remove debris and blow out dust regularly from the air intake doors, engine radiator and charge air cooler, hydraulic oil cooler, diesel fuel cooler and air conditioning condenser core to prevent overheating of the engine and hydraulics and to maintain efficient operation of the machine. Refer to CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR in SECTION 2 of the OPERATOR’S MANUAL. 3. Blow off all forest debris and fine organic material 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 when working in logging conditions where large amounts of combustible forest debris are present.

Visual inspection after blow off to ensure thorough cleanliness is vital. Engine exhaust systems provide numerous small pockets where saw dust, small wood chips and other flammable forest debris can gather. Even small accumulations close to hot exhaust components can ignite and smolder. If dislodged this smoldering debris can fall into other areas of the machine and thereby spread a fire.

4.

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.

5.

Inspect the machine regularly for any signs of diesel fuel or hydraulic system leakage.

Check for worn or eroded fuel or hydraulic lines before starting up any equipment.

6.

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

7.

Steam clean the engine, hydraulic pumps, transmission, brake, fuel and hydraulic tank compartments and all machine belly pans at least once a month or more frequently when working in logging conditions where large amounts of combustible forest debris are present.

Use only nonflammable solutions for cleaning the machine and components.

8.

9.

Inspect the exhaust system daily for any signs of leakage. Check for worn, cracked, broken or damaged pipes or muffler.

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

10. During daily operation of the machine, the occurrence of exhaust leaks are usually accompanied by a change or increase in engine exhaust noise levels. These audible warnings cannot be ignored.

Should any exhaust leaks occur during operation, the machine must be shut down immediately and not put back to work until the necessary repairs have been completed.

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

12. Never leave the machine parked with boom, arch or blade suspended off the ground. Should their supporting hydraulic hoses burn through during a fire, pressurized hydraulic oil may be injected into the fire and the boom, arch or blade will fall rapidly to the ground.

1.20

Tigercat 250C Loader

Safety 17. AFTER transporting (trucking) a machine from one job site to the next, open all doors and access panels and blow off any debris that may have repositioned itself onto the engine and exhaust parts due to wind turbulence caused by the journey.

FIRE PREVENTION continued 13. Turn the battery disconnect switch to OFF at shut down to de-energize all electrical circuits.

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

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

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

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

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

Prevent the fire from happening in the first place by ensuring that all machine systems are frequently inspected and always well maintained.

•

Ensure that any hand held fire extinguishers are charged and in working order. Fire extinguishers require routine care. Follow the manufacturer’s instructions for inspection and maintenance shown on the label of the fire extinguisher and in the extinguisher manufacturer's manual.

•

Ensure that any pressurized water systems on the machine (if applicable) are charged and in working order. Refer to PRESSURIZED WATER SYSTEM MAINTENANCE in SECTION 3 of the OPERATOR’S MANUAL.

•

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

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

Dry chemical extinguishers should be rated ABC and pressurized water extinguishers should be rated A.

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

Class A fires involve ordinary combustibles such as wood, cloth, paper, rubber and many plastics, Class B fires occur with flammable liquids such as diesel fuel, oil and grease and Class C fires apply to energized electrical equipment.

1.21

Tigercat 250C Loader

Safety WHAT TO DO WHEN A MACHINE FIRE OCCURS

FIRE PREVENTION continued •

•

•

•

•

•

•

•

If operating the machine when a fire occurs: 1. Lower all working attachments to the ground.

Ensure that the nozzle of any hand held extinguisher and pressurized water system available on the machine and at the work site fits within the fire extinguisher access holes in the doors of the machine.

Ensure that your fire detection system* is in working order. Refer to FIRE DETECTION SYSTEM in SECTION 2 of the OPERATOR’S MANUAL. Ensure that your fire suppression system** is charged and in working order. Refer to FIRE SUPPRESSION SYSTEM in SECTION 2 of the OPERATOR’S MANUAL. Ensure that you are familiar with the recommended procedures for fire contained in the emergency action plan of your company.

Ensure that you follow all national, state / provincial and local regulations dealing with fire fighting in effect in your specific geographic region. Regulations will vary from region to region but most will usually require that: 1. Workers assigned to fire fighting duties must be physically capable of performing them safely and effectively.

2. Workers designated to use fire fighting equipment as part of an emergency action plan must receive full and proper training from a qualified instructor.

3. Whenever portable fire extinguishers are provided for use in the workplace, training must be provided to familiarize workers with the general principles of fire extinguisher use and the hazards involved with fire fighting.

4. Training must be provided upon initial employment and at least annually thereafter.

Ensure that after you have received the training as outlined above, that you know how to use the fire extinguisher, the pressurized water system (if applicable)

2. Shut the engine off.

3. Activate the fire suppression system**.

4. Radio or call for help. Be certain to report a fire immediately.

5. Exit the machine taking fire extinguisher and pressurized water system hose (if applicable) with you.

6. 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. All fires can be very dangerous and life threatening.

7. Only if you can safely do so, turn OFF the battery disconnect switch.

•

Before deciding to fight the fire, be certain that: 1. The fire is small and not rapidly spreading.

2. There is always a clear, safe escape route to your back.

3. You have received training in the use of the available fire extinguishing systems and are confident that you can operate them effectively.

4. If in any doubt about whether or not to fight the fire – DON’T. Instead stand well clear of the fire and wait for help to arrive.

5. Be aware that engine coolant , diesel fuel or hydraulic hoses could fail during a fire.

If this happens, hot coolant, fuel or oil could possibly be ignited by the fire.

6. If possible a dry chemical fire extinguisher or fire suppression system** should be used first to fight a machine fire.

Then immediately afterwards use the pressurized water hose supplied with the machine (if applicable) or a pressurized water extinguisher (if available). A fire suppressed by dry chemical may re-ignite from the heat retained by any debris or hot machine components in the area.

The water will cool the area, reducing the chances of re-ignition.

and the fire suppression system** on your machine. There is not enough time available to read instructions during a fire emergency.

Ensure that all information necessary for you to immediately contact all sources of help (local fire department, etc) in the event of a fire emergency is recorded and readily available at all times.

1.22

Tigercat 250C Loader

Safety WHAT TO DO AFTER A MACHINE FIRE HAS OCCURRED

FIRE PREVENTION continued

•

1. Ensure that the cause of the fire is determined and all appropriate repairs are completed.

Use the PASS method. This is the most effective use of a fire extinguisher.

•

Before returning the machine to work.

•

Pull the pin at the top of the extinguisher that keeps the handle from being pressed.

Break the plastic seal as the pin is pulled.

•

Aim the nozzle at the base of the fire. Do not aim the nozzle at the flames. In order to put out the fire, you must extinguish the fuel, not the flames. Hose nozzles are often clipped to the extinguisher body.

Release the hose before taking aim.

•

Squeeze the handle to release the pressurized extinguishing agent. The handle can be released at any time to stop the discharge.

*NOTE: Fire detection systems are offered by

•

2. Ensure that the fire detection system*

or the fire suppression system** is properly serviced and in working order (if applicable).

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

Tigercat as an optional installation on some Tigercat product lines. Please disregard any references made to fire detection systems if not installed on your machine.

Sweep from side to side at the base of the fire until the fire is completely out or the fire extinguisher is empty

•

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

**NOTE: Dry chemical fire suppression

systems are offered by Tigercat as an optional installation on some Tigercat product lines. Please disregard any references made to fire suppression systems if not installed on your machine.

20229A

• • •

• •

TYPICAL FIRE EXTINGUISHER ACCESS HOLE

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

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

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

Ensure that the machine and all components have cooled down sufficiently after a fire so that re-ignition does not occur.

Remain with the machine until help arrives.

1.23

Tigercat 250C Loader

Safety

DRY CHEMICAL CLEANUP PROCEDURES

3.

Both ABC dry chemical fire extinguishers and fire suppression systems discharge a chemical powder to extinguish the fire. The chemical makeup and the small particle size of the powder as well as the force of the discharge all contribute to the fire fighting capability. These same characteristics also permit the powder to penetrate into and fully cover all components in the vicinity of the discharge.

To break down the caked dry chemical, spray or wash these areas with a 50/50 mixture of hot water and isopropyl alcohol. Allow this mixture to stand in place for several minutes.

The caked dry chemical when exposed to moisture is also mildly acidic. Therefore when the break down procedure has been completed, follow this immediately with the neutralizing procedure as described in step 2.

The following are recommendations for the cleanup and neutralizing of areas exposed to dry chemical powder.

Workers performing this work should wear protective clothing, safety goggles and a fine particle dust mask to minimize their personal exposure to the dry chemical powder.

Ensure that all electrical systems have been completely de-energized prior to any cleanup.

1.

In areas of the machine that remained cool and dry during the fire, the dry chemical will stay in powder form.

Be certain to clean these areas immediately to prevent any settled residual powder from coming into contact with moisture whether through direct contact or humidity in the air.

Remove the powder residue by blowing off with air, sweeping, dusting or vacuuming using a HEPA filter capable of trapping the small dry chemical particles. Then wipe all surfaces with a damp cloth.

2.

In areas exposed to heat during the fire, the dry chemical powder will melt forming a coating that cakes or crusts on all surfaces.

In areas exposed to moisture, the dry chemical powder will combine with water to form a paste that is mildly acidic. Note that all surfaces covered by this dry chemical paste including electrical contacts are vulnerable to corrosive attack.

To neutralize the acidic paste on large surfaces, spray or wash these areas with a mixture of 3 parts hot water to 1 part baking soda. Allow this mixture to stand for several minutes before rinsing with warm water.

Wash the area with a mild soap and water solution. Rinse thoroughly with water. Blowdry to remove all residual water.

Cleaning of electrical contacts should be done using an electrical contact cleaner that has no flash or fire point and is non-corrosive and non-conductive such as CRC Contact Cleaner 2000.

1.24

Tigercat 250C Loader

SAFETY LABELS

Safety READ OPERATOR'S MANUAL and USE THE SEAT BELT AT ALL TIMES

SAFETY LABELS The following safety labels must be periodically cleaned and inspected to ensure legibility is maintained. Replace any label that becomes illegible, damaged or removed.

OPERATOR'S MANUAL LOCATION This label indicates the storage location of the operator's manual. This label is located on the outside of the operator's manual case inside the cab.

This label gives two messages.

The centre panel notifies the operator to always read the operator’s manual before operating the machine. Pay close attention to WARNINGS and HAZARD identifications.

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

The bottom panel notifies the operator that the operator's seat is equipped with lap belt. Use this restraint systems at all times when operating the machine. DO NOT ATTEMPT TO MOVE OR OPERATE the machine until the seat belt is fastened properly.

1.25

Tigercat 250C Loader

Safety CHECK DAILY

SAFETY LABELS FIRE PREVENTION!

This label is installed in the cab. In addition to the previous label it is a reminder to check the machine daily for the possibility of debris build-up, leaks, damaged wires and hoses and take the necessary action required to clean up any debris accumulation, repair any leaks, damaged wires or hoses.

The label also advises to check and ensure that all fire fighting devices are in good working order.

This label advises operator's of the following: READ UNDERSTAND AND FOLLOW THE FIRE PREVENTION GUIDELINES IN THIS MANUAL. These guidelines provide all the necessary action required to preventing fires on this machine. DO NOT OPERATE THIS MACHINE until you have read these instructions and have performed any necessary maintenance required that will prevent the potential of a fire from starting on this machine.

It is also important to note that fire prevention inspections and maintenance MUST BE PERFORMED FREQUENTLY (several times per day). A clean combustible free machine as well as frequent inspections of the exhaust components, hydraulic hoses and electrical cables and performing any necessary repairs immediately will help prevent fires.

Maintain a CHARGED fire extinguisher on the machine at all times, know where it is and KNOW HOW TO USE IT!

1.26

Tigercat 250C Loader

Safety

FIRE EXTINGUISHER ACCESS HOLE

EXTERIOR LABELS – SELF PROPELLED MACHINES The following safety labels are installed on the exterior of self-propelled machines. These labels are located on the machine in the area where the specific safety concern is applicable. Labels must be periodically cleaned and inspected to ensure legibility is maintained. Replace any label that becomes illegible, damaged or removed.

ENTANGLEMENT HAZARD

This label indicates the location of each FIRE EXTINGUISHER ACCESS HOLE. The label is installed on each fire extinguisher hole on the engine door, pump compartment door and L.H. service door.

This label warns of an ENTANGLEMENT HAZARD. This label is located on the rear chassis.

The machine is equipped with exposed drive shafts in the rear chassis and center joint. Not keeping a safe distance from rotating exposed drive shafts could result in death or serious injury.

1.27

Tigercat 250C Loader

Safety STORED ENERGY HAZARD

SAFETY LABELS CRUSH HAZARD

This label warns of the crush zone in the center joint area. This can occur when the machine steering is used. DO NOT WORK IN THIS AREA UNTIL THE ARTICULATION LOCK BAR IS INSTALLED! RETAINING PIN

This label warns of a STORED ENERGY HAZARD. The machine is equipped with an accumulator for the brake system. The accumulator has stored energy in the form of hydraulic pressure.

Servicing the accumulator or any hydraulic components before releasing pressure could result in death or serious injury.

FRONT CHASSIS

LYNCH PIN SPAC-002

LOCK BAR

REAR CHASSIS

LOCK BAR IN LOCKED POSITION

DO NOT SERVICE ACCUMULATOR OR ANY HYDRAULIC COMPONENTS BEFORE RELEASING PRESSURE.

RETAINING PIN

Refer also to RELEASING BRAKE SYSTEM PRESSURE in SECTION 2 of the operator's manual and SECTION 4 of the service manual.

FRONT CHASSIS

LYNCH PIN SPAC-003

LOCK BAR

REAR CHASSIS

LOCK BAR IN STORED POSITION

Before working in the center joint area, lifting or transporting the machine to another vehicle, INSTALL THE CHASSIS ARTICULATION LOCK BAR between the chassis and center joint to prevent accidental articulation which could result in death or serious injury.

Refer to ARTICULATION LOCK in SECTION 2 of THIS MANUAL for complete instructions.

1.28

Tigercat 250C Loader SECTION 3 – LUBRICATION & MAINTENANCE CONTENTS - SECTION 3

MARCH 2012

AIR CLEANER........................................................................................................................................3.16 AIR CONDITIONING...............................................................................................................................3.18 AIR FILTER.............................................................................................................................................3.16 AIR FILTER RESTRICTION INDICATOR................................................................................................3.16 APPROVED HYDRAULIC OILS............................................................................................................. 3.11 CASE DRAIN STRAINER.......................................................................................................................3.15 EMERGENCY CAB EXITS........................................................................................................................3.6 FIRE PREVENTION..................................................................................................................................3.6 FIRST 125 HOUR INSPECTION AND SERVICE.....................................................................................3.2 HYDRAULIC OIL RETURN FILTERS......................................................................................................3.14 NEW MACHINE MAINTENANCE.............................................................................................................3.2 OIL LOST FROM LEAKAGE.....................................................................................................................3.5 OIL SAMPLE COLLECTION PROCEDURES...........................................................................................3.4 OIL SAMPLING PROGRAM......................................................................................................................3.3 PAG OIL..................................................................................................................................................3.18 PILOT PRESSURE FILTER....................................................................................................................3.15 PRE-DELIVERY INSPECTION.................................................................................................................3.2 PRESSURE SETTINGS..........................................................................................................................3.25 PREVENTIVE MAINTENANCE SCHEDULE............................................................................................3.2 REFRIGERANT.......................................................................................................................................3.18 SCHEDULED MAINTENANCE EVERY 8 HOURS...................................................................................................................................3.7 EVERY 24 HOURS.................................................................................................................................3.8 EVERY 125 HOURS...............................................................................................................................3.8 EVERY 250 HOURS...............................................................................................................................3.9 EVERY 500 HOURS...............................................................................................................................3.9 EVERY 500 HOURS:............................................................................................................................3.10 EVERY 1000 HOURS.............................................................................................................................3.9 GENERAL.......................................................................................................................................3.5, 3.6 SERVICE AND LUBRICATION POINTS.................................................................................................3.13 TORQUE CHART....................................................................................................................................3.20 TORQUE CHART, GENERAL.................................................................................................................3.21 TORQUE, FLUID CONNECTIONS..................................................................................... 3.22, 3.23, 3.24 WEIGHTS OF COMMERCIAL WOOD....................................................................................................3.26

Tigercat 250C Loader

Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE

NEW MACHINE MAINTENANCE

*INITIAL PRE-DELIVERY INSPECTION: PERFORM THE INITIAL PRE-DELIVERY INSPECTION USING Tigercat FORM NUMBERS 5337 AND 5347; 'PDI AND 125 HOUR INSPECTION REPORT'

*FIRST 125 HOUR INSPECTION AND SERVICE REPORT: WITH THE OWNER'S MECHANIC PRESENT, PERFORM AN INSPECTION AND SERVICE ACCORDING TO THE Tigercat FORM NUMBERS 5337 AND 5347; 'PDI AND 125 HOUR INSPECTION REPORT' THIS MUST BE COMPLETED WITHIN THE FIRST 125 HOUR TIME FRAME.

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

WARNING

All hydraulic connections Hose clamps Pin retainers Center joint pin securing bolts (if applicable) Check torque on swing bearing retaining bolts Engine mounting bolts Pump mounting bolts Swing gearbox mounting bolts Swing motor mounting bolts Cab securing bolts Boom pin nuts Heel pin nuts (if applicable) Trailer mounting studs

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

•

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

•

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

•

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

Transmission securing bolts (if applicable) Axle mounting bolts (if applicable) Wheel retaining bolts (if applicable) Any other loose nut, bolt or fitting NOTE: Use of filters other than genuine Tigercat replacement filters is not recommended.

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.

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

3.2

Tigercat 250C Loader

Lubrication and Maintenance

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

Location

200 Series First Sample

Follow-up Samples

Hydraulic Oil

125 hrs

Every 1000 hrs or 6 Months

Swing Drive Gearbox

125 hrs

Every Oil Change (500 hours or 3 Months)

Track Drive Gearboxes (if applicable)

125 hrs

Every 1000 hrs or 6 Months

Transmission (if applicable)

125 Driving hrs

Every Oil Change (500 hours or 3 Months)

Front & Rear Axles (if applicable)

125 Driving hrs

Every Oil Change (1000 hours)

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

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

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

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

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

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

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

Contact your Tigercat Dealer Parts Department to order Kits.

3.3

Tigercat 250C Loader

Lubrication and Maintenance

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

FILTER RESTRICTION INDICATOR

OIL SAMPLING CONNECTOR 250CT-012

HYDRAULIC OIL RETURN MANIFOLD

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

The accuracy of the lab analysis results is very dependent on the quality of the oil sample taken. Collection of clean oil samples that are representative of the main body of oil are essential if meaningful lab results are to be obtained.

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

•

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

•

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

• •

•

To obtain a representative sample, oil sample valves must be purged before the sample is taken. Drain a minimum of 90 – 120 mL (3 – 4 oz) of oil into a separate container and discard this oil.

•

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

Gearbox, Transmission and Axle Samples: • These samples can be taken during the oil change process.

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

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

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

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

3.4

•

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

•

Place the required drain container under the machine to capture the used oil.

•

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

Tigercat 250C Loader

Lubrication and Maintenance

GENERAL Inspect the EXHAUST SYSTEM DAILY for any signs of LEAKAGE. Check for worn, cracked, broken, or damaged pipes or muffler. Also check for missing or damaged bolts or clamps.

Should any exhaust leaks or defective parts be found, repairs must be made immediately.

Engine exhaust leaks can cause fires. DO NOT OPERATE the machine until the exhaust leak is repaired.

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.

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

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.

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

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

Clean up oil spills in engine enclosure immediately.

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

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.

*OIL LOST FROM LEAKAGE

LOST OIL (LITERS) LOST OIL (GALLONS)

PER PER PER PER PER PER MONTH YEAR DAY MONTH YEAR LEAKAGE RATE DAY ONE DROP IN 10 SECONDS 0.424 12.72 152.0 0.112 3.36 40.0 ONE DROP IN 5 SECONDS 0.852 25.6 306.6 0.225 6.75 81.0 ONE DROP PER SECOND 4.26 127.76 1533.1 1.125 33.75 405.0 THREE DROP PER SECOND 14.2 425.86 5110.31 3.75 112.5 1350.0 DROPS BREAK INTO STREAM 90.83 2725.5 32706.0 24.00 720.0 8640.0

3.5

Tigercat 250C Loader

Lubrication and Maintenance

GENERAL CHECK EMERGENCY EXIT, MONTHLY: An alternate exit route is provided: the right side window can be used as an emergency exit. This exit is only to be used if the side door cannot be opened.

234T-031

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

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

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

SLIDING WINDOW HANDLE

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

Open the right side window by lifting the latch handle and slide the window open.

1

1

INSIDE CAB

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

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

234T-046B 234T-047

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

R.H. WINDOW SCREEN

On machines equipped with window screens, there are two hand knobs (1), one on the inside and one on the outside that can be removed to open the window screen. Only one hand knob has to be removed to open the window screen as follows:

Also refer to FIRE PREVENTION in Section 1 for additional information.

From inside the cab: Open the cab window and turn the inside hand knob (1) counterclockwise to remove the hand knob and open the window screen. Push the window screen out to open it. Exit the cab if you can safely do so.

From outside the cab: The window screen can also be opened from the outside by unscrewing the hand knob on the outside (1) and remove it. When the hand knob is removed the screen can be swung open.

It is therefore essential that this exit be inspected monthly to ensure it is operational.

3.6

Tigercat 250C Loader

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 8 HOURS:

Clean: • Oil cooler, engine radiator, A/C condenser and charge air cooler

• Check engine coolant level • Check engine oil level

• Remove potentially damaging limbs or sticks and all debris

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

Check: • For leakage around hydraulic components and flexible hoses

• Check air cleaner unloader valve.

• Check air intake filter restriction indicator.

Replace primary filter if indicator is in red zone.

Replace secondary (safety) filter every third primary filter change to guarantee maximum performance and reliability.

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

• All engine air intake system components (including charge air cooler) rubber elbows, connector hoses, tubes and clamps for damage, hardening, wear, cracks, leaks, loose clamps or loose hanger bracket hardware and repair or replace immediately.

• Exhaust system for leaks.

• Check hydraulic oil level Lubricate: • Swing bearing; 1 fitting – 4 shots while swinging

• Conduct an overall visual inspection.

• Swing pinion; 1 fitting – 10 shots while swinging

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

• Rotary manifold seal; 1 fitting – 1 shot while swinging • *Boom joint; 2 fittings – purge • *Stick joint; 2 fittings – purge • *Cylinder pins; boom, stick & tilt; 4 fittings – purge *Lubricating cylinder pins and boom joints:-

250C-002 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 • Yoke pins; 2 fittings – purge • Grapple rotate pinion; 1 fitting – 4 shots, rotate 90° after each shot • Grapple arm pins; 6 fittings – purge • Grapple cylinder pins; 4 fittings – purge

3.7

Tigercat 250C Loader

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 24 HOURS:

EVERY 125 HOURS:

• Perform 8 hour maintenance

• Perform 8 hour maintenance • Perform 24 hour maintenance

And in addition: • Lubricate stabilizer arm pins; 8 fittings – purge • Lubricate stabilizer cylinders; 8 fittings – purge • Lubricate grapple rotate bearing; 1 fitting 4 shots, rotate 90° after each shot

And in addition: • Check return filter restriction indicator with engine running at high idle and oil flow Check: • Fluid level in batteries unless maintenance free • Engine Rpm • All hydraulic pressures • Hydraulic pumps and motor securing bolts • Torque tightening points as per new machine maintenance Visually check for damage to: • Main and stick booms and cylinders • Lower frame, stabilizer arms and cylinders • Swing bearing area • Attachment Make repairs immediately Visually inspect for: • Frayed electrical wiring and hydraulic hoses • Wear in any other components Clean/replace: • Air conditioner re-circulation filter • Cab fresh air filter • Refer to diesel engine service manual and attachment manual for additional required maintenance at this scheduled time period.

3.8

Tigercat 250C Loader

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 250 HOURS:

EVERY 500 HOURS:

• Perform 8 hour maintenance

• Perform 8 hour maintenance

• Perform 24 hour maintenance

• Perform 24 hour maintenance

• Perform 125 hour maintenance

• Perform 125 hour maintenance

And in addition: • Check fire extinguisher and turn it to mix contents.

• Lubricate swing gearbox lower bearing; 2 fittings – 5 shots each †

• Perform 250 hour maintenance And in addition: • Replace engine fuel filter • Replace fuel/water separator filter • Replace oil in swing gearbox. Fill reservoir to half way mark

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.

• Replace hydraulic oil return filters † • Replace swing pump charge pressure filter † • Replace hydraulic oil pilot pressure filter † • Lubricate door and cover hinges; 8 fittings – 1 shot Check: • Torque on swing bearing and swing gearbox retaining bolts • Refer to diesel engine service manual and attachment manual for additional required maintenance at this scheduled time period.

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

3.9

Tigercat 250C Loader

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 5000 HOURS:

EVERY 1000 HOURS: • Perform 8 hour maintenance

• Perform 8 hour maintenance

• Perform 125 hour maintenance

• Perform 125 hour maintenance

• Perform 250 hour maintenance

• Perform 250 hour maintenance

• Perform 500 hour maintenance

• Perform 500 hour maintenance

• Replace air cleaner unloader valve.

• Perform 1000 hour maintenance

And in addition: • Check fuel in tank strainer

• Perform 2000 hour maintenance

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

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

EVERY 2000 HOURS: • Perform 8 hour maintenance • Perform 125 hour maintenance • Perform 250 hour maintenance • Perform 500 hour maintenance • Perform 1000 hour maintenance And in addition: • Drain and refill hydraulic oil tank with recommended hydraulic oil. See APPROVED HYDRAULIC OILS • Replace all air intake rubber components such as elbows and connectors – High temperatures in this area can cause the rubber to harden.

See AIR INTAKE MAINTENANCE in THIS SECTION. • Refer to diesel engine service manual and attachment manual for additional required maintenance at this scheduled time period.

3.10

Tigercat 250C Loader

Lubrication and Maintenance

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

IMPORTANT! The machines hydraulic oil is used in the Tigercat Self Propelled Articulating Carrier's drive system. For axle, transmission and park brake oil see the Service and Lubrication chart in section 3 of the carrier's manual.

3.11

Tigercat 250C Loader

Lubrication and Maintenance

3.12

Tigercat 250C Loader

Lubrication and Maintenance

SERVICE AND LUBRICATION POINTS.XL R1

3.13

Tigercat 250C Loader

Lubrication and Maintenance

RETURN MANIFOLD

FILTER HEAD

GASKET FILTER ELEMENT

FILTR_SEALS 2

SQUARE SECTION GASKET INSTALLATION

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

Apply clean oil to new gasket surfaces.

Install new gasket into groove in filter head.

Screw on new filter until gasket makes contact.

Tighten filter an additional 3/4 turn.

1-WATER ABSORBING RETURN FILTER (COLOUR BLUE) 3-HYDRAULIC RETURN FILTERS 250CT-008

HYDRAULIC RETURN FILTERS

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

HYDRAULIC OIL RETURN FILTERS 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 (blue) filter to assist with the removal of moisture from the hydraulic oil. The filters are rated 10 micron absolute..

FILTER HEAD

GASKET

Each filter head has a bypass valve with a 172 kPa (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 saw cut function operating, the filter restriction indicator should be in the GREEN zone. If the pointer is in the RED zone replace all four filter elements.

FILTER ELEMENT FILTR_SEALS 2

 '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.

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.

'O' RING GASKET INSTALLATION

6. Start the engine and check for leaks.

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

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

3.14

Tigercat 250C Loader

Lubrication and Maintenance

CHARGE PUMP FILTER

250CT-014

HYDRAULIC PILOT FILTER

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

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

250CT-013

CHARGE PUMP FILTER

SWING PUMP CHARGE PRESSURE FILTER The swing pump charge pressure filter is a full flow filter mounted on a filter head with built-in bypass. The filter is located in the output side of the charge pump.

For service and replacement intervals see SERVICE AND LUBRICATION CHART in THIS SECTION. Changing the filter or strainer: 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.

250CT-015

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

CASE DRAIN STRAINER

CASE DRAIN STRAINER The case drain strainer is used to filter all case drain oil from the pumps and motors before it returns to the reservoir.

The strainer element requires no regular maintenance over the life of the machine. This element requires maintenance only in the case of damage or contamination due to a hydraulic pump or motor failure.

IMPORTANT! The strainer element is NOT a filter element.

Always use the correct replacement element. Use of an incorrect (filter type) element will result in pump damage.

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

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

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

8. Turn filter an additional 1/2 turn by hand to tighten. DO NOT use bottom nut for filter installation or damage/leakage may result.

Bottom nut is to assist in filter removal only.

9. Start the engine and check for leaks.

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.

3.15

Tigercat 250C Loader

Lubrication and Maintenance

AIR CLEANER INTAKE HOSE

AIR CLEANER PRECLEANER HOUSING

AIR CLEANER ASSEMBLY

AIR FILTER RESTRICTION INDICATOR

AIR CLEANER UNLOADER VALVE 250CT-012

ENGINE COMPARTMENT FRONT ACCESS

AIR CLEANER

AIR CLEANER UNLOADER VALVE

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

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.

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

AIR FILTER RESTRICTION INDICATOR A filter restriction indicator is located in the engine enclosure beside the air cleaner. The indicator is remote mounted and is connected to the outlet side of the air filter with a hose. Replace the primary air filter when the restriction indicator shows RED. This indicator provides a continuous reading whether the engine is running or is shut down. After replacing the filter, reset the indicator by pressing the reset button.

NOTE: Replace the safety element every third primary filter change.

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

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

The valve should suck closed at 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.

3.16

Tigercat 250C Loader

Lubrication and Maintenance AIR CLEANER ASSEMBLY

AIR FILTER RESTRICTION INDICATOR

250C-003

ENGINE COMPARTMENT FRONT ACCESS IMPORTANT STEPS TO FOLLOW WHEN CHANGING FILTER ELEMENTS

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

1. Release the cover latches gently to reduce the amount of dust dislodged.

INTAKE TUBING AND JOINTS Check all air intake system components, rubber elbows, connector hoses, tubes and clamps for damage, hardening, wear, cracks, leaks, loose clamps or loose hanger bracket hardware and repair or replace immediately.

2. Avoid dislodging dust from filter element(s) by gently pulling the element out of the housing.

Replace all air intake rubber components such as elbows and connectors every 2000 hours – High temperatures in this area can cause the rubber to harden.

NOTE: Filter elements should never be cleaned and reused. Cleaning causes dust to bypass the filter and be deposited on the inner surface of the filter media. The dust is then drawn directly into the engine.

3. Check your old filter sealing surfaces. This will help detect if foreign material on the sealing surface caused leakage.

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.

4. Always clean the inside of the housing.

5. Always clean the sealing surface before inserting a new filter element.

6. Inspect the new filter for damage.

7. Insert the new filter properly. Apply pressure to the filter frame not the pleated filter surface.

8. Check connections hoses and tubes for an air tight fit. Ensure that all clamps, bolts and connections are tight. Check rubber elbows for splits or wear points. Leaks in these locations send dust directly to the engine.

NOTE: Refer to diesel engine manufacturer's operation and maintenance manual for more details and additional required maintenance of the Air Cleaner or replacement of the air filter elements.

3.17

Tigercat 250C Loader

Lubrication and Maintenance

CHECKING AIR CONDITIONING SYSTEM

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.

R134a REFRIGERANT

PAG OIL (polyalkylene glycol)

1.25 kg (3 lb 6 oz)

74 mL (2.5 oz)

Any service work must be performed by authorized A/C technicians. The system should be charged with R134a refrigerant. At least the minimum amount of PAG (polyalkylene glycol) oil, shown above, should be present in the system and must be used on O-rings and fittings during assembly.

If using compressed air for cleaning, use at 2 bar (30 psi) or less.

Always use personal protective equipment to guard against flying debris.

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.

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

Clean or replace as required. c. Check to see that compressor clutch will engage. d. Check blower operation and air vents.

A/C COMPRESSOR

250CT-033

e. Check the condenser core for dirt and debris.

A/C COMPRESSOR

3.18

Tigercat 250C Loader

Lubrication and Maintenance

CLEANING COOLER PACKAGE

PROCEDURE:

The A/C condenser core is located on the right side of the machine and is one of the cores in a stack of four that make up the cooler package. The cooling fan is mounted on the front of the engine. The fan draws air from the right side of the machine through the door screen and the cooler package blowing it out of the opposite side of the machine.

CHARGE AIR COOLER 250CT-018

OPEN THE SCREEN DOOR ON R.H. SIDE OF ENGINE COMPARTMENT

RADIATOR

A/C CONDENSER

1. Remove the four capscrews and washers and swing open the screen door on the right side of the engine compartment.

This cooling assembly must be checked daily and may require thorough cleaning on a regular basis depending on operating conditions. Compressed

CAUTION

OIL COOLER

If using compressed air for cleaning, use at 2 bar (30 psi) or less.

Always use personal protective equipment to guard against flying debris.

250CT-019

CHECK CHARGE AIR COOLER, RADIATOR, A/C CONDENSER AND OIL COOLER The cooler package should be manually checked every 8 hours (every shift) or more often where conditions cause accumulation of twigs, leaves, pine needles and dust. All of the engine enclosure doors should also be checked.

air or water may be used for cleaning. Use personal protective equipment to guard against flying debris.

If an oil leak occurs in this area it should be thoroughly power-washed with a mild soap to ensure that all of the oil is removed. The presence of oil causes dust and dirt to cling to surfaces which will impair the reversible fan's ability to remove dust and dirt particles.

Care must be taken when cleaning this assembly, as the components can be damaged by careless handling and cleaning.

3.19

Tigercat 250C Loader

Lubrication and Maintenance

TORQUE CHART LOCATION

THREAD DIAMETER

Hoist Cylinder 41568B Piston nut Gland bolts Stick Cylinder 41795B Piston nut Gland bolts Heel Cylinder 40048B Piston nut Gland bolts Grapple Cylinder 46556B Piston nut Gland bolts Stabilizer Cylinder 40441B Piston nut Gland bolts Boom joint and cylinder pin retaining bolts

TORQUE (LUBRICATED) lbf-ft Nm

M68-2 6H M14-2 (12.9)

4900 129

6644 175

M68-2 6H M14-2 (12.9)

4900 129

6644 175

2"-12 UNF (GC) M14-2 (10.9)

3230 111

4379 149

1 3/4"-12 UNF (GC) 1/2"-13 UNC (G8)

1750 80

2355 108

M60-2 6H M14-2 (10.9)

2100 129

2835 175

3/4"-10 UNC (G8)

282-310

393-420

2"-12 UNF (G8)

400

540

1 3/4"-12 UNF (G8)

400

540

7/8"-9 UNC (G8)

400-450

540-610

1 1/4"-7 UNC (G5)

500

680

7/8"-9 UNC (G8)

400-450

540-610

M20 (12.9)

400

540

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

400-450 75 218

540-610 100 295

M10 (12.9)

40

54

Pump drive Drive plate to flywheel Bell housing to engine

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

33-36 47

45-49 63

Pump mounting Main Pump to Engine Swing Pump to Main Pump

3/4"-10 UNC (G8) M16 (12.9)

315-347 200

427-470 270

Main and Stick boom pin retaining nut Heel to Stick boom pin retaining nut Cab securing bolts

*

Trailer mounting studs Swing bearing bolts

Swing gearbox mounting bolts Engine mounting Bolts, bracket/mount to chassis Bolts, bracket to engine Flex drive coupling hub setscrew Engine cooling fan 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 250C 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

IMPERIAL BOLT TORQUE SPECIFICATIONS GRADE 8 BOLTS GRADE 5 BOLTS LUBRICATED lbf-ft Nm 8 - 10 11 - 13 20 - 28 27 - 38 33 - 36 45 - 49 52 - 57 71 - 77 80 - 88 109 - 119 115 - 127 156 - 172 159 - 175 216 - 237 282 - 310 393 - 420 455 - 501 617 - 679 682 - 750 925 - 1016 966 - 1062 1310 - 1441 1360 - 1496 1844 - 2027 LUBRICATED lbf-ft Nm 10 - 13 14 - 17 18 - 25 25 - 33 37 - 41 50 - 55 58 - 64 79 - 86 90 - 99 122 - 134 128 - 141 174 - 191 180 - 198 244 - 268 315 - 347 427 - 470 501 - 550 679 - 745 746 - 821 1012 - 1113 1083 - 1191 1469 - 1613 1509 - 1660 2046 - 2250 4.8

METRIC

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

8.8

9.8

10.9

4.8

8.8

9.8

10.9

12.9

4.8

8.8

9.8

10.9

12.9

10

5 5

SIZE

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

10

10

5

12.9

10

12.9

12

10

12

METRIC BOLT TORQUE SPECIFICATIONS

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

12.9

12

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

10

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

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

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

M6 M8 M10

4.8 12.0 23.0

3.5 8.5 17.0

6.0 15.0 29.0

4.5 11.0 21.0

9.0 22.0 43.0

6.5 16.0 32.0

11.0 28.0 55.0

8.5 20.0 40.0

13.0 32.0 63.0

9.5 24.0 47.0

17.0 40.0 80.0

12.0 30.0 60.0

15.0 37.0 75.0

11.5 28.0 55.0

19.0 47.0 95.0

14.5 35.0 70.0

M12 M14 M16

40.0 63.0 100.0

29.0 47.0 73.0

50.0 80.0 125.0

37.0 60.0 92.0

75.0 120.0 190.0

55.0 88.0 140.0

95.0 150.0 240.0

70.0 110.0 175.0

110.0 175.0 275.0

80.0 130.0 200.0

140.0 225.0 350.0

105.0 165.0 225.0

130.0 205.0 320.0

95.0 150.0 240.0

165.0 260.0 400.0

120.0 190.0 300.0

M18 M20 M22

135.0 190.0 260.0

100.0 140.0 190.0

175.0 240.0 330.0

125.0 180.0 250.0

260.0 375.0 510.0

195.0 275.0 375.0

330.0 475.0 650.0

250.0 350.0 475.0

375.0 530.0 725.0

275.0 400.0 540.0

475.0 675.0 925.0

350.0 500.0 675.0

440.0 625.0 850.0

325.0 560.0 460.0 800.0 625.0 1,075.0

410.0 580.0 800.0

M24 M27 M30

330.0 490.0 675.0

250.0 360.0 490.0

425.0 625.0 850.0

310.0 650.0 450.0 950.0 625.0 1,300.0

M33 900.0 M36 1,150.0

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

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

3.21

Tigercat 250C Loader

Lubrication and Maintenance

Parker

Assembly Torque The four-bolt port is simply a circular opening (flow passage) surrounded by four tapped holes in a certain pattern for acceptance of the flange clamping bolts. The flat surface of the port compresses the O-ring contained in the groove in the flange head when the clamp bolts are torqued. In some instances, the groove is in the port and not in the flange head. The bolts, through the clamp halves, clamp down the flange head on to the flat surface of the port compressing and trapping the O-ring in the groove and leaving no gap for it to extrude under pressure. The hydraulic pressure is thus sealed by the compressed O-ring as long as the bolts are tightened enough to maintain solid metal to metal contact between the flange head at the outside diameter of the O-ring and the top of the port.

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

• Four bolts and washer

WASHERS BOLTS FLANGE CLAMP

Flange Port Assembly

FLANGE HEAD

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

2. Lubricate the O-ring.

3. Position flange and clamp halves.

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

5. Hand tighten bolts.

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

O-RING TAPPED HOLES

FLANGE.JPG

Fig. T8 – 4 Bolt Split Flange Components

FLANGE2.JPG

Fig. T9 – Flange Bolt Tightening Sequence

Dash Size

Flange Size

Inch Bolt (J518)

Torque lbf-ft

Metric Bolt (ISO 6162)

Torque Nm

Dash Size

Flange Size

Inch Bolt (J518)

Torque lbf-ft

Metric Bolt (ISO 6162)

Torque N-m

8 12 16 20 24 32 40 48 56 64 80

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

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

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

M8 M10 M10 M12 M12 M12 M12 M16 M16 M16 M16

25 49 49 85 85 135 95 220 220 220 220

8 12 16 20 24 32

1/2 3/4 1 1 1/4 1 1/2 2

5/16-18 3/8-16 7/16-14 1/2-13 5/8-11 3/4-10

17 +/- 2 30 +/- 4.5 46 +/- 4.5 69 +/- 6 125 +/- 8 208 +/- 20

M8 M10 M12 M14 M16 M20

25 49 85 135 210 425

* Does not meet ISO 6162 specification.

Table T7 – Code 62 Flange Recommended Bolt Torque

3.22

Tigercat 250C Loader

Lubrication and Maintenance

Parker

Assembly Torque

JIC 37 Degree Flare SAE Dash Size

Thread Size

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

NPTF

Tube Connection Swivel or Hose Connection FFWR FFWR

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

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

SAE Dash Size

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

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

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

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

Thread Size

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

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

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

BSPT

Tube Connection Swivel or Hose Connection FFWR FFWR

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

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

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

O'ring Face Seal / Seal-Lok SAE Dash Size

Tube Connection Swivel or Hose Connection TFFT TFFT

Thread Size

SAE Dash Size

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

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

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

Thread Size

Tube Connection Swivel or Hose Connection TFFT TFFT

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

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

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

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

SAE J1926 Straight Thread Port Assembly Torques ASSEMBLY TORQUE = 10 % -0 SAE DASH SIZE

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

THREAD SIZE

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

Nm

TRIPLE-LOK FERULOK PIPE FITTINGS lbf-ft Nm (lbf-in)

20 20 20 40 46 80 135 185 235 270 340 415 510

(85) (155) (260) (280) (350) (620) 85 135 175 200 250 305 375

SEAL-LOK lbf-ft (lbf-in) (310) (310) (310) (360) (420) 60 100 135 175 200 250 305 375

PLUGS

ADJUSTABLE

NON-ADJUSTABLE

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

SEAL-LOK lbf-ft (lbf-in) (310) (310) (310) (360) (420) 60 100 135 175 200 250 305 375

3.23

Nm 20 20 20 40 46 80 135 185 235 270 340 415 510

TRIPLE-LOK FERULOK PIPE FITTINGS lbf-ft Nm (lbf-in) (60) 7 (100) 11 (180) 20 (250) 28 (350) 40 (620) 70 85 115 135 183 175 237 200 271 250 339 305 414 375 509

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

Nm 3.5 6 13.5 19 46 80 135 185 235 270 340 415 510

HEX HEAD P5ON-S lbf-ft (lbf-in) (85) (155) (260) (280) (350) (620) 85 135 175 200 250 305 375

Nm 10 18 29 32 40 70 115 183 237 271 339 414 509

Tigercat 250C Loader

Lubrication and Maintenance

EATON Aeroquip

Assembly Torque

Recommended Parallel Connection Assembly torque

Eaton recommends that a Torque wrench be used to assure proper fitting assembly of these connections.

Straight Thread O-Ring Boss Low Pressure with 37º (SAEJ514)

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

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

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

The values listed are for steel connections. Contact Teaton for torque values for other materials.

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

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

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

ORS

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

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

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

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

SAE 37º (JIC) Thread Size (inches) 9/16-18 11/16-20 13/16-16 1-14 1 3/16-12 1 7/16-12 1 11/16-12 2-12

Swivel Nut Torque lb.-ft.

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

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

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

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

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

Swivel Nut Torque lb.-ft.

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

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

BSPP Straight Adapter or Locknut Torque lb.-ft.

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

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

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

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

3.24

Tigercat 250C Loader

Lubrication and Maintenance

PRESSURE SETTINGS Engine rpm...........................................................................1875 rpm 900 rpm

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

Pilot System Main Relief ................................. 34.5 bar (500 psi) + 1/2 turn in

@ Idle

Main Valve High Pressure Limiting Control MAIN PUMP P.O.R. (‘PX’ port)........................310 bar (4500 psi) Margin Pressure (‘PX’ – ‘LS’)............................. 26 bar (375 psi)

@ Full throttle @ Idle

Main Valve Port reliefs Hoist DOWN................................................................................

Hoist UP......................................................................................

Stick IN........................................................................................

Stick OUT....................................................................................

Feed Reducer Live Heel Retract............... *227.5 bar (3300 psi) Feed Reducer Live Heel Extend.............. * 227.5 bar (3300 psi) Feed Reducer Grapple OPEN...................... *172 bar (2500 psi) Feed Reducer Grapple CLOSE.................... *241 bar (3500 psi) Feed Reducer Saws RETRACT................. * 172 bar (2500 psi) Feed Reducer Saws CUT............................ * 172 bar (2500 psi) Feed Reducer Grapple Rotate CCW............ *121 bar (1750 psi) Feed Reducer Grapple Rotate CW............. * 121 bar (1750 psi) Feed Reducer Delimber OPEN................... * 172 bar (2500 psi) Feed Reducer Grapple Saw (Option) *2017 bar (3000 psi) Feed Reducer Stabilizer UP *138 bar (2000 psi) Feed Reducer Stabilizer DOWN * 2017 bar (3000 psi) Note: Pressures set at Idle unless otherwise specified. * Set pressure with gauge on 'PL' port

Mode 3, 8 Seconds @ Full throttle Mode 3, 8.5 Seconds @ Full throttle Mode 3, 5.5 Seconds @ Full throttle Mode 3, 5.25 Seconds @ Full throttle Mode 3, 3 Seconds @ Full throttle Mode 3, 4 Seconds @ Full throttle

Swing Pump Charge Pressure........................................................24 bar (350 psi) Pump POR ............................................................310 bar (4500 psi) Plus 1/2 turn @ Full Throttle HIGH PRESSURE RELIEF Swing CCW................352 bar (5100 psi) HIGH PRESSURE RELIEF Swing CW..................352 bar (5100 psi) Swing machine slowly 5 times in each direction before setting pressures. Do not hold pressure over relief more than 8 seconds at a time. Wait 5 seconds to avoid overheating.

Note: Pressures set at Idle unless otherwise specified.

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.

3.25

Tigercat 250C Loader

Lubrication and Maintenance

Weights of Commercial Wood

Species

kg/m3

lb/ft3

Species

kg/m3

lb/ft3

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

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

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

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

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

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

Note: The values shown here are green weights.

3.26

Tigercat 250C Loader SECTION 4 – HYDRAULIC SYSTEM CONTENTS – SECTION 4

JUNE, 2014

C

COMPARISON OF OPEN CENTER TO CLOSED-CENTER CLOSED-CENTER SYSTEM............................................................................................................... 4.10 OPEN-CENTER SYSTEM...................................................................................................................... 4.9 OPERATING TIPS................................................................................................................................ 4.11

H

HYDRAULIC OIL RESERVOIR.................................................................................................................. 4.3 CHANGING OR CLEANING THE STRAINER/DIFFUSERS.................................................................. 4.5 HYDRAULIC TANK VACUUM SYSTEM................................................................................................. 4.3 ELECTRICAL OVERVIEW.................................................................................................................. 4.4 SYSTEM CHECKS.............................................................................................................................. 4.4 TROUBLESHOOTING........................................................................................................................ 4.4 VACUUM SYSTEM ELECTRICAL SCHEMATIC................................................................................ 4.4 HYDRAULIC PUMPS................................................................................................................................. 4.6 MAIN PUMP............................................................................................................................................4.7 MAIN PUMP CONTROLLER ADJUSTMENT......................................................................................... 4.7 MAIN PUMP LS VALVE SETTING....................................................................................................... 4.14 SWING PUMP........................................................................................................................................ 4.7 HYDRAULIC RETURN FILTERS............................................................................................................. 4.20 HYDRAULIC SYSTEM OPERATION......................................................................................................... 4.2 PILOT CIRCUIT...................................................................................................................................... 4.2 SWING SYSTEM.................................................................................................................................... 4.2 L

LOAD SENSING........................................................................................................................................ 4.8 BASIC PRINCIPALS............................................................................................................................... 4.8 COMPARISON OF OPEN CENTER TO CLOSED-CENTER................................................................. 4.9 FLOW-ON-DEMAND AND LOAD COMPENSATION........................................................................... 4.12 LOAD SENSING SYSTEM CIRCUIT DIAGRAM.................................................................................. 4.12 SET MARGIN PRESSURE................................................................................................................... 4.13 M

MAIN CONTROL VALVE.......................................................................................................................... 4.16 COUNTER-PRESSURE VALVE........................................................................................................... 4.16 DESCRIPTION..................................................................................................................................... 4.16 END SECTION..................................................................................................................................... 4.17 FEED REDUCTION VALVES............................................................................................................... 4.17 HIGH PRESSURE LIMITING CONTROL............................................................................................. 4.19 INLET SECTION................................................................................................................................... 4.16 LOAD SENSING SYSTEM................................................................................................................... 4.16 MAIN CONTROL VALVE FUNCTIONS................................................................................................ 4.18 MAIN CONTROL VALVE SCHEMATIC................................................................................................ 4.16 MAIN PRESSURE RELIEF VALVE...................................................................................................... 4.16 PILOT PRESSURE SUPPLY................................................................................................................ 4.16 PORT RELIEF VALVES........................................................................................................................ 4.17 PRESSURE COMPENSATION............................................................................................................ 4.17 SPOOLS............................................................................................................................................... 4.17 SPOOL SECTIONS.............................................................................................................................. 4.17 MAIN HYDRAULIC CIRCUIT OVERVIEW................................................................................................. 4.2

Tigercat 250C Loader

Hydraulic system

MAIN HYDRAULIC CIRCUIT OVERVIEW The hydraulic circuit main piston pump supplies oil to the load sense system operating the stabilizers, hoist, stick, grapple open/close, rotate and the saw functions.

The control valve is a seven-section plus mid inlet section, sectional valve. A load sense signal is sent from the (PL) port to the pump controller whenever one of the functions is activated. The spool for that function supplies oil to the circuit.

When all spools are in neutral, no oil is flowing through the valve and hence the system is closed center. The pump maintains a standby pressure of approximately 34 bar (500 psi) and supplies just enough oil to make up for leakage. The hoist, stick, saw, grapple rotate and grapple clamp valve sections use a cylinder spool that traps oil in the circuit when the spool is in neutral. The stabilizers, grapple saw and delimber close valve sections use a motor spool that has a passage between the work ports and the return passage to tank when the spool is in neutral.

HYDRAULIC SYSTEM OPERATION The hydraulic system has two separate circuits: 1. Variable displacement swing drive closed loop hydraulic circuit with internal charge pump.

2. Variable displacement main hydraulic circuit for the boom hoist and stick/delimber/slasher/ grapple open/close, rotate and stabilizer.

The pilot circuit is supplied oil by the main pump through the main hydraulic control valve.

This is a closed center system utilizing a variable displacement axial piston pump with load sensing and horsepower limiting control. The load sensing system ensures that the pump delivers only the amount of oil 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 in this section.

The horsepower limiting control ensures that the engine does not lug down below the full load rpm, by reducing the output from the main hydraulic pump. Refer to ENGINE ANTI-STALL description in Section 9.

4.2

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

SWING SYSTEM This closed loop circuit uses a variable displacement piston pump that delivers oil to the swing motor and back to the pump. A foot pedal operated pilot valve located in the cab directs pilot oil to the swing pump controller.

The internal charge pump provides make up oil to keep the swing pump charged as well as provide cooling and lubricating oil for the pump.

The swing motor is a bent axis piston type that is bolted to the swing gearbox. The gearbox is a double reduction planetary gear unit. This provides continuously variable swing speeds up to 9 rpm. A rotary manifold provides hydraulic connection to the undercarriage or lower frame and permits continuous 360° swing.

PILOT CIRCUIT The pilot circuit is supplied with oil from the main pump through the main control valve. The pilot system is turned on and off by the pilot shut off valve, located on the pilot manifold. The system is controlled by the armrest switch and the pilot reset button. Refer to PILOT SYSTEM description in Section 5.

Tigercat 250C Loader

Hydraulic system DUAL FILTER HEADS (2)

RESERVOIR BREATHER RETURN MANIFOLD

RETURN FILTERS (4) RETURN TUBES

CASE DRAIN STRAINER

OIL LEVEL SIGHT GAUGE 250C-008 250C-009

STRAINER/ DIFFUSER

HYDRAULIC RESERVOIR

HYDRAULIC OIL RESERVOIR

TANK DRAIN

ACCESS COVER WITH O-RING SEAL

HYDRAULIC TANK VACUUM SYSTEM (OPTIONAL)

The hydraulic reservoir is located at the left-hand rear corner of the machine.

VACUUM SWITCH

Hydraulic oil is drawn from the tank by the pumps through the suction hoses and tubes at the base of the tank. 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 2 bar (25 psi) which opens in the event the elements become restricted. A strainer/ diffuser is attached to the end of each of the 2 return tubes in the tank. These reusable return strainers have a 250 micron particle retention, screening oil as it re-enters the tank.

250C-024

VACUUM SWITCH

A rocker switch with an indicator light is located on the side panel in the cab. The light is on when the vacuum system is activated. The vacuum pump only operates when the ignition key is in the OFF position, and the engine does not crank.

Alternatively, the engine does not crank if the vacuum pump is on. The system does not operate if the battery disconnect switch is in the OFF position.

Case drain oil from the main pump, swing pump, swing motor and pilot return lines go through a spin-on case drain strainer before returning to tank.

Refer to SECTION 2 of the OPERATOR'S MANUAL for additional service information.

When activated, the vacuum pump system pumps out tank air through a one-way check valve creating a vacuum that holds the oil in the reservoir. This system eliminates the need to drain the hydraulic tank beforehand, when servicing pumps and other hydraulic components.

Do not use the vacuum pump when changing hydraulic filters. Using the vacuum pump system while changing filters creates the risk of introducing much more air into the hydraulic system.

4.3

Tigercat 250C Loader

Hydraulic system TROUBLESHOOTING If the pump fails to operate, check the line fuse in wire 130 near the fuse blocks in the main electrical panel in the cab. If the fuse is OK, check the voltage at wire 135 at the pump motor.

If voltage is present, check the motor wiring connections and the motor itself. If no voltage is present, perform the checks below.

The vacuum system can be used when changing the case drain strainer.

ELECTRICAL OVERVIEW The rocker switch connects the voltage on wire 130 to wire 139. The current flows to the relay (#32) coil that then shifts the relay and allows current to flow from wire 135 to the pump motor.

The pump cycles on and off to maintain a vacuum of 31 kPa (9 in. of Hg) in the tank.

If the pump does not run with the vacuum switch depressed, check voltage at wire 139 in the main panel. If no voltage is present, check the vacuum switch and wiring connections. If voltage is present at wire 139, remove relay #32 and check for voltage at pin 30 and pin 85. If voltage is not present at pin 30, check fuse and wiring. If voltage is present at pin 85 and the pump doesn’t run, replace relay #32 with a new relay. If voltage is not present at pin 85, check the operation of the vacuum switch. Remove the DIN connector from the vacuum switch and check for voltage at wire 139. If there is voltage at wire 139, check the vacuum switch. There should be continuity between pin 1 and 2 if there is no vacuum in the tank. If there is no continuity, replace the vacuum switch.

SYSTEM CHECKS • With ignition switch ON and vacuum switch OFF, verify engine cranks. This procedure is a starting system check.

• With vacuum switch ON, verify the pump operates only when the ignition switch is in the OFF position, and the engine does not crank.

• With the pump operating, check that the one-way valve is displacing an air charge.

The pump cuts-out between the 2 – 3 minute mark. After the pump cuts-out, verify that the vacuum is held in the tank by leaving the switch in the ON position. Wait to see if the pump cuts-in. If it does, check for possible leaks.

TAN

135 TAN 139A

3

TAN 139

7 TAN

250C-007

TAN

TAN 17

VACUUM SYSTEM ELECTRICAL SCHEMATIC

4.4

Tigercat 250C Loader

Hydraulic system

CHANGING OR CLEANING THE STRAINER/ DIFFUSERS The strainer diffuser requires no regular maintenance over the life of the machine. This element only requires maintenance in the case of damage or contamination due to a hydraulic pump or motor failure.

Procedure: 1. Position machine on flat level ground with stabilizers down and grapple resting on the ground.

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

3. Drain the hydraulic tank by removing the drain plug in the bottom of the tank.

The strainer/diffusers should be checked whenever the hydraulic tank is drained. Refer to SERVICE AND LUBRICATION POINTS in Section 3.

4. Remove the access cover and O-ring.

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

IMPORTANT! The strainer element is not a filter element.

Always use the correct replacement element. Use of an incorrect (filter type) element results in pump damage.

6. Remove the strainers using the hex on the top of the strainer. Carefully clean the strainers.

Avoid rough handling to prevent damage.

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

Changing or cleaning the strainer/diffusers should be performed in the event of a pump failure or hydraulic oil contamination.

8. Reinstall the strainers using the hex end.

9. Reinstall access cover with a new O-ring.

10. Refill the reservoir using the hand fill pump.

NOTE: Changing strainer/diffusers and replacing the hydraulic oil tends to aerate the oil. For maximum pump life, run the vacuum pump for 1 hour after servicing. This helps to remove entrained air from the oil prior to applying working pressures to the pumps.

ACCESS COVER

STRAINER/ DIFFUSER 250C-008

TANK DRAIN

4.5

Tigercat 250C Loader

Hydraulic system

ENGINE BELL HOUSING

MAIN PUMP

SWING PUMP

250B-035

HYDRAULIC PUMPS

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

ELECTRONIC DISPLACEMENT SOLENOID VALVE

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

PUMP 'LS' RELIEF VALVE

For information on the hydraulic circuits that these pumps are part of, refer to HYDRAULIC SYSTEM OPERATION in this section.

'LS' MARGIN PRESSURE ADJUSTING SCREW

250BT-008

4.6

MAIN PUMP CONTROLLER

MAIN PUMP CONTROLLER

Tigercat 250C Loader

Hydraulic system

360 L/M (95 GPM)

PUMP 'LS' RELIEF VALVE 'LS' MARGIN PRESSURE ADJUSTING SCREW

250C-054

MAIN PUMP CONTROLLER ADJUSTMENT

MAIN PUMP

250C-018

Refer to LOAD SENSING – SET MARGIN PRESSURE in this section.

The main pump is an axial-piston, variable displacement pump with load sensing (LS), pressure compensating, and horsepower limiting controls.

At this point the LS control valve shifts back to its previous condition and the swashplate control piston is 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.

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 approximately 34 bar (500 psi) in the pump output line. The swashplate control piston is in a condition where the spring, swashplate and the control pressure forces are balanced.

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

MARGIN PRESSURE When a control lever is moved to activate that 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 is protected by a high pressure limiting control which is attached to the main control valve manifold. Refer to MAIN CONTROL VALVE – HIGH PRESSURE LIMITING CONTROL in this section.

The pump then adjusts its output volume until the pump output pressure exceeds the LS pressure, by a small amount. This difference is known as MARGIN PRESSURE (also known as differential pressure or Delta P).

SWING PUMP For the operation and adjustments of this pump, refer to SECTION 15.

4.7

Tigercat 250C Loader

Hydraulic system

LOAD SENSING BASIC PRINCIPALS (Figures 1 and 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.

FLOW

W USED 853SM18

PRESSURE

FIXED DISPLACEMENT PUMP

853SM16

FIG. 2

FIG. 1

HP =CO

(Figures 3 and 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 horsepower, oil flow over the relief valve is less, therefore reducing the wasted power losses and heat generation.

WASTED

WASTED

FLOW

(Figures 5 and 6) The load control system was developed to address the problems outlined above. This system combines the energy saving benefits of flow-on-demand with load compensation at each work port. The compensator eliminates the need for operator flow adjustments (throttling).

ANT NST

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.

W

USED 853SM19

FIG. 3

HP REGULATED PUMP

FIG. 5

PRESSURE 853SM16

FIG. 4 FIG. 6

HP

FLOW

NT

STA ON

=C

∆p LS W USED PRESSURE

853SM17

LOAD SENSING (FLOW ON DEMAND) 4.8

853SM16

Tigercat 250C Loader

Hydraulic system

COMPARISON OF OPEN CENTER TO CLOSED-CENTER OPEN-CENTER SYSTEM

853SM21

853SM20

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

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 changes.

2. If the load increases on a boom cylinder, the boom slows or stops. Moving the lever further increases the pressure against the load, and when high enough, the load begins 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.

4.9

Tigercat 250C Loader CLOSED-CENTER SYSTEM Load sensing systems use variable flow pumps and only flow oil when required. Unlike the open center system, the control valve does not have an open center 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 21 bar (300 psi) higher than the load pressure to compress the spring and reduce the flow of the pump. This 21 bar (300 psi) is the differential or margin pressure.

Hydraulic system of the stroking piston. The stroking piston then adjusts the flow of the pump to find a new balance point. The stroking piston changes the pump’s flow until pump pressure is 21 bar (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 maintains 21 bar (300 psi) of stand-by pressure and pump flow is zero.

853sm22

The following are key differences from opencenter systems:

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 21 bar (300 psi) that was holding the spring in the compressed state is reduced and the spring moves the pump to increase flow. Flow increases to a level that requires 21 bar (300 psi) to force the oil through the valve opening. At this point the load pressure combined with the spring force is high enough to oppose the pump output pressure, and the stroking piston stops moving.

Changing the control valve lever changes the size of the opening in the valve and upsets the balance 4.10

4. The load sensing valve maximum flow is not equal to the pump maximum flow as with the open-center system. The valve maximum flow is determined by the maximum size of orifice it provides.

5. The speed of the load does not change as the load changes. If the load increases on a boom cylinder, the pump pressure increases 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 does not increase the lifting force.

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

Tigercat 250C 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 provides 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 center systems responded to larger lever angles with increased boom speeds, but this system does 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 LOAD SENSING – 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.

4.11

Tigercat 250C 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 is delivered to a function by the pump. This saves energy and reduce heat generation in the hydraulic system. Load compensation means that all functions continue to receive oil regardless of their pressure, and without further movement of the control levers.

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.

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 automatically adjust flow according to the pilot pressure applied to the spool to move functions, independent of load pressure.

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.

To make both functions move the operator would

MAIN PUMP

TEST PORT

PILOT PRESSURE SIGNAL TEST PORT

PILOT SOLENOID VALVE

T2

G

P3

P2 T3

C

B

INLET

P1

A T1

PRESSURE TRANSDUCER MAIN DIRECTIONAL CONTROL VALVE

FLOW PILOT FILTER

PL TEST PORT 250C-047

LOAD SENSING SYSTEM CIRCUIT DIAGRAM 4.12

SWING PUMP

'LS' SIGNAL

Tigercat 250C Loader

Hydraulic system

LOAD SENSE RELIEF ADJUSTING SCREW (TURN OUT TO DECREASE PRESSURE)

MARGIN PRESSURE ADJUSTING SCREW (TURN OUT TO DECREASE PRESSURE)

MAIN PUMP CONTROL VALVE

250BT-012A

SET MARGIN PRESSURE

LOAD SENSE PRESSURE

Margin pressure is set at the factory to 26 bar (375 psi). If required, it can be adjusted as follows:

Margin Pressure is the difference between the load sense pressure and the pump output pressure, with engine at Idle and pilot circuit engaged. For the load sensing system to operate correctly, the differential pressure at (PX) should be 26 bar (375 psi) higher than (LS).

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

NOTE: If the margin pressure is not set correctly, the machine controls response may be jerky or sluggish.

ELECTRONIC DISPLACEMENT SOLENOID VALVE

250C-048

A

PUMP LS RELIEF VALVE

LS PX 'LS' MARGIN PRESSURE ADJUSTING SCREW 250BT-008

PL MAIN PUMP CONTROLLER

MAIN PUMP CONTROLLER

The margin pressure adjustment is made at the main pump controller attached to the main pump.

The pressure gauge connections are the (PL) and (PX) gauge test ports on the main valve inlet section.

VIEW A

250C-049

4.13

MAIN VALVE TEST PORTS – INLET SECTION

Tigercat 250C Loader

Hydraulic system MAIN PUMP LS RELIEF VALVE SETTING

CAUTION

ELECTRONIC DISPLACEMENT SOLENOID VALVE

Use caution when in the cab as a slight touch of the controls can cause sudden machine movement

PUMP LS RELIEF VALVE

CAUTION Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

'LS' MARGIN PRESSURE ADJUSTING SCREW 250BT-008

WARNING

MAIN PUMP CONTROLLER

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

MAIN PUMP CONTROLLER

2. Use a differential pressure gauge with a differential gauge with 0.5 bar (10 psi) increments.

CHECKING LS RELIEF VALVE SETTING For system pressure values, refer to PRESSURE SETTINGS in Section 3.

3. With hydraulic oil at operating temperature, connect one side of the differential pressure gauge to the (PL) gauge test port located on the inlet section of the main control valve and the other side of the gauge to the pressure (PX) gauge test port.

NOTE: The main and port relief valves are not adjustable. The following procedure is for checking main pump LS relief valve pressure only.

1. Position machine on flat level ground.

4. Start the engine and set engine speed to low idle.

5. Turn the Anti-stall system OFF. 6. Press PILOT RESET button to activate pilot system.

'PX' TEST PORT 'PL' TEST PORT

7. Observe gauge.

8. Loosen locknut on margin pressure adjusting screw on main pump controller. Turn adjusting screw until the differential reading on gauge is 26 bar (375 psi). Turn CCW to decrease Margin Pressure. Turn CW to increase.

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

250C-031

MAIN VALVE TEST PORTS

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

IMPORTANT! This is a sensitive adjustment, significant changes in pressure are noticed with only a small movement of the adjusting screw.

3. Connect a 0–350 bar (0–5000 psi) pressure gauge to the (PL) valve test port on the inlet section of the main control valve.

9. Allow a short time for pressure reading to stabilize, then re-tighten locknut on adjusting screw.

4.14

Tigercat 250C Loader

Hydraulic system

4. Start the engine and put the throttle control at high idle position. Lower left arm rest and depress the pilot reset switch to activate the pilot system.

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

5. While holding the L.H. joystick in the hoist up position (fully extended), check gauge pressure reading. Refer to PRESSURE SETTINGS – MAIN VALVE HIGH PRESSURE LIMITING CONTROL in Section 3 for pressure value.

While holding the L.H. joystick in the hoist down position (fully retracted), check gauge pressure reading. Refer to PRESSURE SETTINGS – MAIN VALVE HIGH PRESSURE LIMITING CONTROL in Section 3 for pressure value.

If pressure is less than set value in one direction but OK in the other direction, the port relief valve for the low reading circuit is malfunctioning. Replace the port relief valve.

If pressure is less than set value in both directions, turn pump LS relief valve adjusting screw in (the pressure reading should increase if the value was set too low) until set value is obtained on gauge.

If adjusting the LS relief setting and the pressure does not change, the main relief is malfunctioning and should be replaced.

PUMP LS RELIEF VALVE MARGIN PRESSURE ADJUSTING SCREW 250C-071

MAIN PUMP CONTROLLER

MAIN PUMP CONTROLLER

6. If LS relief valve was adjusted after checking pressures, reset to correct value. Tighten locknut while making sure the adjusting screw does not turn.

4.15

Tigercat 250C Loader

Hydraulic system

MAIN CONTROL VALVE

MAIN PRESSURE RELIEF VALVE The mid-inlet section of the main valve houses a 330 bar (4785 psi) direct acting port relief. This pressure relief valve is intended to protect the main pump and main valve from pressure spikes in the system. The cartridge also has a makeup function that allows oil to flow from the tank gallery to the pump gallery in the event of reduced pressure in the pump circuit. The relief cartridge is not adjustable.

DESCRIPTION The main control valve is located in the upper frame. It can easily be accessed by removing the valve compartment cover deck plate on the lefthand side of the upper frame.

The main valve is a load-sensing and pressure compensated proportional valve and consists of seven spool sections. The number of sections in the valve varies with options installed. The valve also includes an Inlet Section, and two End Sections.

LOAD SENSING SYSTEM Shuttle valves installed in each spool section of the main valve provide the load sense signal from the main valve function sending the highest pressure signal. The load sense signal is sent from the (PL) port in the main valve to (PL) port on the main pump.

INLET SECTION The inlet section is equipped with connection ports to the main pump, tank, and load sense signal (LS) to the main pump. Integrated into the inlet section are the main valve main pressure relief, a load sense signal copy valve, and a counter-pressure valve.

COUNTER-PRESSURE VALVE The counter-pressure valve, housed in the inlet section, raises the pressure in the valve’s tank gallery. Raising the counter-pressure reduces the risk of cavitation damage (which decreases the risk of damaging cylinder seals).

PILOT PRESSURE SUPPLY Pilot pressure supply is provided as an internal function of the Main Valve. Pressure is regulated internally to 35 bar (508 psi).

250C-011

MAIN CONTROL VALVE SCHEMATIC

4.16

Tigercat 250C Loader

Hydraulic system

END SECTION The end section is equipped with a separate tank connection for the pilot circuit. The main tank gallery in the boom valve and the pilot circuit tank gallery are not connected. The (T1) port is connected to the return filter manifold.

SPOOL SECTIONS All of the main valve spool sections are equipped with proportional, electro-hydraulic spool actuators. The actuators are spring centered to the neutral position, and are shifted by sending a 24-volt proportional current signal to the appropriate solenoid.

SPOOLS Each of the spools installed in the main valve is selected specifically for the function it is controlling. For example, the hoist boom section spool has different characteristics than the stabilizer spool. These spools cannot be interchanged.

PRESSURE COMPENSATION The primary purpose of pressure compensation is to maintain a constant flow rate to functions (maintain the same speed of movement), regardless of pressure variations in the system.

The pressure compensator also contains a load-hold check valve. An orifice is installed immediately down stream of the pressure compensator to smoothly regulate the response of the compensator.

250C-055

LS CONTROL & VALVE SECTION SCHEMATIC

FEED REDUCTION VALVES Feed reduction valves, also known as POR (Pressure Override) valves, are installed in the Grapple Open/Close, Grapple Rotate, Saws Cut/ Retract, Delimber Open, Grapple Saw Option and Stabilizer sections of the main valve. The purpose of the feed reduction is to limit the maximum pressure for those functions flowing oil over relief

PORT RELIEF VALVES The main valve is equipped with port reliefs on each side of all spool sections except the track drive sections. The function of the port relief is to protect the valve and the function cylinder or motor from pressure spikes in the system. The port reliefs also act as anti-cavitation valves, which means they allow oil to flow from the tank gallery in the valve to the service ports in the event of reduced pressure. The port reliefs cannot be adjusted.

IMPORTANT! Port relief valves installed in each section are specifically designed for use in that section only, and must not be interchanged with those in other valve sections.

4.17

Tigercat 250C Loader STICK IN/OUT SECTION

Hydraulic system

GRAPPLE OPEN/ CLOSE SECTION

GRAPPLE ROTATE SECTION

SAW CUT/ RETRACT SECTION

DELIMBER OPEN GRAPPLE SAW CUT OPTION SECTION

STABILIZER UP/ DOWN SECTION

UP

B

A

A

A DOWN

B

CUT

B

B

OPEN

B

CW

B

B

CCW

CUT

A

RET

CLOSE

A

OPEN

OUT

A

IN

A

DOWN

UP

HOIST UP/DOWN SECTION

UP FEED REDUCER DELIMBER OPEN FEED REDUCER

DOWN FEED REDUCER

A A

SAW CUT FEED REDUCER

GRAPPLE B CLOSE FEED REDUCER GRAPPLE OPEN FEED REDUCER 250C-048

234-072

GRAPPLE ROTATE FEED REDUCER BOTH DIRECTIONS

B

SAW RETRACT FEED REDUCER

MAIN CONTROL VALVE FUNCTIONS

MAIN CONTROL VALVE 4.18

GRAPPLE SAW CUT OPTION FEED REDUCER

Tigercat 250C Loader

Hydraulic system

HIGH PRESSURE LIMITING CONTROL

NOTE: (PL) and (LS) are the same pressure.

The (PL) port located on the bottom of the inlet section, is equipped with a test fitting for testing LS pressure.

The main pump is protected by an LS relief valve.

Measure this pressure with a gauge at (PX) test port on the inlet section of the main valve.

See LOAD SENSING – SET MARGIN PRESSURE in this section.

The differential pressure between (PX) port pressure and (PL) port pressure is known as Margin Pressure. It is observed while a function is operating.

250C-012

For information on system pressure values, refer to PRESSURE SETTINGS in Section 3.

SCHEMATIC DIAGRAM OF 'LS' CONTROL and VALVE SECTION 4.19

Tigercat 250C Loader

Hydraulic system

HYDRAULIC RETURN FILTERS

RETURN MANIFOLD

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 (blue) filter in place to assist with the removal of moisture from the hydraulic oil. The filters are rated 10 micron absolute.

Each filter head has a bypass valve with a 1.7 bar (25 psi) cracking pressure so that oil can bypass the filters if they become restricted.

The in side of the filter heads are connected to a return manifold. A filter restriction indicator and an oil sampling connector are mounted onto the manifold.

1-WATER ABSORBING (BLUE) RETURN FILTER

Check the condition of the filter elements with the hydraulic oil at normal operating temperature.

Place engine throttle control to FULL. With no machine functions operating, the filter restriction indicator should be in the GREEN zone. If the indicator is in the RED zone, replace all filter elements.

358-17

4.20

DOUBLE FILTER HEADS

3-HYDRAULIC RETURN FILTERS

HYDRAULIC RETURN FILTERS

Tigercat 250C Loader SECTION 5 – PILOT SYSTEM CONTENTS – SECTION 5

JUNE, 2014

PILOT SYSTEM COMPONENTS............................................................................................................... 5.2 FOOT PEDAL PILOT VALVE.................................................................................................................. 5.3 GENERAL DESCRIPTION..................................................................................................................... 5.2 PILOT CIRCUIT DIAGRAM.................................................................................................................... 5.4 PILOT MANIFOLD VALVE...................................................................................................................... 5.2 PILOT SUPPLY VALVE........................................................................................................................... 5.2 PILOT SYSTEM ELECTRICAL CIRCUIT DIAGRAM............................................................................. 5.4 PILOT SYSTEM FILTER......................................................................................................................... 5.2 SET PILOT PRESSURE............................................................................................................................ 5.5

Tigercat 250C Loader

Pilot system

PILOT SYSTEM COMPONENTS

GAUGE TEST PORT

GENERAL DESCRIPTION The pilot circuit oil supply comes from the main pump through the main directional control valve.

A pilot supply valve located within the main valve, reduces and maintains pilot circuit oil pressure.

Pilot circuit oil passes through the pilot pressure filter, and then to the pilot manifold valve. The pilot manifold valve spools are solenoid-operated to supply oil to the various pilot-actuated functions of the machine. A foot pedal distributes pilot oil to shift the swing pump control valve, signaling the pump to supply oil to the selected swing direction.

PILOT MANIFOLD

PILOT RELIEF VALVE 250BT-011

PILOT MANIFOLD VALVE

PILOT MANIFOLD VALVE The pilot manifold valve is located below the floor plates in the hydraulic valve compartment. This valve distributes oil to the following circuits:

PILOT SUPPLY VALVE (Pressure reducing/relieving valve) The pilot supply valve is a pressure-reducing relief valve built into the mid-inlet section of the main control valve. The reducing/relieving valve is not adjustable. Refer to SET PILOT PRESSURE in this section.

• Swing control foot pedal

(P1) port

• Gauge test port

(P3) port

• Spare

(A) solenoid valve

• Delimber Open Hold

(B) solenoid valve

• Spare

(C) solenoid valve

Pilot oil enters the manifold valve through the Inlet Port.

The Pilot Shut-off Valve controls the flow of oil from the inlet port to the outlet ports (labeled P1, P2, P3, and G) and to the solenoid-operated pilot valves. The Pilot Shut-off Valve is activated by pressing the Pilot Reset switch (located on the control panel in the cab). The left-hand seat armrest must first be completely lowered.

LOCATED LOWER LEFT SIDE OF ENGINE COMPARTMENT

Two outlet ports (P1 and P2) on each end of the pilot manifold valve, feed the main control valve (PS) port and the swing foot pedal valve. A gauge test port (P3) has a quick disconnect fitting installed to connect a pressure gauge.

PILOT FILTER ELEMENT

250B-016

PILOT SYSTEM FILTER

The solenoid operated pilot valve spools supply on-demand pilot oil to the corresponding functions. These valves are activated by controls in the cab. Two of the valve sections are spares.

PILOT SYSTEM FILTER This cartridge-type filter has a built-in differential pressure relief valve. If the pressure differential at the oil filter exceeds 3.5 bar (50 psi), this valve bypasses the pilot oil back to the tank. This also results in lower pilot pressure. If a loss of control or slow response is experienced, the filter element may need to be changed.

Tank ports (T1 and T2) collect oil from all pilot controls. Tank port (T3) drains the return oil to the reservoir.

5.2

Tigercat 250C Loader

(P2) TO MAIN VALVE

Pilot system

GAUGE TEST SPARE DELIMBER PORT OPEN

PILOT SHUT OFF VALVE

SPARE

(P1) TO MAIN VALVE 'PS'

INLET PILOT RELIEF VALVE

(T2) RETURN OIL TO TANK 250C-013

(T1) RETURN OIL TO TANK

PILOT MANIFOLD VALVE

FOOT PEDAL PILOT VALVE This pilot valve is a manually foot-operated, directional control valve. It operates on the same principle as a direct operating, pressure reducing valve. This valve direct pilot oil to the swing pump controller. The controller changes the swash plate angle of the pump causing the machine to swing.

1 5

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

3 TANK PORT

4 8

2

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

WORK PORT AW017

5.3

PRESSURE PORT

WORK PORT

FOOT PEDAL PILOT VALVE

Tigercat 250C Loader

Pilot system

ROTARY MANIFOLD

HYDRAULIC RESERVOIR

NUMBERS IDENTIFY ROTARY MANIFOLD PORT (11 PLACES)

FRONT OF MACHINE

PORT V

PORT 1 PORT 11

CCW CW

PILOT SOLENOID VALVE

CW

CCW

PILOT FILTER YS

SWING PUMP

PS

MAIN DIRECTIONAL CONTROL VALVE

LSP

PL

250C-014

250BT-022

PILOT CIRCUIT DIAGRAM

PILOT SYSTEM ELECTRICAL CIRCUIT DIAGRAM

5.4

Tigercat 250C Loader

Pilot system

GAUGE TEST PORT

PILOT MANIFOLD BODY

PILOT MANIFOLD

RELIEF VALVE CARTRIDGE LOCKNUT ADJUSTING SCREW

OUT IN

PILOT RELIEF VALVE 250BT-011

PILOT MANIFOLD VALVE

SET PILOT PRESSURE

240B-01

IMPORTANT! Avoid pushing oil over relief longer than 5 seconds. Doing so causes excessive heating of the hydraulic fluid.

For system pressure values, refer to PRESSURE SETTINGS in Section 3.

Procedure: 1. Position machine on flat level ground.

2. Make sure that the hydraulic oil is at operating temperature.

3. Connect a 0–10 bar (0 –1000 psi) pressure gauge to the gauge test fitting on the pilot manifold valve.

4. Loosen locknut and turn adjusting screw all the way out on pilot relief valve. Tighten locknut on adjusting screw.

5. Have an assistant start the engine and set throttle at IDLE position.

6. Loosen locknut on pilot relief valve and turn adjusting screw in until gauge pressure is equal to set value shown in Section 3, – PRESSURE SETTINGS – PILOT SYSTEM 7. Turn adjusting screw in an additional 1/2 turn.

8. Tighten the locknut while making sure adjusting screw does not turn.

9. Stop engine and remove pressure gauge.

5.5

PILOT RELIEF VALVE

Tigercat 250C Loader

Pilot system

5.6

Tigercat 250C Loader SECTION 6 – ELECTRICAL SYSTEM & COMPUTER CONTENTS – SECTION 6

JUNE, 2014

C

COMPUTER CONTROL SYSTEM ELECTRICAL KIT – SERVICE AND DIAGNOSTICS........................................................................... 6.63 IQAN SOFTWARE................................................................................................................................ 6.66 MD3 MODULE REPLACEMENT................................................................................................ 6.12, 6.65 REAR SIDE OF THE MD3 DISPLAY.................................................................................................... 6.65 SERVICING THE MD3 WITH IQANRUN 2 SOFTWARE..................................................................... 6.67 XA2 MODULE LED INDICATORS........................................................................................................ 6.10 XA2 MODULE WIRING PIN ASSIGNMENT......................................................................................... 6.10 XS2-A0 MODULE WIRING PIN ASSIGNMENT................................................................................... 6.11 XS2 MODULE LED INDICATORS........................................................................................................ 6.11 D

DPF ELECTRONIC CONTROLS............................................................................................................. 6.42 AFTER TREATMENT DEVICE OPERATION....................................................................................... 6.43 ALERT WARNING LEVELS.................................................................................................................. 6.44 DPF ICONS..........................................................................................................................................6.42 INHIBIT.................................................................................................................................................6.43 PARKED ACTIVE DPF REGENERATION............................................................................................ 6.45 E

ELECTRICAL SCHEMATICS................................................................................................................... 6.82 CAB ACCESSORIES – 2502001 TO 2502040..................................................................................... 6.94 CAB ACCESSORIES – 2502041 TO 2503000.................................................................................... 6.95 ENGINE / BATTERIES – 2502001 TO 2502040 (SHT 1)..................................................................... 6.82 ENGINE / BATTERIES – 2502001 TO 2502040 (SHT 2)..................................................................... 6.83 ENGINE / BATTERIES – 2502041 TO 2503000 (SHT 1)..................................................................... 6.84 ENGINE / BATTERIES – 2502041 TO 2503000 (SHT 2).................................................................... 6.85 FUEL HEATER OPTION – 2502041 TO 2503000.............................................................................. 6.100 HVAC – 2502041 TO 2503000............................................................................................................. 6.99 HVAC / FUEL HEATER – 2502001 TO 2502040.................................................................................. 6.98 INSTRUMENTATION – 2502001 TO 2502040..................................................................................... 6.86 INSTRUMENTATION – 2502041 TO 2503000..................................................................................... 6.87 INSTRUMENT PANEL WIRING DIAGRAM (2502001 – 2502040).................................................... 6.107 INSTRUMENT PANEL WIRING DIAGRAM (2502041 – 2503000).................................................... 6.108 JOYSTICK CONTROL LEVERS – 2502001 TO 2502010.................................................................... 6.91 JOYSTICK CONTROL LEVERS – 2502011 TO 2502040.................................................................... 6.92 JOYSTICK CONTROL LEVERS – 2502041 TO 2503000.................................................................... 6.93 LIGHTING – 2502001 TO 2502040...................................................................................................... 6.96 LIGHTING – 2502041 TO 2503000...................................................................................................... 6.97 NETWORKING – 2502001 TO 2502010.............................................................................................. 6.88 NETWORKING – 2502011 TO 2502040.............................................................................................. 6.89 NETWORKING – 2502041 TO 2503000.............................................................................................. 6.90 STABILIZERS – 2502001 TO 2502040.............................................................................................. 6.101 STABILIZERS – 2502041 TO 2503000.............................................................................................. 6.102 TILT CAB OPTION – ALL.................................................................................................................... 6.106 VALVE /PUMP CONTROL – 2502001 TO 2502040........................................................................... 6.103 VALVE/PUMP CONTROL, LOADER WITH BAR SAW – 2502041 TO 2503000................................ 6.104 VALVE/PUMP CONTROL, LOADER WITH CIRCLE SAW – 2502041 TO 2503000.......................... 6.105 ELECTRICAL SYSTEM.............................................................................................................................. 6.4 BATTERY DISCONNECT SWITCH........................................................................................................ 6.4 FUSE AND RELAY PANEL – CAB.......................................................................................................... 6.6 FUSES AND RELAYS – ELECTRICAL BOX.......................................................................................... 6.7 SENSORS AND ALARMS...................................................................................................................... 6.4 SENSORS & ELECTRICAL COMPONENT LOCATIONS...................................................................... 6.5 SYSTEM FUSES AND RELAYS............................................................................................................. 6.4

Tigercat 250C Loader

Electrical System & Computer

ELECTRONIC CONTROL SYSTEM.......................................................................................................... 6.8 ELECTRONIC JOYSTICK FUNCTION.................................................................................................. 6.9 MAIN VALVE SPOOL SECTIONS.......................................................................................................... 6.9 M

MAIN DISPLAY SCREENS...................................................................................................................... 6.15 ADJUST MENU.................................................................................................................................... 6.15 ANTI-STALL MODE SELECTION..................................................................................................... 6.16 CONTROL ADJUST.......................................................................................................................... 6.23 MACHINE MODE ADJUSTMENTS................................................................................................ 6.23 DELIMBER STATUS......................................................................................................................... 6.20 LIMP MODE OPERATION................................................................................................................ 6.24 OIL GRADE SELECTION................................................................................................................. 6.16 SAW ADJUSTMENT MODE.............................................................................................................. 6.17 SAW FLOW ADJUSTMENT.............................................................................................................. 6.21 SLASHER SAW AUTO RETRACT TIME.......................................................................................... 6.18 TOP SAW AUTO RETRACT TIME.................................................................................................... 6.19 ENGINE MENU..................................................................................................................................... 6.15 INFORMATION MENU......................................................................................................................... 6.26 MD3 COMPUTER – ELECTRONIC CONTROL & DISPLAY................................................................... 6.13 MAIN DISPLAY..................................................................................................................................... 6.14 MAIN DISPLAY ITEMS..................................................................................................................... 6.14 MENU SCREENS..................................................................................................................................... 6.27 ADJUST MENU.................................................................................................................................... 6.27 ACCESSORIES................................................................................................................................ 6.32 AUTO SLASHER SAW RETRACT TIME........................................................................................ 6.32 DELIMBER STATUS....................................................................................................................... 6.34 GRAPPLE SAW AUTO RETRACT TIME........................................................................................ 6.33 TOP SAW AUTO RETRACT TIME................................................................................................. 6.33 ATTACHMENT FLOW SETTINGS.................................................................................................... 6.28 SLASHER SAW FLOW %.............................................................................................................. 6.28 TOP SAW FLOW %........................................................................................................................ 6.28 ENGINE............................................................................................................................................. 6.34 ANTI-SURGE STATUS................................................................................................................... 6.35 COLD IDLE SPEED........................................................................................................................ 6.34 COLD IDLE SPEED STATUS......................................................................................................... 6.35 MACHINE PARAMETERS................................................................................................................ 6.29 ANTI-STALL.................................................................................................................................... 6.30 GRAPPLE QUICK REVERSAL STATUS........................................................................................ 6.31 HOIST LIMIT SENSOR STATUS.................................................................................................... 6.31 IDLE DOWN WAIT TIME................................................................................................................ 6.30 OIL GRADE.................................................................................................................................... 6.30 STICK LIMIT SENSOR STATUS.................................................................................................... 6.31 INFO MENU SCREEN.......................................................................................................................... 6.40 LOGS................................................................................................................................................ 6.41 MODEM............................................................................................................................................. 6.41 MODULES......................................................................................................................................... 6.40 MEASURE MENU................................................................................................................................. 6.36 PREFERENCES MENU....................................................................................................................... 6.36 DATE/TIME ADJUSTMENT.............................................................................................................. 6.38 DISPLAY ADJUSTMENT.................................................................................................................. 6.37 BACKLIGHT ADJUSTMENT........................................................................................................... 6.37 MESSAGES AND WARNINGS................................................................................................................ 6.47 ALERT MESSAGES (YELLOW)........................................................................................................... 6.55 CHARGE FILTER FAULT ALERT...................................................................................................... 6.57 ENGINE FAULT CODE ALERT MESSAGES.................................................................................... 6.56 HARDWARE FAULT – JOYSTICK.................................................................................................... 6.57 HARDWARE FAULT – MD3.............................................................................................................. 6.58 6.2

Tigercat 250C Loader

S

Electrical System & Computer

HARDWARE FAULT – XA2............................................................................................................... 6.58 LOW FUEL LEVEL – FLASHING ICON............................................................................................ 6.59 WAIT TO START............................................................................................................................... 6.60 CHANNELS.......................................................................................................................................... 6.61 COLD WEATHER STARTING.............................................................................................................. 6.60 CRITICAL MESSAGES AND WARNINGS (RED)................................................................................ 6.48 COMMUNICATION FAULT – L.H. JOYSTICK.................................................................................. 6.53 COMMUNICATION FAULT – R.H. JOYSTICK.................................................................................. 6.53 ENGINE FAULT CODE MESSAGES – CRITICAL............................................................................ 6.54 ENGINE STOP.................................................................................................................................. 6.51 HARDWARE FAULT – ENGINE........................................................................................................ 6.52 HARDWARE FAULT – MD3.............................................................................................................. 6.51 HARDWARE FAULT – XA2............................................................................................................... 6.52 HYDRAULIC OIL LEVEL LOW.......................................................................................................... 6.49 HYDRAULIC OIL TEMPERATURE HIGH......................................................................................... 6.50 INPUTS.................................................................................................................................................6.61 OUTPUTS.............................................................................................................................................6.61 XA2-A0 MODULE – NO CONTACT ERROR........................................................................................ 6.59

SELF-PROPELLED CARRIER ELECTRONIC DRIVE/STEER CONTROLS.......................................... 6.77 BASIC SELF-PROPELLED CARRIER................................................................................................. 6.80 BRAKE THUMBSWITCH.................................................................................................................. 6.80 DRIVE MODE SWITCH.................................................................................................................... 6.80 PARK BRAKE SWITCH.................................................................................................................... 6.81 RIGHT-HAND JOYSTICK LEVER..................................................................................................... 6.80 RIGHT-HAND JOYSTICK THUMBSWITCH..................................................................................... 6.80 TIGERCAT CARRIER........................................................................................................................... 6.77 CENTER FOOT CONTROL – BRAKES............................................................................................ 6.78 DRIVE MODE SWITCH.................................................................................................................... 6.77 DRIVE/STEER CONTROLS............................................................................................................. 6.78 GEAR SELECTION, TRANSMISSION............................................................................................. 6.79 PARK BRAKE.................................................................................................................................... 6.77 RIGHT-HAND JOYSTICK LEVER..................................................................................................... 6.78 RIGHT-HAND JOYSTICK THUMBSWITCHES................................................................................. 6.78 SERVICING THE MD3 WITH IQANRUN 2 SOFTWARE......................................................................... 6.67 ADJUST................................................................................................................................................ 6.74 CONNECT TO THE MD3 CONTROLLER WITH IQANRUN 2 SOFTWARE........................................ 6.68 GET SETTINGS FILE........................................................................................................................... 6.71 LOGIN................................................................................................................................................... 6.69 LOGS.................................................................................................................................................... 6.76 MEASURE/ GRAPH............................................................................................................................. 6.75 RESETTING THE PASSWORD........................................................................................................... 6.41 SYSTEM INFO...................................................................................................................................... 6.76 UPDATE APPLICATION....................................................................................................................... 6.70 UPDATE MD3 APPLICATION SOFTWARE......................................................................................... 6.72

6.3

Tigercat 250C Loader

Electrical System & Computer

ELECTRICAL SYSTEM

SYSTEM FUSES AND RELAYS Electrical circuit protection is provided by two electrical fuse and relay panels. One is located below the instrument panel in the cab. The other is in the front of the engine compartment. The fuse and relay panels are discussed in more detail later in this section.

ALTERNATOR

FUSE AND RELAY PANEL

BATTERIES

250CT-005

ENGINE COMPARTMENT ACCESS REAR

Two 12-volt batteries with 950 cold cranking amps are connected in series to provide a 24volt electrical power supply. An 80-amp, 24-volt alternator is used to charge the electrical system.

250C-003

ENGINE COMPARTMENT ACCESS FRONT

BATTERY DISCONNECT SWITCH

250CT-007 250C-002

CAB FUSE AND RELAY PANEL

BATTERY DISCONNECT SWITCH

SENSORS AND ALARMS

The Battery Disconnect Switch completely disconnects all electrical circuits on the machine from the battery. It is located behind the front engine area access panel. Turn this switch to OFF whenever the machine is left unattended for an extended period of time.

The hydraulic and engine systems on the 250C Loader use sensors to monitor proper system operation. These sensors are connected to the MD3 computer.

The operator may sound the safety alert horn as a warning alarm at any time. The horn switch is located on the control panel to the right of the operator. Press switch to sound horn.

NOTE: Panel buzzer sounds when engine oil pressure is too low, coolant temperature is too high, hydraulic oil temperature is too high or level is too low.

6.4

Tigercat 250C Loader

Electrical System & Computer

SENSORS & ELECTRICAL COMPONENT LOCATIONS

MD3 COMPUTER CONTROL MODULE

WASHER FLUID LEVEL SENSOR

CONTROL PANEL

PILOT MANIFOLD AND SOLENOIDS JOYSTICKS

PILOT PRESSURE SENSOR

PILOT SHUTOFF SWITCH

XA2 VALVE MODULE STABILIZER SOLENOID VALVE

ELECTROHYDRAULIC CONTROL VALVE

FUSE & RELAY ELECTRICAL BOX (SHOWN TURNED UP)

ENGINE ECU XS2 CAB MODULE

BATTERY DISCONNECT SWITCH

COOLANT LEVEL PROBE A/C COMPRESSOR

SWING PUMP ANTI-DRIFT SWITCH

DPF TEMP. & PRESSURE SENSOR

MAIN PUMP DISPLACEMENT CONTROL SOLENOID STARTER CHARGE FILTER

HYDRAULIC OIL LEVEL SENSOR

250C-010

SAFETY ALERT HORN (SWITCH ON CONTROL PANEL)

ALTERNATOR

HYDRAULIC OIL TEMPERATURE SENSOR

12 VOLT BATTERIES 24 VOLT SYSTEM

A/C PRESSURE SWITCH

SENSORS AND ELECTRICAL COMPONENT LOCATIONS

6.5

Tigercat 250C Loader

Electrical System & Computer

FUSE AND RELAY PANEL – CAB The cab fuse and relay panel is located below the control panel behind a removable cover.

Each circuit of the machine is protected by a fuse.

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

250C-002

CAB FUSE AND RELAY PANEL

FUSE AND RELAY PANEL LABEL 6.6

Tigercat 250C Loader

Electrical System & Computer

FUSES AND RELAYS – ELECTRICAL BOX This main fuse and relay electrical box is located in the engine compartment.

MAIN FUSE AND RELAY ELECTRICAL BOX

250CH-001

RELAY 10 STARTER LOCKOUT

DIODE MODULE 8

FUEL HEATER (OPT) 20A SPARE

START SOLENOID RELAY

GRID HEATER RELAY

60A

150A

STARTER / CAB

GRID HEATER

RELAY 11 FUEL HEATER (OPTIONAL)

50264BENG R0

MAIN FUSE AND RELAY ELECTRICAL BOX LABEL 6.7

Tigercat 250C Loader

Electrical System & Computer

ELECTRONIC CONTROL SYSTEM MD3 COMPUTER – ELECTRONIC CONTROL & DISPLAY

ELECTRONIC JOYSTICKS

9 PIN DIAGNOSTIC CONNECTOR XA2 VALVE MODULE

ENGINE ECU

XS2 CAB MODULE

ELECTRO– HYDRAULIC CONTROL VALVES

250C-015

The electronic control system on this machine is made up of a network of components (shown above). The system includes the following:

PILOT CONTROL VALVES

As an example, the joystick movement/position is transmitted to the MD3 controller electronically.

This message is then transmitted to the XS2 cab module from the MD3 control module, then to the XA2 valve module, and on to the hydraulic control valve solenoid controls. The applicable hydraulic control solenoids are energized, allowing hydraulic oil to flow to the boom or grapple functions activated by the joystick movement.

• MD3 Computer – Electronic Control & Display • Electronic Joysticks • XS2 Cab Module • XA2 Valve Module

The engine ECU provides electronic information to the MD3 computer using the J1939 CAN bus link. This information is shown on the computer display.

• Engine ECU • Hydraulic Control Valve Electronic Solenoids • Various controls, switches, sensors and valves not shown.

The MD3 computer is the main control module in the system. The MD3 computer program is the operating system for the computer display as well as the control system for the machine operating parameters.

6.8

Tigercat 250C Loader

Electrical System & Computer

ELECTRONIC JOYSTICK FUNCTION Components and Operation: When not actuated, the lever (1) is held in neutral position by the return springs (8). When operating the lever (1), the plunger (5) pushes against return spring (8). The magnet (7) mechanically linked to the plunger (5) moves upward or downward while following the actuation direction of the lever.

The electrical signal generated by the sensor (4) is proportional to the deflection of the lever.

A rubber boot (6) protects the mechanical components of the housing from external contamination.

MAIN VALVE SPOOL SECTIONS All of the main valve spool sections are equipped with proportional electro-hydraulic solenoid controls. The spools are spring-centered to the neutral position.

Sending an electrical signal to the desired electrohydraulic solenoid control causes the solenoid to shift. Internal pilot oil is then directed to the chosen spool actuator, shifting the spool and directing pump oil flow to the selected cylinder or motor.

250C-019

FEED REDUCER

PORT RELIEF ‘A’ SIDE

PORT RELIEF ‘B’ SIDE

ELECTRONIC JOYSTICK

24V PROPORTIONAL ELECTRO-HYDRAULIC SOLENOID CONTROLS

SPOOL PRESSURE COMPENSATOR 234-068

CROSS SECTION OF ELECTRO-HYDRAULIC OPERATED SPOOL SECTION

6.9

Tigercat 250C Loader

Electrical System & Computer flash indicates a memory error.

• Continuous flashing red indicates a fatal error.

XA2 MODULE LED INDICATORS B

Internal diagnostics in the MD3 can be used to get more information about the XA2 module. The following values are supervised:

A

• Internal temperature (°C) • Power supply (V) XA2-WIREASSIGN

If a system error is detected, the MD3 displays an error message. Additionally, the XA2 module has 2 LED indicator lights. The green LED (A) is Supply Voltage. The yellow/red LED (B) is the Status Indicator.

42 28 14

1 ID TAG ADDR-H 2 HOIST PWR COUT-A 3 STICK PWR COUT-B 4 GRPPL, ARM PWR COUT-C 5 SAW CUT PWR COUT-D 6 GRPPL, ROT PWR COUT-E 7 ANTI-STL PWR COUT-F 8 DELIMB OPN DOUT-A 9 GRPPL SAW DOUT-B 10 CHRG FILT SERV VIN-A 11 SWING ACTIV 12 HYD OIL LEV VIN-C 13 HYD OIL TEMP VIN-D 14 ID TAG ADDR-L

SUPPLY VOLTAGE LED (GREEN).

Green LED indicates supply voltage is ON. LED off indicates supply voltage is OFF. STATUS INDICATOR LED (YELLOW/RED).

LED flashing yellow indicates status is correct.

LED flashing red indicates error status as follows:

• One red flash, and then 1, 2, or 3 yellow flashes indicates an error controlled by the MD3.

• Two red flashes, and then 1 or 2 yellow flashes indicates an error controlled by the MD3.

• Three red primary flashes in a row and one yellow secondary flash indicates that the fault is related to the CAN bus.

• Three red flashes, and then 2 yellow flashes indicates that the fault is related to the address.

• Four red flashes, and then 1 yellow

29 15 1

15 -BAT 16 HOIST BASE CRET-A+ 17 STICK BASE CRET-B+ 18 GRPPL CLOSE CRET-C+ 19 SAW CUT CRET-D+ 20 GRPPL CCW CRET-E+ 21 ANTI-STL CRET-F+ 22 PILOT RESET DOUT-C 23 GRPPL RESP DOUT-D 24 LOW FULE LEV DIN-E 25 STAB ACTIV DIN-F 26 CAN-H(A) TO JOYSTK 27 CAN-H(B) BLANK 28 +BAT(+24V)

29 -VREF 30 HOIST ROD CRET A31 STICK ROD CRET B32 GRPPL OPEN CRET C33 SAW RETR CRET D34 GRPPL CW CRET E35 RESVD CRET F36 DELIMB OPEN, HLD DOUT E 37 B-UP ALRM DOUT F 38 BLANK,DIN,VIN,FIN 39 BLANK,DIN,VIN,FIN 40 CAN-L(A) FROM JOYSTK 41 CAN-L(B) BLANK 42 +VREF +5V

• Reference voltage (V) • CAN address voltage (V) XA2 MODULE WIRING PIN ASSIGNMENT NOTE: The XA2 module is equipped with 8 voltage inputs (VIN-A to VIN-H) that may be configured as digital inputs (DIN), frequency inputs (FIN) or directional frequency inputs (DFIN). The XA2 module is also equipped with 6 double proportional outputs (COUT-A to COUT-F) that may be configured as digital outputs (DOUT) and digital inputs (DIN). See wiring pin assignment diagram above for details. The functions of these inputs are determined by the machine program.

NOTE: Refer to ELECTRICAL SCHEMATICS in this section for detailed pin and wiring assignment.

6.10

Tigercat 250C Loader

Electrical System & Computer

XS2 MODULE LED INDICATORS

Internal diagnostics in the MD3 can be used to get more information about the XS2 module. The following values are monitored:

B

• • • •

A

Internal temperature (°C) Power supply (V) Reference voltage (V) CAN address voltage (V)

XS2-A0 MODULE WIRING PIN XS2-WIREASSIGN

If a system error is detected, the MD3 displays an error message. Additionally, the XS2 module has 2 LED indicator lights. The green LED (A) is Supply Voltage. The yellow/red LED (B) is the Status Indicator.

42 28 14

SUPPLY VOLTAGE LED (GREEN).

Green LED indicates supply voltage is ON.

1 ADDR-H 2 DOUT-G 3 DOUT-H 4 DOUT-I 5 DOUT-J 6 DOUT-K 7 DOUT-L 8 GRAPPLE OPEN,DOUT-A 9 GRAPPLE CLOSE DOUT-B 10 RH JOYSTK X-AX VIN-A 11 RH JOYSTK Y-AX VIN-B 12 LH JOYSTK X-AX VIN-C 13 LH JOYSTK Y-AX VIN-D 14 ID-TAG ADDR-L

LED off indicates supply voltage is OFF. STATUS INDICATOR LED (YELLOW/RED).

LED flashing yellow indicates status is correct.

LED flashing red indicates error status as follows:

• One red flash, and then 1 yellow flash indicates an error controlled by the MD3 controller.

• Two red flashes, and then 1 yellow flash indicates an error controlled by the MD3 controller.

• Three red flashes, and then 1 yellow flash indicates the fault is related to the CAN bus.

• Three red flashes, and then 2 yellow flashes indicates the fault is related to the address.

• Four red flashes, and then 1 yellow flash indicates a memory error.

• Continuous flashing red indicates a fatal error.

29 15 1

15 -BAT 16 RH JOYSTK,SW#1 DIN-I 17 RH JOYSTK,SW#2 DIN-K 18 RH JOYSTK,SW#3 DIN-M 19 RH JOYSTK,SW#4 DIN-O 20 RH TRIGGER DIN-Q 21 BLNK DIN-S 22 BLNK DOUT-C 23 BLNK DOUT-D 24 BRAKE (SP) DIN-E 25 DRIVE MODE (SP) DIN-F 26 CAN-H (A) TO MD3 27 CAN-H (B) TO XA2-A0 28 BAT SUPPLY (+24V)

29 -VREF GND 30 LH JOYSTK,SW#1 DIN-J 31 LH JOYSTK,SW#2 DIN-L 32 LH JOYSTK,SW#3 DIN-N 33 LH JOYSTK,SW#4 DIN-P 34 LH TRIGGER DIN-R 35 BLNK DIN-T 36 BLNK DOUT-E 37 BLNK DOUT-F 38 CIRCLE SAW DIN-G 39 AUTO SAW RET DIN-H 40 CAN-L (A) FROM MD3 41 CAN-L (B) FROM XA2-A0 42 VOLTAGE REF +5V

ASSIGNMENT NOTE: The XS2-A0 module is equipped with 8 voltage inputs (VIN-A to VIN-H) that may be configured as digital inputs (DIN-A to DIN-H).

The function of these inputs is determined by the machine program.

NOTE: Refer to ELECTRICAL SCHEMATICS in this section for detailed pin and wiring assignment.

6.11

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ID-TAG Addressing Each module has a specific address, enabling the MD3 to communicate with it through the CAN bus.

The MD3 distinguishes between different modules by verifying the module type, and its unique address.

Example: If a system has an XS2 module with address 0, the system denotes this one as XS2-A0, The letter A refers to CAN bus A.

Assembling of the Id-Tag RESISTANCE -

XS2 -A0

0

287 Ω

XA2 -A0

0

287 Ω

XA2 -A1

1t

590 Ω

1 ADDR-H, pos.1

ASSEMBLING ID-TAG (XS2 OR XA2)

• If the module is located at the end of the CAN bus then select the appropriate Id-Tag denoted with a T. ID-TAG

14

CONNECTING ID-TAG (XS2 OR XA2)

Selecting appropriate Id-Tag • Check the address number of the module.

NO TAG

15

Id-Tag

Terminating To eliminate interference in communication through the CAN bus, the CAN bus must be terminated. Because the MD3 module is always located at the beginning of the bus, the master is provided with an internal termination. If an IQANXA2 module is located at the end of the CAN bus then use an Id-tag having a combined address and terminating function. This is denoted with a T for terminating, after the appropriate address such as 0T, 1T, 2T.

MD3

29

28

ADDR-L, pos. 14

In order to assign any XS2 module a unique CANaddress, an Id-Tag has to be connected to the positions ADDR-H and ADDR-L.

MODULE

42

The Id-Tag is placed in the connector in order to address/terminate the module. The Id-Tag is mounted under the connector casing. Bend the Id-Tag’s cables towards the opposite side, where the other cables enter the connector.

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WARNING BUZZER

MD3 COMPUTER USB PORT

WARNING LIGHT MD3 COMPUTER

MAIN DISPLAY SCREEN

250CT-034 250CT-035

MD3 COMPUTER – ELECTRONIC CONTROL & DISPLAY

Up And Down Arrow Buttons Navigation buttons that are used to scroll through selections on a menu screen. The buttons are configured by program software to bring up a display screen, bring up an adjustment group, or act as a virtual input.

The MD3 computer electronic control module is the operator interface to the electronic control system on the machine. It works as the master control module (central unit in the system).

System information is displayed on the 89 mm (3.5 in) backlit, color graphic transflective screen.

OK Button Pushing this button equals enter. It saves the value or confirms the selection you have made.

The front of the MD3 module consists of a control panel with a display screen and 9 buttons. The buttons are arranged on the bottom and righthand side.

Menu Button Always brings up the Menu screen. It is not programmable.

F1 Through F4 Function Buttons , , , .

Programmed buttons that are configured by program software to bring up a display screen, bring up an adjustment group, or act as an input. See Main Display Screen Items for more information

Esc or Back button Returns you to the previous display screen. May be configured by program software to bring up a display screen, bring up an adjustment group, or act as a virtual input.

6.13

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MAIN DISPLAY 1

2

3

4

12

11

5

6

7

8

250CT-034

9

MAIN DISPLAY SCREEN

MAIN DISPLAY SCREEN ITEMS This is the main system display screen, visible on power-up of the control system. It displays icons for all the systems being monitored by the MD3 controller.

1. Pilot Reset On/Off Icon 2. Anti-stall On/Off Icon 3. Machine Mode Icon 4. Fuel Level Icon 5. Engine rpm Gauge 6. Engine Menu – Select F1 7. Adjustment Menu – Select F2 8. Engine Coolant Temperature Gauge 9. Information Menu – Select F3 10. Alarm Indicators – Select F4 11. Hydraulic Oil Grade Indicator 12. Hydraulic Oil Temperature Gauge 6.14

10

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MAIN DISPLAY SCREENS

ADJUSTMENT MENU

ENGINE MENU

From the main display screen, press F2 to select the Adjustment menu.

From the main display screen, press F1 to select the Engine menu.

When selected, the Adjustment menu icon and all the adjustment selections are displayed. The adjustment selections are as follows:

When selected, the Engine menu icon and the engine functions are displayed. The engine display functions are as follows: • Charge Air Temperature – °C or °F

• Anti-Stall Mode – Select F1

• Turbocharger Boost Pressure – (bar or psi)

• Oil Grade Adjustments – Select F2

• Engine Load %

• Saw Adjustment Mode – Select F3. (Slasher Saw Auto Retract Time, Delimber Status, as equipped.)

• Engine Speed rpm • Engine Temperature – °C or °F

• Control Adjust – Select F4

• Battery Voltage – Volts • Engine Oil Pressure – (bar or psi) • Fuel Rate – L/h or US gph (instantaneous) Note: Press F1 units.

to set metric or Imperial (US) 6.15

Tigercat 250C Loader

Electrical System & Computer

ANTI-STALL MODE SELECTION

OIL GRADE SELECTION

Press F1 to select the Anti-Stall menu from the Adjustment menu.

Press F2 to select Oil Grade menu from the Adjustment menu.

Two choices are given, ON or OFF. Press the up or down arrow buttons to scroll to the desired selection. Press OK to select.

Five choices are given ISO22, ISO32, ISO36, ISO46 and ISO68. Press the up or down arrow to scroll to the desired oil grade. Press OK to select.

Press the Back button to return to the adjustment menu. Press it again to return to the main menu.

Press the Back button to return to the adjustment menu. Press it again to return to the main menu.

6.16

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SAW ADJUSTMENT MODE

Press F3 to select the Saw Adjustment menu from the Adjustment menu.

The following adjustments can be selected from the Saw Adjustment menu:

• Slasher Saw Auto Retract Time – Select F1.

The example above shows that auto retract time is set to 5 seconds (5.00s) • Top Saw Auto Retract Time – Select F2. The example above shows that auto retract time is set to 5 seconds (5.00s) • Delimber Status – Select F3. The example above shows a check mark indicating machine is equipped with a delimber.

• Saw Flow Adjustment – Select F4. This adjustment requires entering a PIN Code when selected the first time in a shift (or after the engine has been shut off). Entering a PIN code is covered later in this section.

6.17

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Electrical System & Computer

Slasher Saw Auto Retract Time

If a different value is desired, use the up or down arrow buttons to reset the value.

The value shown above has been adjusted to 2.25 seconds. When the new value is selected, press OK to accept the new value and to return to the Saw Adjustment menu.

Press F1 to select the Slasher Saw Auto Retract Time menu from the Saw Adjustment menu.

The value can be set between 0 – 5 seconds for the Auto Retract Time. This is the amount of time that the saw retract stays active after the slasher saw cut button is released. The time should be adjusted to allow the slasher saw bar to fully retract. If the time is set longer than necessary, heat is generated in the hydraulic system by the main control valve.

The new value for slasher saw auto retract is now displayed (2.25s).

If no other adjustments are required continue to press the Back button to return to the main menu.

NOTE: To disable the auto saw retract, set the retract time to 0 seconds.

6.18

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Electrical System & Computer

Top Saw Auto Retract Time

If a different value is desired use the up and down arrow buttons to reset the value.

Shown above, the value has been adjusted to 2.25 seconds. When the new value is selected, press OK to accept and to return to the Saw Adjustment menu.

Press F2 to select the Top Saw Retract Time menu from the Saw Adjustment menu.

The value can be set between 0 – 5 seconds for the Top Saw Retract Time. This is the amount of time that the saw retract stays active after the top saw cut button is released. The time should be adjusted to allow the top saw bar to retract fully.

If the time is set longer than necessary, heat is generated in the hydraulic system by the main control valve.

The new value for top saw auto retract is now displayed (2.25s).

If no other adjustments are required continue to press the Back button menu.

NOTE: To disable the auto saw retract, set the retract time to 0 seconds.

6.19

to return to the main

Tigercat 250C Loader

Electrical System & Computer

Delimber Status

Shown above, the selection has been changed to No Delimber indicated by the (X) mark beside the delimber icon. The icon has turned grey to indicate the delimber function is disabled. If the

The photo above shows a check mark beside the delimber icon on the display. This indicates delimber option is selected.

selection is correct, press the Back button return to the previous menu.

to

If no other adjustments are required, continue to press the Back button to return to the main menu.

Press F2 to select delimber status mode. Two choices are available for selection — Delimber or No Delimber. To change the status, use the up and down arrow buttons to scroll to the desired selection. Press OK to accept the selection.

6.20

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Saw Flow Adjustment

A new message appears on the display – Enter PIN Code. The factory PIN is 0-0-0-0. This number remains the same until the password (PIN Code) is changed. Press OK 4 times to enter 0‑0-0-0.

The Saw Flow Adjustment (F4) provides access to the Top Saw Cut flow rate and Slasher Saw Cut flow rate adjustments.

At this point the check mark is displayed beside the PIN number to show that the correct PIN code has been selected. The flow adjustment icon is also displayed above F4.

Press F4 to select the Saw Flow Adjustment from the Adjustment menu.

This function is password protected and requires entering a 4 digit PIN number to make adjustments.

If you wish to change the password, select F3, SET PWD. Use the up and down arrow buttons to select the new 4 digit PIN. Press OK to accept.

IMPORTANT! Before making any adjustments make sure you are aware of the flow requirements of your particular saw. Over driving the saw motor with more flow than required can damage your saw.

Record the new PIN code number. Once the computer and ignition key are turned off, this new number must be entered when prompted.

If you forget the password, see RESETTING THE PASSWORD in this section.

Select F2 (ENTER PIN) to enter the PIN code.

6.21

Tigercat 250C Loader

Electrical System & Computer Press F3 to select the Slasher Saw Flow adjustment. Press the up arrow to increase the value or the down arrow to decrease the value.

When the desired value has been selected, press OK to accept the value and return to the Flow Adjustment menu.

Press F4 to select the Flow Adjustment menu.

The two adjustments are used to control hydraulic oil flow to the Top Saw (F2) and Slasher Saw (F3).

The adjustments are factory-set for a hydraulic oil flow of 189 L/m (50 gpm) to both the top saw and the slasher saw.

NOTE: To set metric or imperial measure,

IMPORTANT! Before making any adjustments, make sure you are aware of the oil flow requirements of your particular saw. Over-driving the saw motor with more oil flow than required can damage your saw.

press F1

to change mode.

If no further adjustments are required press the Back button to return to the main menu.

Press F2 to select the Top Saw Flow adjustment.

Press the up arrow to increase the value or the down arrow to decrease the value. When the desired value has been selected, press OK to accept the value and return to the Flow Adjustment menu.

6.22

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Electrical System & Computer

CONTROL ADJUST

Press F1 to select the Machine Mode from the Control Adjustment menu.

Machine Mode Adjustments

Control Adjust provides access to the Machine Mode adjustments.

From the main display screen, press F2 to select the Adjust menu.

When F1 has been selected, a dialogue box appears in the lower right-hand side of the display.

There are 4 modes to choose from:

In the Adjust menu, press F4 to select the Control Adjust menu.

• M-0 = Training Mode • M-1 = Machine Mode 1 • M-2 = Machine Mode 2 • M-3 = Machine Mode 3 The machine mode is factory-set at M-2 (Machine Mode 2). Select M1 for smoother operation and M3 for more aggressive operation.

Use the up or down arrow buttons to scroll to the desired selection. Press OK to accept the selection.

Press the Back button menu.

6.23

to return to the adjust

Tigercat 250C Loader

Electrical System & Computer

LIMP MODE OPERATION

When the Machine Adjust menu appears, press F4 to access the Machine Mode adjustments.

If a critical joystick communication fault occurs, the following fault warning message appears on the display: No contact or invalid data. Limp mode is now available. Limp Mode provides the operator with the ability to operate the fault joystick functions using the buttons on the MD3 display.

This feature allows the boom to be placed in a safe position before the machine is shut down.

Seek service assistance if a joystick fault is active.

The Machine Mode Adjustment menu appears on the display with the Limp Mode icon located above F2.

Press F2 to select the Limp Mode feature.

To access Limp Mode, press F2 to hide the warning message.

Press F2 to access the Machine Adjust menu.

6.24

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Electrical System & Computer

After pressing F2, an information message appears on the display. The message requires confirmation before Limp Mode is activated.

In Limp Mode, the following functions are operated as indicated:

The message is displayed as: Entering Limp Mode. Screen commands are now active! Extra care must be taken when manually activating controls. Pilot system is ACTIVE!

Hoist Boom Up/Down: Press and hold F1, then press the up arrow to extend the cylinder (raise the boom) or the

Press F2 to hide the message and proceed with Limp Mode.

down arrow the boom).

to retract the cylinder (lower

Stick Boom In/Out: Press and hold F2, then press the up arrow to extend the cylinder (boom Out) or the down arrow

to retract the cylinder (boom in).

Grapple Rotate: Press and hold F3, then press up arrow to rotate clockwise or down arrow to rotate counterclockwise.

Grapple Open/Close: Press and hold F4, then press up arrow to close the grapple or down arrow to open the grapple.

NOTE: Holding the up or down arrow increases the function speed to a maximum of 50%. To stop the function, simply release the F1, F2, F3 or F4 buttons and the speed is reset to 0%.

6.25

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Electrical System & Computer

INFORMATION MENU

Press F3 to access the Information menu.

The Information screen displays the following selections: • Engine Hours • Machine Hours • Hydraulic Oil Temperature • Fuel Used in US gal or Litre since last reset • Trip Time since last reset • Fuel Consumption in US gal/hr or Liter/hr • Metric/Imperial Measure Reset – Select F1 • Fuel Used Reset – Select F2 Select F1 to set Imperial (US) or metric measure.

Select F2 to reset fuel used and trip time to (0).

Press the Back button display screen.

to return to the main

6.26

Tigercat 250C Loader

Electrical System & Computer

MENU SCREENS Press the Menu Button screen.

ADJUST MENU From the main Menu screen press F1 to access the Adjust menu.

to go to the Menu

This menu is an alternate method of accessing the Adjustment menu to make machine adjustments. See Adjustment menu earlier in this section for details.

The Menu screen displays the following selections: • Adjust – Select F1 • Measure – Select F2 • Preferences – Select F3 • Info – Select F4 To return to the main Menu, press the Back button .

The Adjust menu has the following menu items.

• Attachment Flow Settings • Machine Mode • Machine Parameters • Accessories • Engine

6.27

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Electrical System & Computer

ATTACHMENT FLOW SETTINGS

Press the down arrow to scroll to the Slasher Saw Flow % selection if desired, then press OK.

NOTE: Attachment Flow Settings only appears on this menu when the PIN code has been entered to permit access to this adjustment. For details on entering PIN code, see Saw Flow Adjustment under the Main Display screens, earlier in this section.

Press the Back button previous menu screen.

to return to the

Slasher Saw Flow %

Use the up or down arrow buttons to select the menu item. Press OK to confirm the selection.

Top Saw Flow %

IMPORTANT! Before making any adjustments make sure you are aware of the oil flow requirements of your particular saw. Over-driving the saw motor with more oil flow than required can damage it.

IMPORTANT! Before making any adjustments make sure you are aware of the oil flow requirements of your particular saw. Over-driving the saw motor with more flow than required can damage it.

Use the up or down arrow buttons to reset the value at 0% to 100%. Press OK to confirm the selection.

Press the Back button to return to the previous menu screen. Continue to press the Back button to return to the Adjust menu screen.

Press OK to select Top Saw Flow %. Use the up or down arrow buttons to reset the value at 0% to 100%. Press OK to confirm the selection.

6.28

Tigercat 250C Loader

Electrical System & Computer

MACHINE MODE

MACHINE PARAMETERS

Press OK to choose Mode Select.

In the Machine Parameters menu the following items can be selected:

There are 4 modes to choose from:

• Anti-Stall

• M-0 = Training Mode

• Oil Grade

• M-1 = Machine Mode 1

• Idle Down Wait Time

• M-2 = Machine Mode 2

• Hoist Limit Sensor Status

• M-3 = Machine Mode 3

• Stick limit Sensor Status

The machine mode is factory-set at M-2 (Machine Mode 2). Select M1 for smoother operation and M3 for more aggressive operation.

• Grapple Quick Reversal Status Use the up or down arrow buttons to scroll to the desired selection. Press OK to accept the selection.

Use the up or down arrow buttons to scroll to the desired selection. Press OK to accept the selection.

Press the Back button menu.

to return to the Adjust

6.29

Tigercat 250C Loader

Electrical System & Computer

Anti-Stall

Idle Down Wait Time

In the Anti-Stall menu 2 choices are available — ON or OFF.

In the Idle Down Wait Time menu, the value can be adjusted from 5 seconds to 60 seconds. Use the up or down arrow buttons to change the value. Press OK to set the new value. The factory default value is 5 seconds. This function is a feature of Auto Idle Down.

Auto Idle Down If the engine is set to run at full throttle and no functions are activated for a 5 seconds, the engine idles down automatically. The engine returns to the set idle rpm as soon as a function is activated.

Use the up or down arrow buttons to scroll to the desired selection. Press OK to set the selection.

Press the Back button to return to the machine parameters menu.

Use the up or down arrow buttons to scroll to the Oil Grade selection. Press OK to set the selection.

Oil Grade

In the Oil Grade menu 5 choices are available — ISO 22, ISO 32, ISO 36, ISO 46, and ISO 68.

Use the up or down arrow buttons to scroll to the desired selection. Press OK to set the selection.

NOTE: During cold weather, the computer limits maximum engine rpm until the hydraulic oil has reached a specified temperature, based on the oil grade selected. See COLD WEATHER STARTING in this section.

Press the Back button to return to the Machine Parameters menu.

Use the up or down arrow buttons to scroll to the Idle Down Wait Time selection. Press OK to set the selection.

Press the Back button to return to the Machine Parameters menu.

6.30

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Electrical System & Computer

Hoist Limit Sensor Status ON or OFF

The sensor can be turned ON or OFF using the arrow up or down arrow buttons.

Press OK to accept the selection.

Press the Back button to return to the Machine Parameters menu.

Grapple Quick Reversal Status ON or OFF

This screen displays the status of the Hoist Limit Sensor. This sensor is used to aid the hydraulic control system in providing a soft stop at both ends of the hoist cylinder stroke. This feature aids smoother boom operation.

The sensor can be turned ON or OFF using the arrow up or down arrow buttons.

Press OK to accept the selection.

This screen displays the status of the Grapple Quick Reversal.

Press the Back button to return to the Machine Parameters menu.

Grapple Quick Reversal provides a quick-open feature for the grapple. When enabled, the quickopen-then-close movement allows unwanted material (roots etc.) to be quickly dropped, without losing the load.

Stick Limit Sensor Status ON or OFF

Press the Back button to return to the Machine Parameters menu.

This screen displays the status of the Stick Limit Sensor. This sensor is used to aid the hydraulic control system in providing a soft stop at both ends of the stick (outer) cylinder stroke. This feature aids smoother boom operation.

6.31

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ACCESSORIES

Auto Slasher Saw Retract Time

In the Accessories menu the following items can be selected.

In the Auto Slasher Saw Retract Time selection, the value can be adjusted from 0 to 5 seconds.

This sets the time for the slasher saw to auto retract once cutting has completed.

• Auto Slasher Saw Retract Time

Use the up or down arrow buttons to change the value. Press OK to set the value.

• Top Saw Retract Time • Grapple Saw Retract Time • Delimber Status Use the up or down arrow buttons to scroll to the desired selection. Press OK to set the selection.

Press the Back button Accessories menu.

to return to the

Use the up or down arrow buttons to scroll to the next menu. Press OK to select the menu item.

6.32

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Electrical System & Computer

Top Saw Auto Retract Time

Grapple Saw Auto Retract Time

In the Top Saw Retract Time selection, the value can be adjusted from 0 to 5 seconds. This sets the auto retract time after the saw has completed cutting.

In the Grapple Saw Retract Time selection, the value can be adjusted from 0 to 5 seconds.

This sets the auto retract time after the saw has completed cutting.

Use the up or down arrow buttons to change the value. Press OK to set the value.

Use the up or down arrow buttons to change the value. Press OK to set the value.

Press the Back button Accessories menu.

Press the Back button Accessories menu.

to return to the

to return to the

Use the up or down arrow buttons to scroll to the next menu item. Press OK to select the menu item.

Use the up or down arrow buttons to scroll to the next menu item. Press OK to select the menu item.

Press the Back button Menu screen.

Press the Back button Menu screen.

to return to the main

6.33

to return to the main

Tigercat 250C Loader

Electrical System & Computer

Delimber Status

ENGINE

In the Delimber Status menu, 2 choices can be selected — Delimber or No Delimber.

In the Engine menu, there are 3 choices that can be selected:

Use the up or down arrow buttons to scroll to the desired selection. Press OK to set the selection.

Shown above, Delimber is the choice selected.

• Cold Idle Speed – rpm (value shown) • Cold Idle Speed Status – On/Off • Anti-Surge Status – On/Off Use the up or down arrow buttons to scroll to the desired menu. Press OK to select.

Cold Idle Speed

Press the Back button Menu screen.

to return to the main

As previously mentioned, the Measure, Preferences and Info menus can be selected on the main Menu screen. These menu items are discussed in detail later in this section.

During cold weather, the computer limits maximum engine rpm on start up until the hydraulic oil has reached operating temperature, based on the oil grade selected. In the example shown above, the engine Cold Idle Speed is limited to 1200 rpm.

Use the up or down arrow buttons to change the engine rpm setting. Press F2 to reset to the original rpm. The blue dot on the dial shows the previous setting.

Continue to press the Back button to return to the Main Menu Display.

Press OK to set.

6.34

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NOTE: For proper operation of the Cold Idle Speed feature, the hydraulic oil type settings should match the hydraulic oil currently in use.

Oils grade selections are based on ambient temperatures.

Anti-Surge Status

Refer to APPROVED HYDRAULIC OILS in Section 3 for hydraulic oil operating ranges.

See COLD WEATHER STARTING in this section.

Cold Idle Speed Status

The Anti Surge feature limits engine lug-down under load, and surges in rpm that can occur if the engine is unloaded quickly.

Use the up or down arrow buttons to select ON or OFF. Press OK to select.

Press the Back button Menu screen.

This menu identifies if the Cold Idle Speed feature is enabled.

Use the up or down arrow buttons to select ON or OFF. Press OK to select.

Press the Back button Menu screen.

to return to the main

6.35

to return to the main

Tigercat 250C Loader

Electrical System & Computer

MEASURE MENU

PREFERENCES MENU

The information that is available in the Measure menus is used by Tigercat service technicians.

From the main Menu screen, press F3 to select the Preferences menu.

From the main Menu screen, press F2 to access the Measure menu.

The following menu items can be selected.

• Display

The following menu items can be selected.

• Date/Time

• Engine Parameters

• Language (d isplays other languages that may be available)

• IQAN Status • Joysticks • Boom Controls • Grapple Controls • Saw/Delimber • Inputs/Outputs Use the up or down arrow buttons to select the menu item. Press OK to confirm the selection.

Press the Back button main Menu screen.

(or F1) to return to the

6.36

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Electrical System & Computer

DISPLAY ADJUSTMENT

Screen Saver Adjustment

Select F1 for the Display adjustment menu. The following adjustments can be selected:

Select F3 to open the Screen Saver adjustment screen. Use the up or down arrow buttons to scroll through the choices. Three choices are available:

RETURN TO MAIN MENU – Select F1

• SCREEN SAVER OFF

BACKLIGHT ADJUSTMENT – Select F2

• DIMMED – Timeout 5 seconds

SCREEN SAVER – Select F3

• BLACK – Timeout 5 seconds

Backlight Adjustment

After making a selection, press OK to confirm.

Press the Back button menu screen.

After selecting F2, the Backlight adjustment menu opens. Use the up or down arrow buttons to adjust the display backlight. The range is 10 to 100. The default setting is 100.

When the desired setting is selected, press OK to set the selection. A good rule to follow is the lower the number, the longer the life of the display unit.

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DATE/TIME ADJUSTMENT

Date Adjustment

Press F2 to select the Date/Time adjustments in the Preferences menu.

Press F1 to select Date. Use the up or down arrow buttons to scroll through the Year list to select the year. Press OK to confirm year selected.

Two choices are available for adjustment:

When the year has been confirmed, the display highlights the Month. Use the up or down arrow buttons to select the month. Press OK to confirm month selected.

Date – Select F1 Time – Select F2

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Date Adjustment (continued)

Time Adjustment Select F2 Time adjustment from the DATE/TIME display screen.

When the month has been confirmed the display highlights the Day. Use the up or down arrow buttons to select the day. Press OK to confirm day selected.

The Time screen is displayed. Use the up or down arrow buttons to select the Hour. Press OK to confirm selection. The display shows the Minutes highlighted.

The display returns to the Date/Time menu.

Use the up or down arrow buttons to select the minute. Press OK to confirm the selection. The display returns to the Date/Time menu screen.

Press the Back button menu screen.

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INFO MENU SCREEN

MODULES

From the main Menu screen, press F4 to access the Info menu.

Press F1 to select the Modules menu. This menu provides information on the following machine modules: • MD3 Computer Module • XS2 Cab Input Module • XA2 Expansion Module • Cummins Engine ECU The information in these menus is used by Tigercat service technicians.

The software version and machine ID information are displayed on the screen.

The following menu items can be selected.

• Modules – Select F1 • Modem – Select F2 • Logs – Select F3 Shown above, the MD3 module has been selected. Specific technical information for the MD3 is displayed on the screen.

Press the Back button main Menu screen.

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MODEM

RESETTING THE PASSWORD

Press F2 to select the Modem menu. This menu provides information to service technicians on the modem specifications. The modem permits remote connectivity and diagnostics.

If you forget the password, hold down the F1, UP and DOWN arrows, and OK buttons simultaneously.

Press the Back button main Menu screen.

Release the buttons, then press OK until the X icon appears.

(or F1) to return to the

Enter 1-2-3-4 and press OK. This is now the new password.

LOGS

If you wish to change the password, select F3, – SET PWD. Use the up and down arrows to enter the new 4 digit PIN. Press OK to accept.

When the password code has been set, a check mark icon appears and NEW PASSWORD SET message is displayed. Also the Flow Adjustment icon appears on the lower right corner above F4 to indicate it is now accessible.

This menu is used by Tigercat service technicians.

Press F3 from the Info menu screen to select Logs. This menu lists System Logs and Alarm Logs and the number of records within each log.

The records are a list of all the fault occurrences in each log.

Use the up or down arrow buttons to select the menu item. Press OK to confirm the selection.

Press the Back button main Menu screen.

(or F1) to return to the

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DPF ELECTRONIC CONTROLS This machine is equipped with a Tier 4 diesel engine, designed to meet stringent exhaust emission standards of the US EPA. The engine exhaust emission system is equipped with a 2-stage DPF (catalytic filter). This exhaust emission after treatment system uses Catalyzed Continuously Regenerating Technology to reduce exhaust emissions.

DPF FILTER

DPF ICON

DPF SWITCH

DPF ICONS

OUTLET DPF INLET

DPF Alarm Icon When this icon is displayed, it indicates the DPF is close to full and the operator's assistance is required to perform the Regen.

DPF SENSOR TABLE

NOTE: The pilot switch must be turned off to perform a Regen.

250CT-026

DIESEL PARTICULATE FILTER (DPF)

To ensure optimum performance of the filter and engine, the DPF system monitors engine exhaust pressure and temperature to determine alert level.

From the main menu select F1 to go to the Engine menu page. The DPF Icon is displayed above the F3 button as shown above.

Press F3 to access the Regen information box, then select F4 to initiate Regen. A Regen only occurs if filter warning has occurred.

DPF ICON

This position is used by the operator to manually start an active regeneration of the diesel particulate filter when required by the engine (exhaust emission system).

250CT-027

The DPF Icons alert the operator when the filter requires cleaning by performing an active regeneration (Regen).

IMPORTANT! Refer to the diesel engine manufacturer's manual for further details and operation instructions for the DPF exhaust emission after treatment system.

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Electrical System & Computer AFTER TREATMENT DEVICE OPERATION Engine Work Cycles and the affect on the DPF System: During typical machine operation, the engine works at high idle with a continuous load on the engine. During this type of operation (Working Duty Cycle) the engine performs a passive regeneration of the DPF system cleaning the filter continuously. However, if the engine is operated at low idle and light loads (Light Duty Cycle) for an extended period, the engine cannot perform a passive regeneration. Trapped soot particles accumulate in the filter and an active Regen is required to clean the filter.

INHIBIT This mode disables Regen of the DPF. This allows the operator to Permit or Inhibit Automatic Regen.

Automatic Regen can occur while the machine is operating without warning or requiring acceptance from the operator.

To ensure optimum performance of the DPF filter and engine, the system monitors engine exhaust pressure and temperature. Display icons and alert messages warn the operator when the DPF filter needs cleaning.

Press F2 on the engine screen to launch the menu. Toggle between selections using the up or down arrow buttons. Accept a selection by pressing OK. Once initiated, only activating the pilot reset switch or shutting the engine off interrupts an active Regen.

High Exhaust System Temp (HEST) Lamp HEST Icon

or

When this Icon is displayed, it indicates that the exhaust temperature is high or that an active Regen is in progress. This icon does not appear during an Automatic Regen.

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ALERT WARNING LEVELS DPF First Alert Level – DPF Icon ON

DPF Third Alert Level – DPF Icon Flashing and Critical Display Message ON The DPF icon is Flashing, and an engine fault code (FC1921) and critical message are displayed on the display screen.

The DPF Icon is ON and an engine fault code (FC2639) is displayed on the display screen.

These messages alert the operator that a parked active regeneration of the DPF filter must be performed within the next few hours of engine operation. The machine must be taken to a safe area within this time frame and a parked active regeneration of the DPF filter must be performed.

When this warning occurs, the engine ECU begins to derate the engine fuel system. A non-mission regeneration must be performed by the operator.

When this warning occurs the machine must be taken to a safe area as soon as possible to perform a parked active regeneration of the DPF filter.

DPF Second Alert Level – DPF Icon Flashing The DPF icon flashes, and an engine fault code (FC2639) and alert message are displayed on the display screen.

When this warning occurs the machine must be taken to a safe area as soon as possible to perform a parked active regeneration of the DPF filter.

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DPF Fourth Alert Level: DPF Icon Flashing and STOP Engine Light ON The DPF Icon is off, and engine fault code (SPN 3251 FMI 0) and critical message are displayed on the display screen.

NON-MISSION REGENERATION

WARNING Warning, Fire and Burn Hazard! The high exhaust system temperature produced during an active exhaust system REGEN cycle can cause potential fire damage and inflict serious burn injuries.

Park the machine in a safe area where there are no flammable or combustible materials present and where the engine exhaust is a safe distance from personnel and property.

Keep all personnel clear of the machine.

Clean the engine, machine surfaces in and around the engine compartment and engine exhaust system area of all debris and combustible material before activating the DPF system REGEN switch.

Failure to follow all of the above instructions results in a fire which could cause severe property damage, serious burn injury or death.

When this warning occurs, the engine ECU severely derates the engine fuel system.

Stop the engine. The DPF filter is severely clogged. A parked active regeneration cannot be performed by the operator. A service only Regen is required and can only be performed by an authorized service technician. Contact the engine manufacturer's service representative for assistance.

To perform a non-mission regeneration of the after treatment DPF, follow this procedure: IMPORTANT! Refer to the diesel engine manufacturer's operation manual for complete details and operation instructions of the exhaust emission after treatment device system. A non-mission regeneration is only required when the DPF filter Icon appears on the computer display screen.

WARNING DO NOT perform a Non-mission REGEN in areas that PROHIBIT this operation, for example: near refuelling stations or in any areas where fire hazard warning levels are high.

NOTE: Read and understand the Fire Prevention instructions in Section 1.

1. Park the machine in a safe area where there are no flammable or combustible materials present and where the engine exhaust is a safe distance from personnel and property.

Shut engine OFF. 2. Keep all personnel clear of the machine.

High exhaust system temperature can cause severe burn injury.

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WARNING

WARNING, HOT FLUIDS, HOT MACHINE SURFACES AND HIGH EXHAUST SYSTEM TEMPERATURES CAN CAUSE SERIOUS BURNS! • Before servicing the machine, allow the engine cooling system, fuel system, exhaust system, hydraulic system and machine surfaces to cool down.

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

Observe the HEST Icon on the computer display turns ON. The regeneration cycle takes approximately 20 – 40 minutes (depending upon soot load).

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

3. Allow the engine and machine surfaces to cool down to below 38°C (100°F).

4. Clean the engine, machine surfaces in and around the engine compartment and engine exhaust system area of all debris and combustible material.

5. Start the engine. DO NOT increase the idle speed during the non-mission regeneration cycle.

6. Select the Engine menu F1 on the computer from the Main menu.

7. Push the F3 button to actuate Regen information dialogue box.

NOTE: DO NOT activate the pilot system to operate any machine function controls during the non-mission regeneration cycle unless it is absolutely necessary. Activating the pilot system deactivates and interrupts the Regen cycle, which has to be continued as soon as it is safe to do so.

IMPORTANT! If smoke or fire is detected during the regeneration cycle, STOP THE ENGINE. Investigate and resolve the cause of smoke or fire before continuing.

9. When the non-mission regeneration cycle is complete, the HEST Icon turns off.

The machine can now be returned to normal operations.

8. Press the F4 button to initiate the REGEN cycle.

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MESSAGES AND WARNINGS MD3 COMPUTER

WARNING LIGHT

WARNING BUZZER

The MD3 computer displays messages and warnings, and activates the master alarm and alarm light whenever a system fault occurs. Note that the computer control system automatically performs a bulb test at engine start up to ensure that master alarm and alarm light are functioning.

Refer to STARTING ENGINE in Section 2 of the Operator's Manual.

There are different types of Messages and Alarms, they appear on the screen as a block message.

The types of messages are: • CRITICAL MESSAGE – red • ALERT MESSAGE – amber • INFORMATION MESSAGE – blue Messages can be hidden or acknowledged by pressing F2 (Hide) or OK. All messages that have been hidden or acknowledged are stored in the computer.

In some instances it is necessary to immediately stop the machine, shut the engine OFF and repair the problem causing the message.

Active fault messages that have been hidden can be reviewed by pressing F4. Recalled messages and warnings are displayed in order, starting with the highest priority first.

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CRITICAL MESSAGES AND WARNINGS (RED) Critical messages advise the operator that a critical machine fault is about to occur or a system fault has occurred.

Critical messages have the highest level of priority and are used to alert the operator that immediate action must be taken to prevent damage to machine or to ensure operator safety.

When a critical message is displayed, the master alarm sounds and alarm light flashes continuously. The message remains on the screen until the operator hides it.

Critical messages and warnings flash the critical symbol above the F4 button when active messages are hidden. The symbol continues to flash until the problem is resolved and the fault becomes inactive. Active messages that have been hidden can be reviewed by pressing F4.

The message gives brief details of the fault and advises necessary action.

A list of CRITICAL MESSAGES is as follows:

In some instances immediate action is required to STOP machine operation, SHUT THE ENGINE OFF, and service the machine to correct the problem.

• Hydraulic Oil Level Low • Hydraulic Oil Temperature High • Engine Stop

However, if the machine cannot be stopped immediately for safety reasons, the operator can hide the message. In this instance the machine should only be operated long enough to make the machine safe, then STOP machine operation and SHUT THE ENGINE OFF before serious machine damage can occur!

• Hardware Fault – MD3 • Hardware Fault – Engine • Hardware Fault – XA2 • Engine Coolant Temperature High • Engine Coolant Level low

Messages can be hidden by pressing F2 (Hide).

• Engine CAC Temperature High • Engine Oil Pressure Low • Engine Fault Code Messages – Critical • Diesel Particulate Filter: Regeneration required immediately • Diesel Particulate Filter: Regeneration No Longer Possible. The Diesel Particulate Filter must be serviced 6.48

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HYDRAULIC OIL LEVEL LOW

Hydraulic Oil Level Low.

If the main hydraulic tank oil level is low, this warning is displayed, the alarm warning light flashes, and the alarm sounds.

Stop the engine immediately when this alarm is displayed. Operating machine with a low hydraulic oil level can cause hydraulic pumps to fail. Look for signs of broken hoses or other leaks.

Repair leaks and refill the main hydraulic tank to FULL mark on the sight gauge. Restart engine and inspect for leaks.

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HYDRAULIC OIL TEMPERATURE HIGH

Hydraulic Oil Temperature High.

If the hydraulic oil temperature exceeds the recommended operating range, this warning is displayed, the alarm warning light flashes, and alarm sounds.

If the temperature rises above the recommended operating range for the type of hydraulic oil in use, check the following: • Plugged oil cooler • Malfunction in a hydraulic system • High loads on the hydraulic system • Malfunction of the cooling fan • Low hydraulic oil level • Correct Hydraulic Oil Grade Selection If hydraulic oil temperature rises above the recommended operating range, DO NOT continue to operate the machine.

This alarm must not be used to monitor the hydraulic oil. The operator must use the hydraulic oil temperature gauge on the main menu, together with the operating range chart in Section 3 to prevent damage to the hydraulic system.

Hydraulic oil grade information is shown on the main menu below the hydraulic oil temperature gauge. Operating outside the recommended operating range shortens hydraulic component life.

Refer to COMPUTER – ADJUSTMENT MENU – SERVICE SETTINGS – HYDRAULIC OIL GRADE in this section for hydraulic oil grade selection settings information.

Refer to APPROVED HYDRAULIC OILS in Section 3 for hydraulic oil operating range information.

Refer to COMPUTER – INFORMATION MODE MENU – HYDRAULIC OIL TEMPERATURE in this section for hydraulic oil temperature information display.

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ENGINE STOP

HARDWARE FAULT – MD3

Hardware Fault – MD3

Engine Stop

Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

Critical engine fault active – contact service.

Hardware Fault – MD3 Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

If the engine stops or critical engine alarms are triggered while the ignition switch is in the RUN position, this warning is displayed, the alarm warning light flashes, and the alarm sounds.

If a critical active hardware fault related to the MD3 Display module has been hidden, this warning is displayed, the alarm warning light flashes, and the alarm sounds.

Refer to engine manufacturer's manual for specific information regarding the engine.

To recall the original active fault(s) the operator must turn the key off and on.

A VREF error is an example of the type of original active hardware fault that triggers this message.

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HARDWARE FAULT – XA2

HARDWARE FAULT – ENGINE

Hardware Fault – XA2

Hardware Fault – Engine

Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

Hardware Fault – XA2

Hardware Fault – Engine

Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

If a critical active hardware fault related to the XA2 module has been hidden, this warning is displayed, the alarm warning light flashes, and the alarm sounds.

If a critical active hardware fault related to the engine has been hidden, this warning is displayed, the alarm warning light flashes, and the alarm sounds.

To recall the original active fault(s) the operator must turn the key off and then back on.

To recall the original active fault(s) the operator must turn the key off and then back on.

VREF errors and No Contact errors are examples of original active hardware fault errors that trigger this message.

No Contact error is an example of the original active hardware fault errors that may trigger this message.

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COMMUNICATION FAULT – L.H. JOYSTICK

COMMUNICATION FAULT – R.H. JOYSTICK

LH Joystick Communication

RH Joystick Communication

No contact or invalid data. Limp mode is now available.

No contact or invalid data. Limp mode is now available.

If a critical communication fault related to the L.H. joystick is activated, this warning is displayed, the alarm warning light flashes, and the alarm sounds.

If a critical communication fault related to the R.H. joystick is activated, this warning is displayed, the alarm warning light flashes, and the alarm sounds.

LIMP MODE IS NOW ACTIVATED Limp Mode provides alternate operation of the fault joystick using the buttons on the MD3 module. Limp Mode should only be used long enough to place the machine in a safe condition.

Stop machine operation and shut the engine off to repair the joystick malfunction. Refer to LIMP MODE OPERATION in this section for complete details.

LIMP MODE IS NOW ACTIVATED Limp mode provides alternate operation of the fault joystick using the buttons on the MD3 module. Limp Mode should only be used long enough to place the machine in a safe condition.

Stop machine operation and shut the engine off to repair the joystick malfunction. Refer to LIMP MODE OPERATION in this section for complete details.

No Contact error (the joystick has lost the electrical connection with the MD3 computer) is an example of the type of fault that triggers this message.

No Contact error (the joystick has lost the electrical connection with the MD3 computer) is an example of the type of fault that triggers this message.

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ENGINE FAULT CODE MESSAGES – CRITICAL

SPN: 0 FMI: 0 1 of 1 Engine fault parameter – Fault Identifier

SPN: 0 FMI: 0 1 of 1 Engine fault parameter – Fault Identifier

If a critical engine fault message is received from the engine ECU, a critical engine fault message(s) is displayed, the alarm warning light flashes, and the alarm sounds.

They provide the suspect parameter number (SPN) code and the fault mode identifier (FMI) code, as well as a message describing the fault (when available).

Critical engine fault codes are higher priority messages than alert-level engine fault code messages. Critical messages can be hidden but immediate action must be taken. Stop machine operation and service engine immediately to resolve the cause of the fault.

An example of a critical engine fault message is shown above.

Note that some less common engine fault codes appear without a message describing the fault.

Make a note of the SPN and FMI codes and contact the Tigercat service department for more information.

Refer to engine manufacturer's manual for specific information regarding the engine.

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ALERT MESSAGES (YELLOW) Alert messages advise the operator that machine operation is compromised.

Alert messages have second level priority. They are used to indicate an action is required to prevent future damage to the machine.

All alert messages give brief details of the fault and advise necessary action.

Service the machine at the earliest opportunity to correct the problem. Doing so prevents future damage to the machine.

Computer system generated alert messages are generally triggered by computer system error and fault related conditions.

When a system generated alert message is displayed the external alarm sounds and light flashes 3 times to alert the operator of the message.

The message remains on the screen until the operator hides it.

Note that active hardware fault alert messages are acknowledged by pressing F2 (OK). To recall these messages, turn the ignition key off and then back on. On-screen messages indicate an active hardware fault has been hidden.

INTERACTIVE ALERT MESSAGES • Charge Filter Message – Alert

Alert messages flash the alert symbol above the F4 button when active messages are hidden.

• Eng Warning MSG – Alert • Engine Fault Code Messages – Alert

Press F4 to review active messages that have been hidden. The symbol continues to flash until the problem is resolved and the fault becomes inactive.

• LH Joystick DM1 Alert • Module MD3 Alert MSG • Module XA2 Alert MSG

Note that if both a critical level fault and an alert level fault are present, the critical symbol takes priority until the critical fault becomes inactive.

• RH Joystick DM1 Alert • COUT hardware fault MSG

Programmed alert messages are generally triggered by machine function related conditions.

• DOUT hardware fault MSG • DIN hardware fault MSG

If an alert message is displayed, the external alarm sounds and light flashes 3 times to notify the operator of the message. The message remains on the display until the operator hides it.

• VIN hardware fault MSG • High Exhaust System Temperature • Diesel Particulate Filter: Regeneration required within the next few hours.

Messages can be hidden by pressing F2.

• Diesel Particulate Filter: Regeneration required soon.

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ENGINE FAULT CODE ALERT MESSAGES

SPN: 110 FMI: 16 1 of 1 Engine coolant temperature high – Above normal, severe

If an engine fault message alert is received from the engine ECU, the fault message(s) is displayed, the alarm warning light flashes and the alarm sounds.

These alerts provide the suspect parameter number (SPN) and the fault mode identifier (FMI) codes as well as a message describing the fault (when available).

Engine fault code alerts are lower priority messages than critical level engine fault code messages. Alert messages can be hidden, but action (service engine) is required to resolve the cause of the fault.

An example of an engine alert fault message is shown above.

Note that some less common engine fault codes appear without a message describing the fault.

Make a note of the SPN and FMI codes and contact Tigercat service department for more information.

Refer to engine manufacturer's manual for specific information regarding the engine.

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CHARGE FILTER FAULT ALERT

HARDWARE FAULT – JOYSTICK

This warning is displayed when an active fault related to the Swing Pump Hydraulic Charge Filter has been triggered.

The oil flow through the filter is restricted and requires service. Service machine alert message is an example of the type of fault that triggers this message.

This warning is displayed when an alert level active fault related to the joystick module has been triggered.

Short circuit alert message is an example of the type of fault that triggers this message.

Restart power to joystick (turn key off then back on) to correct. If problem persists, contact the Tigercat service department.

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HARDWARE FAULT – MD3

HARDWARE FAULT – XA2

Hardware Fault – MD3

Hardware Fault – XA2-A0

Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

Hardware Fault – MD3

Hardware Fault – XA2-A0

Active fault has been hidden. Turn key off and on

Active fault has been hidden. Turn key off and on

to recall active hidden hardware faults.

to recall active hidden hardware faults.

This warning is displayed when an active hardware fault alert related to the MD3 Display module has been hidden.

This warning is displayed when an active hardware fault alert related to the XA2-A0 module has been hidden.

To recall the original active fault(s) the operator must turn the key off, then back on.

To recall the original active fault(s) the operator must turn the key off, then back on.

High temperature, low supply voltage and high supply voltage module alert messages are examples of the type of hardware fault that trigger this message.

High temperature, low supply voltage and high supply voltage module alert messages are examples of the type of hardware fault that trigger this message.

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Hardware Fault – XA2 No contact.

XA2-A0 MODULE – NO CONTACT ERROR

LOW FUEL LEVEL – FLASHING ICON

When this message is displayed, expect all machine functions controlled by this module to cease and all alarms and warnings associated with this module to be triggered.

This icon

The icon flashes on and off when the fuel level drops below 76 L (20 gal US).

CHECK FOR OTHER ERROR/ALARM MESSAGES ON SCREEN Press OK to acknowledge each error message.

Note that module offline errors are followed by other alarm messages associated with the modules that are out of contact.

Note also that the XA2-A0 module is the terminal module in the series connection. Therefore, failure of this module alone does not affect any other modules in the series.

If XA2-A0 MODULE NO CONTACT is the only error message, the likely causes are:

• • • •

(1) is a Low Fuel Level warning.

Power – Fuse (XA2 Module) Ground Address (ID-Tag) CAN wire connection

If the XA2-A0 MODULE IS OFFLINE error is not the only error message, check other affected modules (XS2-A0 for example) in sequence order from the MD3 connection.

Refer to MODULE NO CONTACT ERROR for each module for more detailed information.

CHECK MODULE LED STATUS INDICATORS

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WAIT TO START This icon appears on the display during the key ON, engine pre-heat time. Heating elements located in the engine air intake manifold are turned on to warm the intake air when starting the engine. Do not attempt an engine start until this icon automatically turns off.

TEMPERATURE

COLD WEATHER STARTING During cold weather, engine speed is controlled by the computer to limit maximum rpm until the hydraulic system temperature has warmed. The temperature is based on the oil grade selected.

21°C (70°F)

4.5°C (40°F) 1400 RPM ENGINE SPEED

1850 RPM

As the hydraulic system temperature rises, the engine rpm can be increased. The length of time it takes is dependent on ambient temperature and oil grade selected.

For example, when using an oil grade ISO 46 at 21°C (70°F) or above, engine rpm can be increased to a maximum of 1850 rpm.

NOTE: The idle-down function does not work until the engine speed can be increased to full rpm.

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CHANNELS

DIGITAL OUT (DOUT) A PWMOUT with 100% duty cycle is a Digital Out (DOUT). The outputs have a value of low or high.

These are mostly used to activate lamps, on/off valves or to pull relays.

The definition channels is a collective name for the inputs and outputs found on the different IQAN modules. There are also channels internally in the system, to handle for example, MD3 messages and mathematical calculations. The channels are used to collect and/or send data. Input and output channels are described below.

DIAGNOSTIC BREAKOUT HARNESSES Diagnostic breakout harnesses are available from Tigercat to verify computer readings independently.

INPUTS

Refer to ELECTRICAL KIT – SERVICE AND DIAGNOSTICS in this section for more information about diagnostic breakout harnesses.

VOLTAGE IN (VIN) The input signal at these inputs comes primarily from analog sensors, levers, and switches. These devices use a power/signal/ground system to provide an input value (VIN) between the high (+5 V) and low (-5 V) signals generated in the modules.

DIGITAL IN (DIN) An input that is typically on or off, such as a switch. This input is often used to determine if an event has occurred, such as pushing a button or engaging a relay.

FREQUENCY IN (FIN) Typical functions are speed measure or revolution measure. This input can count the number of signals per second to determine the speed of a rotating or reciprocating body.

OUTPUTS PWM OUT (PWMOUT) PWM (Pulse Width Modulation) Out is a way of producing an analog signal level with a digital output that turns on and off many times a second.

By varying the ratio between on and off time (duty cycle) an output proportional to the system voltage can be obtained. PWMOUT maintains a constant output voltage, and the output current is governed by output voltage and the resistance in the circuit.

CURRENT OUT (COUT) In this application outputs labeled COUT are actually PWM signals programmed to operate in closed loop mode. The close loop mode features a PWM signal with current regulation. The programmed COUT channel maintains a constant output current to control proportional solenoids.

The voltage is regulated to maintain the constant current based on the programmed input command independent of the resistance of the circuit.

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EXAMPLE – MEASURE MENU

Use the up or down arrow buttons to select the menu item. Press OK to confirm the selection.

From the main Menu screen, press F2 (Measure) to access the Measure menu.

Use the up or down arrow buttons move through the list of measured values in a measure group.

Module and pin information for the highlighted channel is shown on screen. Grey arrows to the right at the top and bottom of the screen indicate that more channels can be viewed above or below those currently on screen.

Press F2 to toggle between scaled value and raw value readings. Scaled values show the measured value in a scaled unit of measure (°C, %, psi etc). Raw value (where applicable) shows same readings as the raw value (mV, Hz etc.) in which they are measured.

Note that for some channel types the raw value selection is not applicable and the reading is displayed as “-” when viewing raw values. Press F2 to return to the scaled values to view readings for these channels.

The following menu items can be selected.

Press the Back button (or F1) to return to the main Menu screen.

• Engine Parameters • IQAN Status • L.H. Joystick • R.H. Joystick • Boom Controls • Grapple Controls • Saw Delimber • Input/Output

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ELECTRICAL KIT – SERVICE AND DIAGNOSTICS

USB HUB (4 PORT, TYPE A, ISOLATED ) (AN154) This isolated USB hub is used to protect your PC/laptop computer and the MD3 module from ground loops that can cause communication signal problems, or damage to the PC/laptop or module.

This kit includes a variety of electrical connectors, tools, cable, IQAN components, diagnostic breakout harnesses and service harnesses (Tigercat part number 20045B).

SELECTED ITEMS DIAGNOSTIC BREAKOUT HARNESS DEUTSCH CONNECTOR – CURRENT (20036B) This harness is used to check current (amps) flow to a component with a Deutsch connector and verify outputs.

ID-TAG ‘1’ (AN069) This is a replacement address tag. Refer to ID-TAG in this section for more detailed information.

ID-TAG ‘2’ (AN070) This is a replacement address tag. Refer to ID-TAG in this section for more detailed information.

DIAGNOSTIC BREAKOUT HARNESS DEUTSCH CONNECTOR – VOLTAGE (20037B) This harness is used to check voltage (volts) to a component with a Deutsch connector and verify inputs.

DEUTSCH 2 POLE SERVICE HARNESS (24860B) This harness is used to bypass a wiring harness while troubleshooting electrical problems. This method identifies or eliminates the wiring harness as a cause.

DIAGNOSTIC BREAKOUT HARNESS AMP CONNECTOR – CURRENT (20038B) This harness is used to check current (amps) flow to a component with a Amp connector and verify outputs.

AMP 2 POLE SERVICE HARNESS (24859B) This harness is used to bypass a wiring harness while troubleshooting electrical problems. This method identifies or eliminates the wiring harness as a cause

DIAGNOSTIC BREAKOUT HARNESS AMP CONNECTOR – VOLTAGE (20039B) This harness is used to check voltage (volts) to a component with an amp connector and verify inputs.

USB CABLE (TYPE A-B) (AN155) This cable is used to connect the IQAN MD3 (through the machine USB port) to an isolated USB hub plugged into a PC/laptop computer.

IMPORTANT! Connecting the USB cable directly to the USB port on a PC/laptop computer is not recommended. Using an isolated USB hub protects your PC/laptop USB port, and the MD3 module from ground loops that can cause communication signal problems, or damage to the PC/laptop and MD3 module.

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1

2

9

3

4

10

5

6

7

SER DIAG KIT

8

ELECTRICAL KIT – SERVICE AND DIAGNOSTICS – SELECTED ITEMS 6.64

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MD3 MODULE REPLACEMENT

REAR SIDE OF THE MD3 DISPLAY 1

250CT-035

2

3

UPPER INSTRUMENT PANEL 4

MD3-BACK

The back of the MD3 Module consists of the following.

1. Tag with serial number and part number.

2. Connector C2 (VIN inputs, USB communication and alarm output).

2. Remove the upper instrument panel.

3. Connector C1 (voltage supply, CAN communication J1939 and expansion modules).

3. Remove hex capscrews (1 top, 2 bottom) and back cover from the MD3.

4. Membrane valve for condensation prevention inside unit.

4. Disconnect the wiring harness at the module C1 and C2 connectors.

MD3 MODULE WIRING PIN ASSIGNMENT

1. Turn battery disconnect switch off.

MD3-WIREASSIGN

5. Remove the 4 screws and MD3 from the mounting bracket.

6

7 6 7

6 4 9 1 2 3 12 11 10

1

1 PILOT RESTDIN-A 2 THROT INC,DIN-B 3 THROT DEC,DIN-C 4 SPARE, DIN-D 5 GND-VREF 6 USB-D-LOW VOLT

When replacing an MD3 module, the machine serial number information must be reset. Refer to IQANrun 2 – SYSTEM for more information regarding access and maintenance of logs using IQANrun 2 software.

12

7 USB-D+HI VOLT 8 BLNK+5VREF 9 STOP LT DIN-E 10 SPARE,DIN-F 11 AIR FILT,VIN-G 12 BUZZER, DOUT-A

5 8

C1

5 8

C2

1 2 3 4 12 11 10 9

NOTE: Refer to IQANrun 2 – APPLICATION UPDATE in this section for procedure to update the application in an MD3 module.

7 6 7

6. Install new module in reverse order, then reinstall the instrument panel.

1

1 -GROUND 2 CAN-L,BUS-A 3 CAN-L,BUS-B 4 BLNK,CAN-L,BUS-C 5 BLNK,RS232 TRANS 6 BLNK

12

7 +BATTERY,RTC 8 BLNK,RS232-REC 9 BLNKCAN-H,BUS-C 10 CAN-H,BUS-B 11 CAN-H,BUS-A 12 +BAT

NOTE: Refer to the ELECTRICAL SCHEMATIC – NETWORKING, in this section or MACHINE ELECTRICAL SCHEMATIC for detailed pin and wiring assignment.

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IQAN SOFTWARE IQAN Active Studio software can be downloaded from the Tigercat Dealer Website.

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

Contact Tigercat Customer Service for more information about specific hardware requirements.

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

APPLICATION PROGRAM UPDATES FOR PRODUCT SERVICE BULLETINS Machine program updates are also available on the Tigercat dealer website. These program updates are generally associated with specific Product Service Bulletins. Program updates should only be undertaken as part of a PSB campaign or under instruction from Tigercat Customer Service. The latest version of the application can be run on any machine provided that all applicable Product Service Bulletin updates have been completed.

2. Click on Save.

DOWNLOADING APPLICATIONS FROM THE TIGERCAT DEALER WEBSITE NOTE: The following downloading instructions apply to the Tigercat dealer website format at the time of printing. If you experience difficulty due to changes on the website contact Tigercat Customer Service for assistance.

3. Select the folder you wish to save the program in.

4. Click on Save.

The IQAN program file has now been downloaded.

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SERVICING THE MD3 WITH IQANrun 2 SOFTWARE

Get Clone Gets and saves the existing application, settings and machine ID from the MD3. Recommended as a backup prior to tuning or updating the application. Refer to IQANrun 2 – UPDATE APPLICATION – GET CLONE in this section for details.

REQUIRED EQUIPMENT & INFORMATION

• PC/laptop computer • IQAN MD3 SERVICE KIT (40705B) • IQAN Active Studio software,Tigercat part number DG047. Refer to IQAN SOFTWARE in this section for dealer website download information.

• USB hub (4 port, Type A, isolated), Tigercat part number AN155 • USB cable (Type A-B), Tigercat part number AN154 • Service Password. Contact Tigercat Service Department to obtain passwords and additional information.

Send Clone Sends a previously saved clone file to the MD3.

Overwrites the application, factory defaults, adjustable values, stored values and machine ID. Only to be used under the direction of Tigercat Customer Service or Engineering. Refer also to important notes on the use of settings files at the end of IQAN RUN 2 – UPDATE APPLICATION – GET CLONE in this section.

Adjust Allows access to adjustment groups. In addition to adjust groups normally accessible on screen, additional adjust groups are restricted and require username and password login. Refer to IQANrun 2 – ADJUST in this section for details.

IQANrun 2 QUICK SUMMARY Connect To The MD3 With IQANrun 2 Servicing the computer system requires a PC/ laptop computer, the use of IQANrun 2 software, a USB hub and a USB cable. Refer to CONNECT TO THE MD3 WITH IQANrun 2 in this section for details.

Measure (Graph) Allows the user record, graph and measure group channel readings during machine operation, testing or setup procedures. These recordings can be saved or printed. Refer to IQANrun 2 – MEASURE (GRAPH) in this section for details.

Logs Allows the user to access to logs for service troubleshooting, maintenance documentation or clearing. Some log operations require sufficient rights to perform. Refer to IQANrun 2 – LOGS in this section for details.

Login Some service operations require a username and password access. Refer to LOGIN in this section for details.

Update Most commonly used operation. Use it to update the MD3 to a newer program or program revision.

Does not overwrite settings. Refer to UPDATE APPLICATION in this section for details.

System Allows the user to access system information including machine serial number information.

Refer to IQANrun 2 – SYSTEM in this section for details.

Get Setting Gets and saves the existing settings from the MD3. Recommended as a backup prior to tuning or updating the application. Refer to IQANrun 2 – UPDATE APPLICATION – GET SETTINGS in this section for details.

Send Settings Sends a previously saved settings file to the MD3. Overwrites factory default, adjustable and stored values. Only to be used under the direction of Tigercat Customer Service or Engineering.

Refer also to important notes on the use of settings files at the end of IQANrun 2 – UPDATE APPLICATION – GET SETTINGS in this section.

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CONNECT TO THE MD3 CONTROLLER WITH IQANrun 2 SOFTWARE

IMPORTANT !

Connecting the USB cable directly to the USB port on a PC/laptop computer is not recommended.

Using an isolated USB hub protects your PC/ laptop USB port and the MD3 module from ground loops that can cause communication signal problems, or damage to the PC/laptop and MD3 module.

4. Connect the other end of the USB A/B cable to the MD3 USB connector. Exact location of the connector varies between machine models.

1. Turn on PC/laptop and launch IQANrun by double-clicking the shortcut on your desktop.

IQANrun is part of the IQAN Active Studio.

2. Turn the machine key switch to the ON position, so the MD3 has power. Do not start machine.

3. Connect the USB Hub into the PC/laptop USB jack. Then connect the USB cable into the hub.

5. IQANrun 2 now indicates that it is online.

Proceed with service operations and login, if required. Refer to LOGIN in this section.

NOTE: If the MD3 does not contain an application (replacement module), the application has to be Updated before a user can login. Refer to UPDATE APPLICATION and LOGIN in this section.

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LOGIN 6. Press Login on the left-hand side.

9. The Login status at the bottom of the screen now indicates the login username.

7. A dialog box appears asking for a Username and Password. Contact the Tigercat Service Department for the Username and Password.

10. Note that each username and password combination comes with access rights appropriate for that user’s function.

If a user has insufficient rights to perform an operation (or is not logged-in when login is required) a dialog box appears to inform the user that this operation is not possible without the correct login and password.

8. A dialog box appears to confirm a successful login. Click OK to continue.

NOTE – SERVICE PASSWORDS: Contact Tigercat Service department to obtain passwords and additional information.

NOTE: After a successful login, the Windows® operating system1 provides the option to save the password. If Yes is selected, only the username is required at the next login.

1 Windows is a registered trademark of Microsoft Corporation in the United States and other countries.

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UPDATE APPLICATION Updating of machine programs should only be undertaken as part of a PSB campaign or under instruction from Tigercat Customer Service.

GET CLONE FILE

Application programs (*.ida files) are available on the Tigercat dealer website. Refer to DOWNLOADING APPLICATIONS FROM THE TIGERCAT DEALER WEBSITE in this section.

Before updating an application, it is recommended that a Clone File and Settings File are copied from the MD3 and saved as a backup.

GET CLONE FILE AND SAVE (*.IRC) A Clone file contains the application, machine ID, the settings and logs from the MD3. It is a record of exactly what was in the machine before the update.

GET SETTINGS FILE AND SAVE (*.ISA) A Settings file contains only the settings (factory defaults and adjustable values) from the MD3.

1. Click on Get Clone on the left-hand side.

A dialog box appears prompting the user to select whether or not to get the logs with the clone.

Select Yes to continue.

2. IQANrun 2 now gets a clone file. (This task could take several minutes.)

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3. A dialog box appears prompting selection of a suitable folder and file name to save the Clone file (.irc).

GET SETTINGS FILE 1. Click on Get Settings on the left-hand side.

2. A dialog box appears prompting selection of a suitable folder and file name to save the Settings file (.irs).

The file name by default is the machine ID (serial number). It is recommended to use the serial number followed by the date for the file name.

The file name by default is the machine ID. It is recommended to use the serial number followed by the date for the file name.

Press Save to continue.

IMPORTANT! A Clone file should rarely be used. It should only be used if updating the application and/or settings file is not successful in returning a machine’s performance to a previously acceptable state. A Clone file may be date-sensitive and should only be used on the day it was taken.

Press Save to continue.

IMPORTANT! A Settings file should rarely be used. It should only be used if adjusting machine settings manually is not successful in returning a machine’s performance to a previously acceptable state. Settings files may be date-sensitive and should only be used on the day that they were taken.

A Clone should NOT be used on a machine different than that which it was taken from, as machine specific configurations may differ and cause the machine to function improperly.

If a Settings file is used on a machine different than that which it was taken from, all adjustments must be reviewed in IQANrun to ensure machine specific parameters (such as options, pump/motor currents, hour counters) are correct. If this is not done, the machine may not function properly.

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UPDATE MD3 APPLICATION SOFTWARE Ensure that a Clone file and Settings file are saved as a backup prior to Update. Refer to GET CLONE FILE and GET SETTINGS FILE in this section.

6. IQANrun 2 provides a warning to ensure the machine is not moving and that the engine is shut down. The key switch must be in the Run position to power the MD3, however the engine is shut down. If this is the case, press OK to continue.

1. Click on Update on the left-hand side.

2. A dialog box appears prompting the selection of an MD3 application file (.ida).

Select the appropriate application file for the machine.

3. Select Open to continue.

7. IQANrun now sends the application file to the MD3 (IQAN system).

4. IQANrun 2 requests confirmation that the application being loaded is correct.

5. If the application is correct, select Yes to continue.

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8. Once the application is loaded successfully, the dialog box indicates the application file was successfully sent.

The MD3 now restarts and displays the main screen of the application.

The Update is now complete.

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ADJUST

LOCK SYMBOL INDICATES PIN REQUIRED ADJUST

EXAMPLE ADJUST SCREEN WITHOUT LOGIN ACCESS

1. Click on Adjust, on the left-hand side.

2. The adjust groups that are available are displayed.

3. Double-click an adjust group to adjust channels in that group.

Note that a lock symbol to the left of an adjust group indicates that a username/password is required to access that group. Contact the Tigercat service department to obtain password information.

EXAMPLE ADJUST SCREEN WITHOUT LOGIN ACCESS

Some adjust groups are accessible through the MD3 menus, and are unrestricted during normal operation. Other adjust groups are restricted by password and username, and are available either on screen or through the IQANrun 2 software application.

Some adjust groups are only visible on-screen to users with the appropriate username and password login rights.

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MEASURE/GRAPH 1. Click on Measure, on the left-hand side.

START PAUSE STOP

STOP MEASURE

EXPAND MEASURE GROUPS

USER DEFINED MEASURE GROUPS +ADD +ADD

COMMENT COMMENT

COMMENT

-DELETE -DELETE

It is not possible to add and delete measure groups or items while you are measuring. Click on the red square to stop measuring and enable the +Add and -Delete buttons.

2. All of the predefined measure groups available are shown on the right.

Select +Add to add a new measure group. Select New Measure Group, then right-click to rename it appropriately.

Each group can be expanded to view the channels in the groups.

3. To graph the channels in a measure group, double-click the measure group and the graph appears. (A single channel can also be chosen for graphing by double-clicking on that channel.)

Available channels can then be dragged and dropped into the New Measure Group.

To delete user-defined measure groups or items in a group, click on the group or item you wish to remove, then select the -Delete button.

4. Click on the green arrow to start measuring.

Click on the red square to stop measuring.

Click on Pause to pause the graph illustration while continuing to measure.

Note that user-defined measure groups are automatically saved on your PC. These groups are application-program-specific, and are available the next time the same application is inuse on any machine using the same program.

5. Click on Comment to add comments to the measure file at any time. The measure file data must be saved (*.irm) to retain comments for later viewing.

6. Click on the red square to stop measuring and access the zoom function. Select an area of the graph to zoom in and view in more detail. Click on Zoom Out to return to the full graph view.

7. Click on the red square to stop measuring and access save function. Click on Save to save the measure data as an *.irm file.

8. Click on the red square to stop measuring and access print function. Click on Print to print the graph and data recorded.

9. User-defined measure groups can be customized with the available channels in the existing groups.

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LOGS 1. Select Logs on the left-hand side.

SYSTEM INFO 1. Select System on the left-hand side.

SYSTEM LOGS

2. Logs available to view and/or clear are shown on the right.

2. System info is on the right including the application program name and the Machine ID (Serial Number).

NOTE: Username and password accesslevel rights determine whether the logs can be viewed or cleared. Some log items are restricted to higher-level users only.

3. The Machine ID is factory set. However, in the event that the MD3 is replaced, this information would need to be configured for the new module.

3. Double-click on the log you wish to view, or click on a log and then click Select to view the records in the log. Click on Done to return to the logs screen.

Updating Machine ID information requires a Login with sufficient rights.

Click on Machine Id. Enter the correct Serial Number. Click Set.

4. Click on Add Record to add a comment to the system log. For example, to record a filter change or other service event in the log.

Entries are restricted to 250 characters.

If the update is successful a dialog box displays. Click OK to acknowledge the update. A restart of the module is now requested. Follow the on-screen instructions to restart the module before continuing. If further service work is being performed, you need to login to IQANrun 2 again.

5. Click on Clear log to clear log entries for the selected log. Note that this function is rightsrestricted.

6. Click on Get Log to get the log information and save as an *.irf file.

7. Click on Print to print the log being viewed.

8. Click on Save to save the log file as an *.irl file.

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SELF-PROPELLED CARRIER ELECTRONIC DRIVE/STEER CONTROLS

Drive Mode When the drive function is engaged, the MD3 display changes to the Self-Propelled screen, signaling the self-propelled (SP) function is active.

(OPTIONAL)

TIGERCAT CARRIER The Tigercat AC16 Carrier is a 4-wheel drive, articulated-frame carrier. The following information outlines the computer-controlled drive system.

DRIVE MODE/PARK BRAKE SWITCH

DRIVE MODE ON PARK BRAKE OFF

DRIVE MODE OFF PARK BRAKE ON

Press the Drive Mode Accept (top left-hand thumbswitch) button on the joystick to activate the SP function. The R.H. joystick becomes the drive and steering control. The display returns to the main menu screen.

250C-003

The Drive Mode/Park Brake switch is located on the right-hand instrument panel, beside the operator's seat. It enables the self-propelled functions of the machine, including drive/steer, transmission gear selection, and front differential lock. Engaging Drive Mode releases the park brake. Switching it off engages the park brake.

TOP LEFT-HAND THUMBSWITCH

Park Brake Ideally the machine should come to a complete stop before engaging the park brake. If the machine is not at a complete stop, applying the park brake slowly shuts down the drive motors, bringing the machine to a stop before engaging.

RIGHT-HAND JOYSTICK

SPAC-005

A red icon (1) on the display indicates when the park brake is ON. 1

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When the drive mode switch is turned ON, the MD3 computer switches the R.H. joystick from standard loader functions to self-propelled drive functions.

1

Top Left – Drive Mode Accept When the drive mode switch is activated, the top left-hand thumbswitch must be pressed to accept the drive mode feature.

2

Top Right – Differential Lock, Front Axle Press and hold the top right-hand thumbswitch to engage the differential lock. Release it to disengage.

Push and hold to activate the differential lock feature on the FRONT axle and provide driving torque to BOTH front wheels. The differential lock disengages when the button is released.

1 SPAC-009

The MD3 screen displays the main menu showing the drive mode icon (1) and the gear selection icon (2).

When the drive mode switch is turned OFF, the MD3 computer switches the R.H. joystick from self-propelled functions back to standard loader functions.

RIGHT-HAND JOYSTICK LEVER

SPAC-012

When the differential lock is engaged, the front axle differential lock icon (1) on the computer display is green.

CENTER FOOT CONTROL – BRAKES Depress the foot pedal to apply the hydraulic brakes.

250C-004

RIGHT JOYSTICK

Drive Function Push the joystick lever forward to drive the machine forward.

Pull the joystick lever back to drive the machine in reverse.

SPAC-004

Steering Function Move the joystick lever to the left to steer the machine to the left.

Move the joystick lever to the right to steer the machine to the right.

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GEAR SELECTION SWITCH

Shifting Procedure: NOTE: All joystick controls are disabled when a gear change is in progress. Bring the machine to a full stop on level ground.

• Reduce the engine speed to idle.

2ND GEAR (HI) POSITION

• Depress foot brake pedal to hold the machine stationary.

• Push the top of the gear selection switch to change from 1st (Low) to 2nd (High) gear.

1ST GEAR (LOW) POSITION 250C-003

CAUTION Do not shift gears while the machine is in motion. Damage to the drive system will result. The two-speed transmission does not have the capability to mesh moving gears.

Stop the machine to shift gears. This allows the shift to be made with minimum effort and prevents damaging the transmission.

SPAC-010

If the operator shifts gears while the machine is in motion, severe damage will occur to the shift collar and its mating gears, resulting in difficulty or inability to shift from one speed to the other.

On an up-shift, the computer screen displays a warning that a gear change is in progress, and the transmission is changing from 1st to 2nd gear.

1

• Push the bottom of the gear selection switch to change from 2nd (High) to 1st (Low) gear.

SPAC-009

The current drive gear selected is shown on the main display screen (1). In the example above, the transmission is in 1st gear.

On a down-shift, the computer screen displays a warning that a gear change is in progress, and the transmission is changing from 2nd gear to 1st gear.

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BASIC SELF-PROPELLED CARRIER DRIVE MODE SWITCH DRIVE MODE SWITCH 'ON' POSITION

1

DRIVE MODE SWITCH 'OFF' POSITION

250C-001

DRIVE MODE SWITCH The main menu displays the self-propelled drive icon (1) when the system is activated. The icon remains on as long as the drive mode is active.

This switch enables the drive/steer function on self-propelled machines.

Place the Drive Mode Switch in the ON position by pressing the top of the switch. The switch must be on for the self-propelled function to operate.

Press the bottom of the switch to turn the drive function off.

RIGHT-HAND JOYSTICK LEVER Drive Push the joystick lever forward to drive the machine forward.

When the drive function is first engaged, the MD3 display changes to the Self-Propelled (SP) screen to advise the operator that the function is enabled.

The R.H. joystick becomes the drive and steering control. The thumbswitch becomes brake function.

Pull the joystick lever back to drive the machine in reverse.

Steering Move the joystick lever to the left to steer the machine to the left.

MD3 DISPLAYING THE SP FUNCTION.

Move the joystick lever to the right to steer the machine to the right.

R.H. JOYSTICK IS DRIVE/STEER CONTROL.

RIGHT-HAND JOYSTICK THUMBSWITCH

THUMBSWITCH IS BRAKE CONTROL.

234E-149

MD3 DISPLAYING SP FUNCTION ENABLED To acknowledge and activate the SP function, press the joystick thumbswitch.

P

The right-hand joystick thumbswitch is used to activate the brake to stop machine travel. Push and hold the thumbswitch to apply the brake to stop machine travel.

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When the drive mode is ON, the MD3 computer switches the R.H. joystick from standard loader functions to self-propelled drive/steer and brake functions.

PARK BRAKE SWITCH PARK BRAKE SWITCH 'ON' POSITION

1

PARK BRAKE SWITCH 'OFF' POSITION

250C-001

DRIVE SYSTEM ACTIVATED

PARK BRAKE SWITCH

This switch engages/disengages the park brake function on self-propelled machines. The switch is active at all times. Press the top of the switch to turn the park brake ON. Press the bottom of the switch to turn the park brake OFF.

The MD3 screen displays the drive mode icon (1) on the main menu when the system is activated.

2

When the drive mode switch is turned off, the MD3 computer switches the R.H. joystick from self-propelled functions back to standard loader functions.

The red park brake icon (2) on the MD3 display indicates the park brake is engaged.

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ELECTRICAL SCHEMATICS ENGINE / BATTERIES – 2502001 TO 2502040

250C-029

SHEET 1 OF 2 6.82

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ENGINE / BATTERIES – 2502001 TO 2502040

250C-030

SHEET 2 OF 2 6.83

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ENGINE / BATTERIES – 2502041 TO 2503000

250C-022

SHEET 1 OF 2 6.84

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ENGINE / BATTERIES – 2502041 TO 2503000

250C-023

SHEET 2 OF 2 6.85

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INSTRUMENTATION – 2502001 TO 2502040

250C-029

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INSTRUMENTATION – 2502041 TO 2503000

250C-016

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NETWORKING – 2502001 TO 2502010

250C-030

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NETWORKING – 2502011 TO 2502040

Ω

Ω

250C-033

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NETWORKING – 2502041 TO 2503000

250C-017

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JOYSTICK CONTROL LEVERS – 2502001 TO 2502010

250C-034

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JOYSTICK CONTROL LEVERS – 2502011 TO 2502040

250C-035

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JOYSTICK CONTROL LEVERS – 2502041 TO 2503000

250C-018

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CAB ACCESSORIES – 2502001 TO 2502040

250C-036

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CAB ACCESSORIES – – 2502041 TO 2503000

250C-019

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LIGHTING – 2502001 TO 2502040

250C-037

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LIGHTING – 2502041 TO 2503000

250C-020

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HVAC / FUEL HEATER – 2502001 TO 2502040

250C-038

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HVAC – 2502041 TO 2503000

250C-021

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FUEL HEATER OPTION – 2502041 TO 2503000

250C-024

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STABILIZERS – 2502001 TO 2502040

250C-039

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STABILIZERS – 2502041 TO 2503000

250C-028

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VALVE /PUMP CONTROL – 2502001 TO 2502040

250C-040

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VALVE/PUMP CONTROL LOADER WITH BAR SAW – 2502041 TO 2503000

250C-026

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VALVE/PUMP CONTROL LOADER WITH CIRCLE SAW – 2502041 TO 2503000

250C-027

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TILT CAB OPTION – ALL

250C-025

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INSTRUMENT PANEL WIRING DIAGRAM (2502001 – 2502040)

250BT-035

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INSTRUMENT PANEL WIRING DIAGRAM (2502041 – 2503000)

250B-045

6.108

Tigercat 250C Loader SECTION 7 – ENGINE START & STOP CONTENTS – SECTION 7

JUNE, 2014

E

ELECTRICAL SCHEMATICS – ENGINE START CIRCUIT....................................................................... 7.6 START CIRCUIT AT REST – 2502001 TO 2502040.............................................................................. 7.6 START CIRCUIT AT REST – 2502041 TO 2503000............................................................................ 7.14 START CIRCUIT AT REST – BATTERY DISCONNECT SWITCH ON – 2502001 TO 2502040............ 7.8 START CIRCUIT AT REST – BATTERY DISCONNECT SWITCH ON – 2502041 TO 2503000.......... 7.16 START CIRCUIT – IGNITION KEY IN RUN POSITION – 2502001 TO 2502040................................ 7.12 START CIRCUIT – IGNITION KEY IN RUN POSITION – 2502041 TO 2503000................................ 7.20 START CIRCUIT – IGNITION KEY IN START POSITION – 2502001 TO 2502040............................. 7.10 START CIRCUIT – IGNITION KEY IN START POSITION – 2502041 TO 2503000............................. 7.18 ENGINE START CIRCUIT.......................................................................................................................... 7.2 CIRCUIT DESCRIPTION........................................................................................................................ 7.2 STARTING THE ENGINE....................................................................................................................... 7.2 ENGINE STOP CIRCUIT........................................................................................................................... 7.5 STOPPING IN AN EMERGENCY........................................................................................................... 7.5 STOPPING THE ENGINE...................................................................................................................... 7.5 S

STARTING THE ENGINE COLD WEATHER STARTING................................................................................................................ 7.3 PROCEDURE......................................................................................................................................... 7.2 STARTING AN ENGINE THAT HAS RUN OUT OF FUEL...................................................................... 7.4

Tigercat 250C Loader

Engine Start & Stop

ENGINE START CIRCUIT

STARTING THE ENGINE

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

WARNING DO NOT USE ETHER! Engine is equipped with an electric heater starting aid. Use of ether may cause an explosion and severe injury.

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.

WARNING Do not attempt to operate any function or accessory while starting the engine.

Serious injury or property damage may result.

CIRCUIT DESCRIPTION Refer to ENGINE START CIRCUIT ELECTRICAL SCHEMATICS in this section.

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

WARNING Do not start engine by shorting across starter terminals. Start engine only from operator's seat.

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 to energize the coils of the start solenoid relay. The start solenoid relay contacts close and current flows from the alternator to the starter solenoid coil to close the contacts and operate the start motor to crank the engine.

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

2. Turn Battery disconnect switch ON.

For the engine ECU to supply fuel, there needs to be power at the vehicle Key Switch input pin on the 60 pin ECU connector. The Key Input Relay and 3 fuses control the signal to the ECU, which together with the start motor, start the engine.

In order to operate the machine functions after starting the engine, the arm rest must be in the latched down position and the Pilot Reset button depressed. This will energize the pilot shut-off relay, close the contacts and allow current to energize the pilot shut off solenoid valve on the pilot manifold. After the Pilot Reset button is released, current will continue to flow to the diode to latch the pilot shut-off relay in the energized position and allow current to flow to the pilot shutoff solenoid valve.

COMPUTER DISPLAY

For additional information on the PILOT SYSTEM, refer to Section 5.

3. Turn ignition key to RUN position and observe computer display.

Wait for WAIT TO START warning to turn OFF before starting engine.

Make sure any warning messages displayed are understood. Take corrective action before starting engine.

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

7.2

Tigercat 250C Loader

Engine Start & Stop COLD WEATHER STARTING

WARNING

During cold weather, the engine idle speed is controlled by the computer to limit maximum engine speed until the hydraulic system temperature has warmed. The temperature setting is based on the oil grade selected on the computer.

To prevent damage to starter, do not engage starter motor for more than 15 to 20 seconds. Wait 2 minutes between each attempt to start the engine.

If engine fails to start, refer to engine manufacturer's maintenance manual.

As the machine hydraulic system temperature rises, the engine idle speed can be increased.

The length of time it takes is dependent on ambient temperature and hydraulic oil grade selected.

5. Turn ignition key switch to the START position to crank the engine. When engine has started, release key and observe gauges and computer display.

TEMPERATURE

21°C (70°F)

4.5°C (40°F) 1400 RPM

1850 RPM ENGINE SPEED

As an example, engine speed can be increased to maximum 1850 rpm using ISO 46 oil grade, once the temperature reaches 21°C (70°F) or above.

NOTE: The idle down function will not work until the engine idle speed can be increased to full rpm.

COMPUTER DISPLAY

WARNING After engine has started, keep engine speed low until engine oil pressure registers on gauge. If it does not register within 10 seconds, stop engine and investigate cause.

Allow a cold engine to warm up at LOW IDLE for at least 5 minutes before applying any load. Check all gauges often during the warm-up period.

7.3

Tigercat 250C Loader

Engine Start & Stop

STARTING AN ENGINE THAT HAS RUN OUT OF FUEL

prevents starter motor engagement for 2 minutes if the engine fails to start. The engine STARTER LOCKOUT also prevents the starter motor from being engaged when the engine is running.

If the engine has run out of fuel, the fuel line must be primed before making a start attempt.

Refer to engine manufacturer's manual for more information.

WARNING DO NOT USE ETHER! Engine is equipped with an electric heater starting aid. Use of ether may cause an explosion and severe injury.

1. Make sure ignition key is turned OFF. 2. Refill fuel tank completely.

3. Locate the Fuel Filter/Water Separator on the engine. Open the Air Vent Plug 2 turns.

250C-050

AIR VENT PLUG

HAND PRIMING PUMP

FUEL FILTER/WATER SEPARATOR 4. Unscrew the Hand-Priming Pump knob and prime the system by pumping by hand until fuel is coming out of the Air Vent Plug.

5. Tighten the Air Vent Plug to 15 N•m (11 lbf•ft).

6. Hand-tighten the knob of the Hand-Priming Pump.

7. Crank the engine until it starts. Do Not crank continuously for more than 20 seconds.

This engine is equipped with a STARTER LOCKOUT feature. It prevents a start attempt if the starter motor was previously engaged within the last 20 seconds or less. This feature 7.4

Tigercat 250C Loader

Engine Start & Stop

ENGINE STOP CIRCUIT

STOPPING IN AN EMERGENCY The electrical system is equipped with an Emergency Stop Switch. When applied, it cuts power to the key input circuit that provides power to the engine ECU. The emergency stop switch is located in the middle of the instrument panel to the right of the operator's seat. The switch provides a quick engine-stop that shuts the engine off and stops all machine functions from operating. It is used in the event an emergency shutdown is required. Push-in to apply.

STOPPING THE ENGINE IMPORTANT! Stopping the engine immediately after it has been working under load can result in overheating and premature wear of the engine components.

Allow the engine to cool properly by following the stopping procedure outlined below. Do not race engine before shut-down.

1. Make sure grapple and boom assembly are fully lowered and supported by the ground, trailer or carrier.

1

2. Reduce engine speed to LOW IDLE and leave idling for about 3 minutes. Doing so reduces turbo speed and allows engine parts to cool gradually. Cooling the engine gradually also prevents loss of coolant by after-boil and possible hot spot damage.

3. Ensure all controls are in their neutral position, and all accessories and functions are turned off.

When the emergency stop switch (1) is depressed, it immediately turns off electrical power to the engine ECU and the pilot system.

The power from the key input fuse is disconnected which turns the key switch relay off disconnecting the key switch fuse power to the ECU, shutting power off and stopping the engine.

4. Stop engine by turning key switch to the OFF position.

5. Ensure all functions are turned off. Remove ignition key and lock-up cab.

6. Turn battery disconnect switch OFF.

To return the power to the cab turn the knob clockwise, allowing the switch to release and popup to its raised position.

IMPORTANT! Prior to starting the engine, check the position of the emergency stop switch. Make sure it is in the raised position, otherwise the engine will not start.

7.5

Tigercat 250C Loader

Engine Start & Stop

ENGINE START CIRCUIT ELECTRICAL SCHEMATICS START CIRCUIT AT REST – 2502001 TO 2502040

250C-057

SHEET 1 OF 2 7.6

Tigercat 250C Loader

Engine Start & Stop

Start Circuit at rest – 2502001 TO 2502040

250C-057

SHEET 2 OF 2 7.7

Tigercat 250C Loader

Engine Start & Stop

START CIRCUIT AT REST – BATTERY DISCONNECT SWITCH ON – 2502001 TO 2502040

250C-058

SHEET 1 OF 2 7.8

Tigercat 250C Loader

Engine Start & Stop

START CIRCUIT AT REST – BATTERY DISCONNECT SWITCH ON – 2502001 TO 2502040

250C-058

SHEET 2 OF 2 7.9

Tigercat 250C Loader

Engine Start & Stop

START CIRCUIT – IGNITION KEY IN START POSITION – 2502001 TO 2502040

250C-059

SHEET 1 OF 2 7.10

Tigercat 250C Loader

Engine Start & Stop

START CIRCUIT – IGNITION KEY IN START POSITION – 2502001 TO 2502040

250C-059

SHEET 2 OF 2 7.11

Tigercat 250C Loader

Engine Start & Stop

START CIRCUIT – IGNITION KEY IN RUN POSITION – 2502001 TO 2502040

250C-057

SHEET 1 OF 2 7.12

Tigercat 250C Loader

Engine Start & Stop

START CIRCUIT – IGNITION KEY IN RUN POSITION – 2502001 TO 2502040

250C-057

SHEET 2 OF 2 7.13

Tigercat 250C Loader

Engine Start & Stop

START CIRCUIT AT REST – 2502041 TO 2503000

250C-061

SHEET 1 OF 2 7.14

Tigercat 250C Loader

Engine Start & Stop

START CIRCUIT AT REST – 2502041 TO 2503000

250C-061

SHEET 2 OF 2 7.15

Tigercat 250C Loader

Engine Start & Stop

START CIRCUIT AT REST – BATTERY DISCONNECT SWITCH ON – 2502041 TO 2503000

250C-062

SHEET 1 OF 2 7.16

Tigercat 250C Loader

Engine Start & Stop

START CIRCUIT AT REST – BATTERY DISCONNECT SWITCH ON – 2502041 TO 2503000

250C-062

SHEET 2 OF 2 7.17

Tigercat 250C Loader

Engine Start & Stop

START CIRCUIT – IGNITION KEY IN START POSITION – 2502041 TO 2503000

250C-063

SHEET 1 OF 2 7.18

Tigercat 250C Loader

Engine Start & Stop

START CIRCUIT – IGNITION KEY IN START POSITION – 2502041 TO 2503000

250C-063

SHEET 2 OF 2 7.19

Tigercat 250C Loader

Engine Start & Stop

START CIRCUIT – IGNITION KEY IN RUN POSITION – 2502041 TO 2503000

250C-064

SHEET 1 OF 2 7.20

Tigercat 250C Loader

Engine Start & Stop

START CIRCUIT – IGNITION KEY IN RUN POSITION – 2502041 TO 2503000

250C-064

SHEET 2 OF 2 7.21

Tigercat 250C Loader

Engine Start & Stop

7.22

Tigercat 250C Loader SECTION 9 – ENGINE ANTI-STALL CONTENTS – SECTION 9

JUNE, 2014

A

ANTI-STALL – GENERAL.......................................................................................................................... 9.2 ANTI-STALL MODE SELECTION........................................................................................................... 9.2 ANTI-STALL SYSTEM DIAGRAM.......................................................................................................... 9.3 COMPONENTS...................................................................................................................................... 9.2 E

ELECTRICAL SCHEMATIC – VALVE/PUMP CONTROL........................................................................... 9.4 T

TROUBLESHOOTING............................................................................................................................... 9.6 ADDITIONAL FAULT FINDING PROCEDURES.................................................................................... 9.7 ANTI-STALL QUICK CHECK.................................................................................................................. 9.6

Tigercat 250C Loader

Engine Anti-stall

ANTI-STALL – GENERAL

Anti-stall can be turned OFF for maintenance work if required. See ANTI-STALL MODE SELECTION.

The Anti-stall system prevents the engine from lugging down and stalling when the hydraulic system is working under high loads. If a drop in engine rpm is detected, the system destrokes the main pump to reduce engine load and maintain engine speed. Anti-stall occurs without any input from the operator, and in most cases is unaware of the operation of this system.

NOTE: With the system off, the engine may stall under high loads.

ANTI-STALL MODE SELECTION From the main display screen, press F2 to select the Adjustment menu.

Any drop in engine speed below a set rpm results in an increase in signal current being sent to the control solenoid on the main pump. Above the set rpm, the signal current value is 0 mA. As the engine speed drops, the signal current increases proportionally. This signal causes the solenoid valve to shift, destroking the pump. This electrical signal is a pulse-width-modulated signal providing precise modulation of the hydraulic valve, resulting in smooth control of the main pump displacement.

Anti-stall on/off selection is done through the MD3 computer display. Anti-stall operates at any engine rpm, however for normal working operation the engine rpm should be set at high idle with Antistall ON. ELECTRONIC DISPLACEMENT SOLENOID VALVE

From the Adjustment menu, press F1 to select the Anti-Stall menu.

Two choices are given, ON or OFF. Press the up or down arrow buttons to scroll to the desired selection. Press OK to select.

MAIN PUMP CONTROLLER 250BT-008

MAIN PUMP CONTROLLER

COMPONENTS • A speed sensor and engine ECU (Cummins engine components).

• An electronic displacement solenoid valve mounted on the main pump.

Press the Back button to return to the Adjustment menu. Press it again to return to the main display screen.

• An Anti-stall on/off switch accessible through the MD3 controller.

• A wiring harness.

9.2

Tigercat 250C Loader

MD3 COMPUTER CONTROL AND DISPLAY MODULE

Engine Anti-stall

ENGINE ECU

ENGINE

MAIN PUMP SWING PUMP

JOYSTICKS

ENGINE SPEED SENSOR

XA2 VALVE MODULE

XS2 CAB MODULE

ELECTRONIC DISPLACEMENT SOLENOID VALVE

PILOT SOLENOID VALVE

WIRING HARNESS

MAIN DIRECTIONAL CONTROL VALVE

250C-051

ANTI-STALL SYSTEM DIAGRAM 9.3

Tigercat 250C Loader

Engine Anti-stall

ELECTRICAL SCHEMATICS VALVE/PUMP CONTROL – 2502001 TO 2502040

250C-040

9.4

Tigercat 250C Loader

Engine Anti-stall

VALVE/PUMP CONTROL – 2502041 TO 2503000

250C-026

9.5

Tigercat 250C Loader

Engine Anti-stall

TROUBLESHOOTING

Expected Results: • All functions should operate normally (engine may stall).

ANTI-STALL QUICK CHECK The following is a quick procedure to determine if the Anti-stall system is functioning properly. If the machine fails these tests, a more detailed diagnosis is necessary.

• Gauge pressure should be 0–0.7 bar (0– 10 psi).

Problem Occurs with Anti-stall ON The problem is either related to the hydraulic system, the engine, or the Anti-stall system.

Additional problems related to the Anti-stall system may not be evident. Refer to ADDITIONAL FAULT FINDING PROCEDURES in this section.

5. Connect a 0–100 bar (0–1000 psi) gauge to the Horsepower Control gauge test port on the main pump.

IMPORTANT! Always make sure that the hydraulic oil is at operating temperature when performing the following steps.

6. Start engine and leave at LOW IDLE. 7. Engage pilot reset switch.

WHEN DOES THE PROBLEM OCCUR? Problem Occurs with Anti-stall OFF The problem is likely hydraulic related, and can include the electronic displacement solenoid valve on the main pump.

8. Turn Anti-stall ON. The gauge should read 31–34.5 bar (450–500 psi).

9. Slowly increase engine rpm.

Expected Results: • Gauge pressure should begin to decrease as engine speed increases.

1. Connect a 0–100 bar (0–1000 psi) gauge to the Horsepower Control gauge test port on the main pump.

• Gauge pressure should be 0–0.7 bar (0– 10 psi) at full throttle.

2. Start engine and leave at LOW IDLE. 3. Turn Anti-stall OFF. 4. Engage pilot reset switch and activate each function one at a time.

360 L/M (95 GPM)

2

PUMP HP HORSEPOWER CONTROLLER CONTROL TEST PORT

1

250BT-009

MAIN PUMP

2 LS RELIEF PRESSURE SETTING 1 MARGIN PRESSURE SETTING

250C-054

ANTI-STALL CONTROL 9.6

Tigercat 250C Loader

Engine Anti-stall

ADDITIONAL FAULT FINDING PROCEDURES The following procedures can be used to further diagnose problems with the Anti-stall system.

Perform these procedures when additional diagnosis is required. They are not listed in any particular order.

PILOT PRESSURE • Ensure pilot pressure is correct. To verify Pilot Pressure, refer to PILOT SYSTEM in Section 5.

MARGIN PRESSURE • Ensure margin pressure is correct. To verify Margin Pressure, refer to HYDRAULIC SYSTEM in Section 4.

SOLENOID VALVE WIRES (AT CONNECTORS) If the solenoid or wiring has shorted-out, the MD3 computer displays an error message that the Pump HP Limiter has an Open Load or Overload.

However, if there is no error message and Antistall is not functioning, check the wiring and coil resistance as follows: 1. Remove the connector from XA2 valve module.

2. Measure resistance between pin 7 (wire 181-RD) and pin 21 (wire 183-GR) on the connector (see pump control circuit on this page).

250C-052

The resistance should be 11.5 to 18.0 ohms with the hydraulic oil temperature at 21°C–52°C [70 °F–125 °F]).

SOLENOID VALVE COIL (AT COIL) If the solenoid has shorted-out, the MD3 computer displays an error message that the Pump HP Limiter has an Open Load or Overload. However, if there is no error message and the anti-stall is not functioning, check the coil resistance as follows: 1. Remove connector from the electronic displacement solenoid.

2. Measure resistance of solenoid coil.

The resistance should be 11.5 to 18.0 ohms (with hydraulic oil temperature at 21°C–52°C [70°F– 25°F]).

9.7

PUMP CONTROL CIRCUIT SCHEMATIC

Tigercat 250C Loader

Engine Anti-stall

ELECTRICAL POWER TO PUMP CONTROL VALVE SOLENOID When Anti-stall is on, an electrical signal is sent to the pump electronic displacement solenoid from the MD3 computer by way of the XA2 valve module. The signal is current output. The signal value varies from 600 mA at low idle (900 rpm), to 0 mA at full throttle (1850 rpm).

DIAGNOSTIC PLUGS TO FIT MULTI-METER DIAGNOSTIC BREAK-OUT HARNESS

NOTE: The main pump controller is guided by hydraulic oil temperature and engine load. The pump is variably de-stroked until the hydraulic oil temperature is within operating range.

1. Remove wire connector from main pump electronic displacement solenoid valve.

2. Connect diagnostic break-out harness 20036B (part of Tigercat electrical kit 20045B) to the solenoid plug and wire harness connector.

ELECTRONIC DISPLACEMENT SOLENOID VALVE

250C-053 234-178

MACHINE WIRE HARNESS

DIAGNOSTIC BREAKOUT HARNESS

3. Connect a multi-meter to the diagnostic plugs of the break-out harness. Set multi-meter to current flow selection.

4. Start engine. Make sure that Anti-stall is ON. Observe the meter reading at low idle speed (900 rpm). It should read 600 mA.

ELECTRONIC DISPLACEMENT SOLENOID VALVE

5. Increase engine rpm to full throttle (1850 rpm). Meter reading should be (0 mA).

NOTE: When the MD3 computer senses a drop in engine speed, the signal to the displacement solenoid valve increases proportionally. This allows pilot oil to destroke the pump and provide Anti-stall.

PUMP 'POR' VALVE

'LS' MARGIN PRESSURE ADJUSTING SCREW

MD3 AND XA2 EXPANSION MODULE TEST Refer to ELECTRICAL SYSTEM, Section 6 for test procedures.

250BT-008

9.8

MAIN PUMP CONTROLLER

MAIN PUMP CONTROLLER

Tigercat 250C Loader SECTION 10 – OIL COOLER, RADIATOR, AND FAN CONTENTS – SECTION 10

JUNE, 2014

C

CHARGE AIR COOLER SYSTEM........................................................................................................... 10.7 CHARGE AIR COOLER SYSTEM AND AIR FLOW............................................................................. 10.7 E

ENGINE COOLING SYSTEM.................................................................................................................. 10.6 COOLANT FLOW DURING OPERATION............................................................................................ 10.6 FILLING THE SYSTEM WITH COOLANT............................................................................................ 10.6 O

OIL COOLER, RADIATOR, AND FAN...................................................................................................... 10.2 CHARGE AIR COOLER, OIL COOLER, RADIATOR, AND A/C CONDENSER CORE ASSEMBLY.... 10.3 CHECKING COOLANT LEVEL............................................................................................................ 10.2 CHECKING COOLERS........................................................................................................................ 10.2 CHECKING ENGINE DRIVE BELTS.................................................................................................... 10.2 A/C COMPRESSOR BELT TIGHTENER.......................................................................................... 10.3 OIL COOLER CIRCUIT DESCRIPTION............................................................................................... 10.5 OIL COOLER CIRCUIT DIAGRAM................................................................................................... 10.5

Tigercat 250C Loader

Oil Cooler, Radiator, and Fan

OIL COOLER, RADIATOR, AND FAN

FILLER CAP

250C-033

CHARGE AIR COOLER

RADIATOR

248-25

ENGINE COOLANT FILL

CHECKING COOLANT LEVEL A level sight gauge is located in the side of the surge tank (reservoir). Coolant is added through the filler cap, under the access panel located on top of the engine compartment.

A/C CONDENSER

Be sure that the engine has cooled down sufficiently before removing radiator cap. Prior to removing cap, relieve pressure in radiator by loosening cap slowly to first stop. Use the proper solution of coolant antifreeze when filling the surge tank.

OIL COOLER

ENGINE COMPARTMENT ACCESS RIGHT-HAND SIDE CHECKING COOLERS The charge air cooler, hydraulic oil cooler, radiator and A/C condenser core are mounted in front of the engine. The fan draws air through the cooler assembly.

The cooler assembly should be checked every 8 hour shift for accumulation of twigs, leaves, pine needles and dust. All of the engine enclosure doors should also be kept clean.

SERPENTINE FAN BELT

A/C COMPRESSOR BELT 250B-034

CHECK ENGINE BELT(S)

CHECKING ENGINE DRIVE BELTS The cooling fan is belt driven and belt tension is automatically tightened by a spring-loaded tensioner. The belt condition and tension should be checked every 8 hour shift.

WARNING

The A/C compressor is belt tension is tightened by an adjuster on the mounting bracket. Check belt condition and tension every 8 hour shift.

Shut off engine. Only remove reservoir filler cap when cool enough to touch with bare hands. Slowly loosen cap to first relieve pressure before removing completely.

10.2

Tigercat 250C Loader

Oil Cooler, Radiator, and Fan

Loosen jam nuts and adjust belt to obtain a belt deflection of 6–10 mm (1/4–3/8 in) between the pulleys in the middle of the belt span.

JAM NUTS

220-051

A/C COMPRESSOR BELT TIGHTENER

CHARGE AIR COOLER

FILLER CAP SURGE TANK

RADIATOR

SIGHT GAUGE

A/C CONDENSER CORE

OIL COOLER

250B-032 250C-065

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

Tigercat 250C Loader

Oil Cooler, Radiator, and Fan

250C-034

ENGINE COMPARTMENT ACCESS REAR

250B-010

ENGINE COMPARTMENT ACCESS FRONT 10.4

Tigercat 250C Loader

Oil Cooler, Radiator, and Fan

OIL COOLER CIRCUIT DESCRIPTION

A relief valve installed in the line between the cooler inlet and outlet at the filter provides a bypass route for oil to flow in the event the oil cooler has high resistance.

The oil cooler is situated down-stream from the main valve. Approximately half the oil returning to the hydraulic tank is directed to the oil cooler inlet.

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

CHARGE AIR COOLER

RADIATOR A/C CONDENSER CORE OIL COOLER

MAIN DIRECTIONAL CONTROL VALVE

MAIN HYDRAULIC PUMP

DUAL RETURN FILTERS RETURN MANIFOLD TO RESERVOIR

HAND PUMP

250B-037

OIL COOLER CIRCUIT DIAGRAM 10.5

Tigercat 250C Loader

Oil Cooler, Radiator, and Fan

ENGINE COOLING SYSTEM

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

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

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

FILLING THE SYSTEM WITH COOLANT The coolant is added through the filler neck in the surge tank. This coolant fills the bottom radiator hose at the water pump through the shunt hose and then fills the radiator from the bottom upwards. Air is displaced through the vent tubes to the surge tank. As the radiator is filled, coolant flows through the water pump and engine oil cooler to fill the engine. Coolant flows out the top radiator hose through the thermostat bypass and into the engine once the radiator has filled. The engine and radiator vent discharge air directly to the surge tank.

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

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

FLOW OF COOLANT WITH ENGINE RUNNING AT OPERATING TEMPERATURE AND THERMOSTAT OPEN FILLER CAP

When the engine is at operating temperature and the thermostat has opened, any remaining air is purged through the vent tube and the engine vent.

The system then requires more coolant to fully top-off both the engine and the radiator.

TOP RADIATOR HOSE

THERMOSTAT HOUSING

SURGE TANK SHUNT HOSE

RADIATOR VENT HOSE ENGINE VENT HOSE

ENGINE OIL COOLER 250C-068

SHUNT HOSE

BOTTOM RADIATOR HOSE

ENGINE COOLING SYSTEM COMPONENTS AND COOLANT FLOW 10.6

Tigercat 250C Loader

Oil Cooler, Radiator, and Fan

CHARGE AIR COOLER SYSTEM

FLOW OF AIR WITH ENGINE RUNNING

250C-067

OUTLET INLET

CHARGE AIR COOLER SYSTEM AND AIR FLOW

10.7

CHARGE AIR COOLER

Tigercat 250C Loader

Oil Cooler, Radiator, and Fan

10.8

Tigercat 250C Loader SECTION 12 – BOOM CONTENTS – SECTION 12

JUNE, 2014

B

BOOM CIRCUIT DESCRIPTION BOOM CIRCUIT DIAGRAM.................................................................................................................. 12.3 BOOM SYSTEM COMPONENTS............................................................................................................ 12.2 BOOM VALVE SPOOL SECTIONS...................................................................................................... 12.4 PORT RELIEF VALVES.................................................................................................................... 12.4 PRESSURE COMPENSATION......................................................................................................... 12.4 SPOOLS...........................................................................................................................................12.4 ELECTRONIC JOYSTICK CONTROLS............................................................................................... 12.2 HYDRAULIC PUMPS........................................................................................................................... 12.2 MAIN CONTROL VALVE...................................................................................................................... 12.5 C

CIRCUIT PRESSURE SETTINGS........................................................................................................... 12.6 HOIST SECTION RELIEF VALVE SETTING........................................................................................ 12.6 STICK SECTION RELIEF VALVE SETTING........................................................................................ 12.7 H

HYDRAULIC SCHEMATIC – BOOM AND STICK CIRCUITS.................................................................. 12.8 L

LOAD SENSING\ENGINE ANTI-STALL................................................................................................... 12.2

Tigercat 250C Loader

Boom functions

BOOM SYSTEM COMPONENTS

ELECTRONIC JOYSTICK CONTROLS When activated, the electronic joysticks send electrical signals to solenoids on the main valve to activate the spool for that function.

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

Moving either of the joysticks sends an electronic signal to the MD3 computer module. The signal is then directed to the XS2 valve module. From the module, the signal is directed to the solenoid control for the function that is selected.

The electrical signal activates the solenoid and opens a pilot circuit that directs internal pilot oil to the spool actuator of the control valve selected.

This shifts the spool directing pump oil flow to the selected function.

MAIN PUMP

LOAD SENSING/ENGINE ANTI-STALL The hoist boom and stick boom are under the control of the load sensing system incorporated into the main hydraulic circuit.

For a full description of the hydraulic system, refer to Section 4.

SWING PUMP

250BT-007

For a full description of the ENGINE ANTI-STALL, refer to Section 9.

HYDRAULIC PUMPS

For a full description of the PILOT SYSTEM, refer to Section 5.

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

The main pump supplies oil to the hoist and stick circuits through two valve sections in the main directional control valve. The valve sections receive oil from the inlet section and direct the oil through the spool sections, when either of the joysticks are activated.

The main control valve is made up of seven sections, depending on options.

For a more detailed description of the main pump, refer to Section 4.

12.2

Tigercat 250C Loader

Boom functions

OUT/EXTEND UP/EXTEND BOOM STICK CYLINDER

BOOM HOIST CYLINDER

MAIN DIRECTIONAL CONTROL VALVE

TO OIL COOLER

(PL) TEST PORT (PX) TEST PORT MAIN PUMP

MD3 CONTROLLER JOYSTICKS

INTAKE FROM HYDRAULIC TANK

XS2 CAB MODULE

XA2 VALVE MODULE

CHECK VALVE RETURN FILTERS TO TANK

TEST PORT

TO TANK CASE DRAIN CONNECTION

PILOT SHUT OFF VALVE

INLET

250C-072

BOOM CIRCUIT 12.3

HAND FILL PUMP

FROM (YS) PORT ON MAIN CONTROL VALVE PILOT PRESSURE FILTER

PILOT MANIFOLD VALVE

OIL FILL SHUT OFF

FLEXIBLE FILL LINE

Tigercat 250C Loader FEED REDUCTION SIDE ‘B’

PORT RELIEF ‘B’ SIDE

Boom functions PORT RELIEF ‘A’ SIDE

FEED REDUCTION SIDE ‘A’

24V PROPORTIONAL ELECTRO-HYDRAULIC SPOOL ACTUATORS

250C-069

VALVE CROSS SECTION

BOOM VALVE SPOOL SECTIONS All of the main valve spool sections are equipped with 24-volt proportional, electro-hydraulic solenoid-operated spool actuators. The actuators are spring-centered to the neutral position, and are shifted by sending an electrical signal to the appropriate 24-volt solenoid coil.

PRESSURE COMPENSATOR

SPOOL

valve and the cylinder or motor from pressure spikes in the system.

The port relief valves also act as anti-cavitation valves. They allow oil to flow from the tank gallery in the valve to the service ports in the event of an under-pressure situation.

The port reliefs cannot be adjusted. Port reliefs installed in each section are specifically designed for use in that section only, and should not be interchanged with port reliefs from other valve sections.

SPOOLS Each of the spools installed in the main valve was selected specifically for the function it is controlling. For example, the hoist boom section spool has different characteristics than the stabilizer spool. These spools cannot be interchanged.

PRESSURE COMPENSATION The primary purpose of pressure compensation is to maintain a constant flow rate to function (maintain the same speed of movement), regardless of pressure variations in the system.

The pressure compensator also contains a load-hold check valve. An orifice is installed immediately downstream of the pressure compensator to smoothly regulate the response of the compensator.

PORT RELIEF VALVES The main valve is equipped with port relief valve cartridges on each side of all spool sections (except the track drive sections, if equipped). The function of the port relief valve is to protect the 12.4

Tigercat 250C Loader

Boom functions STICK SECTION

UP

B

A

A

B

B

B A

A OPEN

DOWN

CCW

A

CUT

RET

CW

CUT

A

A B

B IN

OPEN

DOWN

CLOSE

OUT

UP

B

HOIST SECTION

MAIN CONTROL VALVE

250C-048

STICK CYLINDER

HOIST CYLINDER

MAIN DIRECTIONAL CONTROL VALVE (OTHER VALVE SECTIONS REMOVED FOR CLARITY)

250B-019

HOIST AND STICK CIRCUIT 12.5

Tigercat 250C Loader

Boom functions

CIRCUIT PRESSURE SETTINGS

3. Connect a 0–350 bar (0–5000 psi) pressure gauge to the (PX) valve test port on the inlet section of the main control valve.

CAUTION

4. Have an assistant start the engine, and put the throttle control to the FULL position.

Lower left arm rest and depress the pilot reset switch to activate the pilot system.

Use caution when in the cab. A slight touch of the controls during this procedure can cause sudden rotation of the upper frame and booms, or movement of the stabilizers.

5. Hold the L.H. joystick in the hoist up position (cylinder fully extended). Record gauge pressure reading.

CAUTION Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

6. Hold the L.H. joystick in the hoist down position (cylinder fully retracted). Record gauge pressure reading.

7. Compare pressure readings to setting values in – PRESSURE SETTINGS – MAIN VALVE HIGH PRESSURE LIMITING CONTROL, Section 3.

WARNING Make sure no one is standing near the machine during this procedure.

To adjust, loosen the LS relief valve adjusting screw locknut. Slowly turn the adjusting screw out until the pressure gauge reading at (PX) port drops below specification. Turn the adjusting screw in until the pressure gauge reading meets relief specification.

If the pressure reading is less than set value in one direction but OK in the other, the port relief valve for the low reading circuit is malfunctioning. Replace the port relief valve.

IMPORTANT! Avoid pushing oil over relief longer than 5 seconds. Doing so causes excessive heating of the hydraulic fluid.

HOIST SECTION RELIEF VALVE SETTING For system pressure values, refer to PRESSURE SETTINGS in Section 3.

NOTE: The main and port relief valves are not adjustable. The following procedure is for checking pressure only.

If adjusting the LS relief valve setting and the pressure does not change, then the main relief is malfunctioning and should be replaced.

Procedure: 1. Position machine on flat level ground.

2. Make sure the hydraulic oil is at operating temperature.

ELECTRONIC DISPLACEMENT SOLENOID VALVE

PUMP (LS) RELIEF VALVE 250C-048

MARGIN PRESSURE ADJUSTING SCREW

MAIN PUMP CONTROLLER

MAIN PUMP CONTROLLER 8. Tighten the locknut while making sure adjusting screw does not turn.

250BT-008

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

250BT-031

MAIN VALVE TEST PORTS – INLET SECTION 12.6

Tigercat 250C Loader

Boom functions 4. Have an assistant start the engine, and put the throttle control to the FULL position.

Lower left arm rest and depress the pilot reset switch to activate the pilot system.

CAUTION

Use caution when in the cab. A slight touch of the controls during this procedure can cause sudden rotation of the upper frame and booms, or movement of the stabilizers.

5. Hold the R.H. joystick in the stick out position (cylinder fully extended). Record gauge pressure reading.

CAUTION

6. Hold the R.H. joystick in the stick in position (cylinder fully retracted). Record gauge pressure reading.

Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

7. Compare pressure readings to set value in – PRESSURE SETTINGS – MAIN VALVE HIGH PRESSURE LIMITING CONTROL, Section 3.

WARNING

To adjust, loosen the LS relief valve adjusting screw locknut. Slowly turn the adjusting screw out until the pressure gauge reading at (PX) port drops below specification. Turn the adjusting screw in until the pressure gauge reading meets relief specification.

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

IMPORTANT! Avoid pushing oil over relief longer than 5 seconds. Doing so causes excessive heating of the hydraulic fluid.

If the pressure reading is less than set value in one direction but OK in the other, the port relief valve for the low reading circuit is malfunctioning. Replace the port relief valve.

STICK SECTION RELIEF VALVE SETTING For system pressure values, refer to PRESSURE SETTINGS in Section 3.

If adjusting the LS relief valve setting and the pressure does not change, then the main relief is malfunctioning and should be replaced.

Procedure: 1. Position machine on flat level ground.

2. Make sure the hydraulic oil is at operating temperature.

8. Tighten the locknut while making sure adjusting screw does not turn.

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

ELECTRONIC DISPLACEMENT SOLENOID VALVE

250C-048

PUMP (LS) RELIEF VALVE

MARGIN PRESSURE ADJUSTING SCREW 250BT-031

MAIN VALVE TEST PORTS – INLET SECTION

250BT-008

3. Connect a 0–350 bar (0–5000 psi) pressure gauge to the (PX) valve test port on the inlet section of the main control valve.

12.7

MAIN PUMP CONTROLLER

MAIN PUMP CONTROLLER

Tigercat 250C Loader

Boom functions

HYDRAULIC RESERVOIR

MAIN HYDRAULIC PUMP

RETURN FILTERS

COOLER

PILOT SHUT OFF

SPARE

DELIMBER OPEN

SPARE

PILOT PRESSURE FILTER

PILOT SOLENOID VALVE

HOIST CYLINDER

MAIN DIRECTIONAL CONTROL VALVE NOTE: SOME PARTS OF SCHEMATIC OMITTED FOR CLARITY STICK CYLINDER

HYDRAULIC SCHEMATIC – BOOM AND STICK CIRCUITS 12.8

Tigercat 250C Loader SECTION 15 – SWING CONTENTS – SECTION 15

JUNE, 2014

C

CIRCUIT DIAGRAM................................................................................................................................. 15.6 CIRCUIT PRESSURE SETTINGS........................................................................................................... 15.7 SET SWING RELIEF VALVE PRESSURES......................................................................................... 15.7 SETTING (POR) RELIEF VALVE PRESSURE..................................................................................... 15.8 G

GEARBOX, SWING DRIVE...................................................................................................................... 15.5 S

SWING BEARING SEAL KIT............................................................................................................................................15.10 WEAR LIMITS....................................................................................................................................... 15.9 SWING MOTOR....................................................................................................................................... 15.3 MOTOR REMOVAL NOTE................................................................................................................... 15.4 SWING PUMP.......................................................................................................................................... 15.2

Tigercat 250C Loader

Swing

SWING DRIVE COMPONENTS

pump is determined by the angle of the tilt-able swashplate. When the swashplate is stroked to a maximum displacement angle, the piston pump produces maximum flow in one direction in the closed loop. As the swashplate is de-stroked, the flow smoothly decreases until there is no flow at a 0° angle. Continuing to angle the swashplate past this neutral position reverses the direction of flow from the piston pump in a step-less manner.

ENGINE BELL HOUSING

MAIN PUMP

SWING PUMP

250B-035

The secondary pump of the drive pump is a fixed displacement, internal gear pump that provides charge oil (cooling, lubricating and make-up oil) for the hydrostatic pump and motors in the closed loop system. The charge pump also provides initial pilot oil for the pilot system.

HYDRAULIC PUMPS

SWING PUMP

FOOT PEDAL CONTROL VALVE

All hydraulic functions are powered by two pumps mounted one behind the other on the flywheel housing of the engine. The first pump (main pump) is a piston pump with load sensing, pressure compensating and horsepower limiting controls.

The swing function is controlled by the center foot pedal valve which sends proportional pilot signals to the swing pump controller to stroke the pump swashplate producing oil flow to the swing motor.

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

Mounted and coupled to the main pump is the swing pump. The primary components of the swing system are the hydraulic pump, hydraulic motor, and swing drive gearbox. The hydraulic pump and hydraulic motor are connected together by two hydraulic hoses. The pump converts the mechanical power of the diesel engine into hydraulic power. This high-pressure flow of hydraulic oil is then transmitted to the hydraulic motor through a connecting hose. The motor then reconverts the hydraulic power back into mechanical power to drive the swing gearbox used to swing the upper frame. Low pressure hydraulic oil flow then returns from the motor to the pump through the other connecting hose, thereby completing a continuous closed-loop hydraulic circuit.

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

1 2

A hydraulic system is termed closed loop when the hydraulic oil returning from the motor is fed straight back to the pump without first returning to tank. When the swing system is operating, one side of the closed loop is a high-pressure supply while the other side is a low-pressure return. The supply and return alternate from side to side of the closed loop, as the direction of swing rotation is changed from left to right.

3 TANK PORT

4 8

The swing drive pump is actually two separate hydraulic pumps mounted in a common case and driven by the same input drive shaft.

2

The primary pump is a variable displacement, swashplate, in-line axial piston-type pump. The volume and direction of oil flow from the piston

WORK PORT AW017

15.2

PRESSURE PORT

WORK PORT

FOOT PEDAL PILOT VALVE

Tigercat 250C Loader

Swing

SWING MOTOR

SWING PUMP CONTROLLER

SWING GEARBOX

SWING PUMP

SWING BEARING

250BT-049

SWING DRIVE CLOSED-LOOP HYDRAULIC CIRCUIT

SWING MOTOR The swing motor is mounted directly onto the input of the swing planetary gearbox. The motor is a fixed displacement, bent axis, axial piston type.

High pressure oil from the swing pump enters the motor through port (A) or port (B), depending on the direction of swing required. This oil is then directed to a set of pistons inside the motor rotating group cylinder housing. These pistons push against the back of the output shaft at an angle, causing the shaft to rotate.

15.3

Tigercat 250C Loader

Swing

MOTOR REMOVAL NOTE:

250BT-018

SWING MOTOR CROSS SECTION

250BT-053

SWING MOTOR AND GEARBOX Before removing the drive motor, drain the oil from the reservoir bottle by disconnecting the hose at the oil fill tube. Replace the oil fill tube.

SWING PUMP

'MA' TEST PORT

A

'MB' TEST PORT

B 'G' TEST PORT CHARGE PRESSURE

250BT-052

SWING PUMP TEST PORTS

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

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

15.4

Tigercat 250C Loader

Swing

SWING DRIVE GEARBOX Power is transmitted from the motor to a double reduction planetary gearbox. The swing gearbox upper gearing is lubricated by oil stored in a reservoir attached to the side of the gearbox cover. The reservoir must remain half full of oil* at all times. The lower bearing area is lubricated by grease where the cavity is filled with grease at assembly, a grease fitting is not provided since additional greasing is not necessary.

To fill the gearbox with oil, unscrew the air bleed plug located on the motor flange, remove the cap on the reservoir and add oil to the reservoir.

When oil begins to come out of the air bleed hole replace the plug and continue to add oil until the reservoir is half full. Replace the cap on the reservoir.

To drain the gearbox unscrew the drain plug and allow oil to drain into a suitable container. To facilitate draining, the oil should be warm. *For correct oil specification and maintenance schedule, refer to LUBRICATION AND MAINTENANCE – SERVICE AND LUBRICATION POINTS, in Section 3.

250BT-017

SWING MOTOR AND GEARBOX

RESERVOIR

CONNECTING HOSE TO GEARBOX

206-16A

15.5

SWING DRIVE LUBRICATION

Tigercat 250C Loader

CCW

Swing

CW B Y1

Y2

A SWING PUMP (REAR VIEW)

SWING FOOT PEDAL

PILOT RESET SWITCH

ARM REST SWITCH

PILOT LOCKOUT RELAY

DELIMBER OPEN PILOT SHUT OFF VALVE

P2

P1

T2

T1

PILOT MANIFOLD VALVE

PRESSURE PILOT FILTER

TO TANK CASE DRAIN CONNECTION

FROM (YS) PORT ON MAIN CONTROL VALVE 250C-075

SWING DRIVE CIRCUIT 15.6

Tigercat 250C Loader

Swing

CIRCUIT PRESSURE SETTINGS

3. Install a 0–350 bar (0–5000 psi) pressure gauge on the (MA) and (MB) test ports on the swing pump.

CAUTION

4. Install a 0–100 bar (0–1000 psi) pressure gauge on the (G) test port on the swing pump.

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

5. Have an assistant start the engine and leave throttle control at IDLE. 6. Lower left arm rest and depress the pilot reset switch to activate the pilot system.

CAUTION

7. Observe gauge at test port (G) and record pressure value.

Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

8. Compare pressure reading to set value in Section 3 – PRESSURE SETTINGS – SWING PUMP – CHARGE PRESSURE.

WARNING

If adjustment is required, loosen locknut and turn adjusting screw in to increase pressure, or out to decrease pressure. Tighten the locknut while making sure adjusting screw does not turn.

Make sure that no one is standing near the machine during this procedure.

IMPORTANT! Avoid pushing oil over relief longer than 5 seconds. Doing so causes excessive heating of the hydraulic fluid.

9. Press and hold the left-hand side of the swing foot pedal to rotate the machine counterclockwise.

10. Record gauge pressure reading at (MB) test port.

SET SWING RELIEF VALVE PRESSURES For system pressure values, refer to PRESSURE SETTINGS in Section 3.

11. Compare pressure reading to set value in Section 3 – PRESSURE SETTINGS – SWING PUMP – HIGH PRESSURE RELIEF.

Procedure: 1. Position machine on flat level ground.

If adjustment is required, loosen locknut on (B) pressure relief valve. Turn adjusting screw in (clockwise) to increase pressure, and out (counterclockwise) to decrease pressure.

Tighten locknut while taking care not to turn adjusting screw.

2. Make sure the hydraulic oil is at operating temperature.

(POR) RELIEF VALVE (A) PRESSURE RELIEF VALVE

A

CHARGE PRESSURE ADJUSTING SCREW

(MA) TEST PORT

(MB) TEST PORT

B SWING PUMP

(G) TEST PORT CHARGE PRESSURE 250BT-007

(B) PRESSURE RELIEF VALVE

SWING PUMP TEST PORTS 15.7

Tigercat 250C Loader

Swing

12. Press and hold the right-hand side of the swing foot pedal to rotate the machine clockwise.

(POR) RELIEF VALVE (A) PRESSURE RELIEF VALVE

13. Record gauge pressure reading at (MA) test port.

A

14. Compare pressure reading to set value in Section 3 – PRESSURE SETTINGS – SWING PUMP – HIGH PRESSURE RELIEF. CHARGE PRESSURE ADJUSTING SCREW

If adjustment is required, loosen locknut on (A) pressure relief valve. Turn adjusting screw in (clockwise) to increase pressure, and out (counterclockwise) to decrease pressure.

(MA) TEST PORT

(MB) TEST PORT

15. Tighten locknut while taking care not to turn adjusting screw.

SETTING (POR) RELIEF VALVE PRESSURE

B SWING PUMP

(G) TEST PORT CHARGE PRESSURE

Procedure: 1. Increase engine speed to FULL throttle.

2. Loosen locknut on Swing (POR) Relief valve. Turn out adjusting screw until gauge value reads as in Section 3, PRESSURE SETTINGS – SWING PUMP – PUMP POR.

250BT-007

3. Tighten locknut while taking care not to turn adjusting screw.

4. Shut engine off, remove gauges and wipe up any spilled oil.

15.8

(B) PRESSURE RELIEF VALVE

SWING PUMP TEST PORTS

Tigercat 250C Loader

Swing

SWING BEARING WEAR LIMITS

The following procedure verifies the amount of wear in the ball race:

It is important that the swing bearing is periodically inspected for wear. Any significant wear is noticeable by observing too much tilting of the upper frame relative to the lower frame.

A small amount of designed-in clearance in the bearing is normal and is present in a new machine.

1. Position machine with boom fully extended as in Position 1, approximately 600 mm (24 in) off the ground.

2. Place a dial indicator on the machine as shown in Detail (A), then set indicator to zero.

3. Lower boom onto a wooden block, as in Position 2.

Too much clearance affects the backlash between the ring gear and the drive pinion, and if left unchecked, causes damage to the gear teeth and ultimately the swing drive gearbox.

4. Raise machine approximately 150 mm (6 in) off the ground as shown in Position 2. Note tilt reading on dial indicator.

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

5. Return machine to Position 1.

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

7. Rotate upper frame 90° and repeat steps 1–6.

8. The bearing is considered to be worn and should be replaced when the total play is measured at 2.7 mm (0.105 in) or greater.

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

POSITION 1

POSITION 2

600 MM 24 IN.

150 MM 6 IN.

DETAIL A

DIAL INDICATOR

15.9

Tigercat 250C Loader

Swing

SWING BEARING SEAL KIT

SEAL

INSTALLATION INSTRUCTIONS 1. Remove all traces of former seal and glue from the seal groove. Groove should then be cleaned with a non-residue commercial solvent.

2. Wipe the seal with the same solvent.

3. Apply a bead of adhesive (BN157) to the seal groove. Avoid extruding the adhesive into the bearing cavity as the seal is installed.

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

SEAL 860C-0004

5. Immediately butt the two ends together, aligning them as quickly as possible. Hold together without movement (motion weakens and may destroy the bond). The joint is strong enough after holding for 2 minutes.

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

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

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

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

15.10

SWING BEARING SEAL

Tigercat 250C Loader

Swing

ADJUST SWING BEARING BACKLASH The backlash permitted on the swing bearing is 0.4–0.63 mm (0.016–0.025 in).

0.5–0.6 MM (0.017–0.026 IN)

4. Install a 1" x 6" long hex head bolt into the nut.

GEAR TEETH MARKED WITH PAINT PINION 1

The swing bearing backlash adjustment is done with the upper and lower structures of the loader disassembled. The bearing must be correctly installed on the upper structure, with the retaining bolts loosened slightly.

ADJUSTMENT PROCEDURE: 1. Make an adjustment tool from a 100 mm (4 in) square piece of 6 mm (1/4 in) thick steel plate.

1/4'' GEAR TEETH MARKED WITH PAINT

4'' 860C-186

4''

ADJUSTMENT TOOL

2. Weld a 1 inch hex nut on the plate as shown.

S855C-083C 880-231

5. Locate the gear teeth marked with paint on the inner swing bearing. Rotate the bearing so the edges marked with paint are meshed with the pinion.

3. Position the fabricated adjustment tool up against the underside of the turntable, in-line with the pinion. Place with the hex nut 12 mm (1/2 in) away from the bearing. Weld the tool to the turntable using 6 mm (1/4 in) fillet weld.

IMPORTANT! Machine ECUs must be disconnected prior to welding. Refer to WELDING, PRIOR TO in Section 1 for safety precautions.

FEELER GAUGES 880-234

6. Use a pry bar to rotate the pinion against the swing bearing. Measure the backlash between the pinion and the swing bearing using feeler gauges.

15.11

Tigercat 250C Loader

Swing

0.5 MM (0.017 IN)

45°

7. Using the adjustment tool, turn in hex head bolt to set minimum gear backlash to 0.4 mm (0.016 in).

10. Measure and adjust gear bearing backlash at pinion every 45 degrees of rotation.

Acceptable backlash values are in the range of 0.4–0.63 mm (0.016–0.025 in). If measured backlash values are less than 0.40 mm (0.016 in), then repeat steps 6 to 8.

8. Tighten swing bearing outer race Bolt 1 to a temporary setup torque of 406 N•m (300 lbf•ft)

11. Torque swing bearing mounting bolts following sequence shown above. Refer to LUBRICATION AND MAINTENANCE – TORQUE CHART, in Section 3 for bolt torque value.

9. Tighten swing bearing outer race Bolts 2 through 12 to a temporary setup torque of 406 N•m (300 lbf•ft). Start at the point of largest gap.

15.12

Tigercat 250C Loader SECTION 16 – STABILIZERS CONTENTS - SECTION 16

JUNE, 2014

C

CIRCUIT PRESSURE SETTINGS......................................................................................................... 16.10 COUNTERBALANCE AND CHECK CARTRIDGES, REMOVAL............................................................. 16.9 COUNTERBALANCE VALVES................................................................................................................ 16.8 CYLINDERS AND COUNTERBALANCE VALVES.................................................................................. 16.8 S

STABILIZER CIRCUIT COMPONENTS................................................................................................... 16.2 STABILIZER CONTROL VALVE........................................................................................................... 16.3 STABILIZER PILOT MANIFOLD........................................................................................................... 16.2 STABILIZER CIRCUIT DESCRIPTION.................................................................................................... 16.4 STABILIZER OPERATION....................................................................................................................... 16.4 LOWERING STABILIZER..................................................................................................................... 16.6 RAISING STABILIZER.......................................................................................................................... 16.4 STABILIZER CIRCUIT COMPONENTS DIAGRAM............................................................................. 16.5 STABILIZER ELECTRICAL CIRCUIT SCHEMATIC............................................................................. 16.6 STABILIZER HYDRAULIC CIRCUIT SCHEMATIC.............................................................................. 16.7

Tigercat 250C Loader

Stabilizers

STABILIZER CIRCUIT COMPONENTS

4 SOLENOIDOPERATED PILOT VALVES

A

ENGINE BELL HOUSING

SYSTEM PRESSURE SUPPLY

MAIN PUMP

(B) REAR LEFT

SWING PUMP 234-040

250B-035

(C) FRONT LEFT

(D) REAR RIGHT

(E) FRONT RIGHT

STABILIZER PILOT MANIFOLD

250C-079

HYDRAULIC PUMPS

HYDRAULIC PUMP Supply oil for the stabilizer circuit is provided by the MAIN pump which is an axial-piston, variabledisplacement pump with load sensing and horsepower limiting controls.

For a more detailed description of this pump, refer to Section 4.

STABILIZER MANIFOLD SCHEMATIC

STABILIZER PILOT MANIFOLD This stabilizer manifold consists of an aluminum housing containing four solenoid-operated valves.

Port (A) supplies oil at system pressure to the four directional valves. Ports (B), (C), (D) and (E) supply oil at system pressure to the stabilizer cylinders.

16.2

Tigercat 250C Loader

FEED REDUCERS

Stabilizers

PORT RELIEF (B) SIDE

PORT RELIEF (A) SIDE

24V PROPORTIONAL ELECTRO-HYDRAULIC SPOOL ACTUATORS

SPOOL

PRESSURE COMPENSATOR

234-068

STABILIZER SPOOL SECTION

B

B

IN

OPEN

RET

UP

B

B

B

B

A

A

A DOWN

B

CUT

CUT

A OPEN

CLOSE

A

CW

OUT

A

CCW

UP

A

DOWN

MAIN CONTROL VALVE

250C-048

STABILIZER CONTROL VALVE

For a detailed description of the main control valve, refer to Section 4.

The stabilizer UP/DOWN/OFF functions are controlled by the main control valve. The main valve is a load sensing and pressure compensated proportional valve. The control valve is located in the upper frame below the floor plates inside the valve compartment.

RELIEF VALVES AND FEED REDUCERS A main relief valve is installed in the mid-inlet section of the valve to protect the hydraulic system against overload pressures. The main relief valve is not adjustable.

The stabilizer valve section has two feed reducers used to set stabilizer circuit system pressure.

16.3

Tigercat 250C Loader

Stabilizers

STABILIZER CIRCUIT DESCRIPTION

The center (OFF) position on the switch deactivates all stabilizer controls. Place this switch in the OFF position whenever the stabilizers are not being used. This prevents accidental operation.

Refer to Stabilizer Circuit Components diagram on the next page.

Use buttons (2), (3), (4) or (5) to control each stabilizer separately or use the All switch (6) to move all stabilizers at once.

The main hydraulic pump supplies oil to the stabilizer circuit. The main control valve receives oil through the inlet section, and directs it to the stabilizer spool section when activated. The stabilizer spool directs oil to the inlet port (A) on the stabilizer manifold.

The All button should be used to make sure each stabilizer is applying equal pressure to the ground prior to operating the loader or lifting any loads.

When the solenoid valves on the manifold are energized (by pressing the switches in the operator's cab), the spools shift and connect the ports with a counterbalance valve mounted to the base end of the stabilizer cylinders to raise or lower the stabilizer.

CAUTION When operating the machine, always make sure that all four stabilizers are firmly placed on the ground. Soft ground conditions can cause instability.

When the solenoid valves are de-energized, the spools in the directional control valves are spring-returned to the closed position. The counterbalance valves prevent spool leakage and cylinder drift to hold the stabilizer in position.

Return oil from the circuit goes back through the main control valve, then is directed back to tank through the oil cooler, the return manifold, and return filters.

RAISING STABILIZERS Place Stabilizer Direction Selector switch in the UP position. Press and hold one of the stabilizer control switches. Electrical current flows through a series of diodes and energizes the UP solenoidoperated pilot valve on the main control valve.

Pilot oil is the directed to the stabilizer control valve spool pilot end cap to shift the spool.

250B-004

Current also flows to energize a solenoid pilot valve on the stabilizer pilot manifold, and allows pilot oil to shift a spool in a directional valve in the manifold.

1

2

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

3

6

5

4

STABILIZER CONTROL SWITCHES

STABILIZER OPERATION The four stabilizers are controlled using the switches located on the instrument panel to the right of the operator's seat.

Select a direction (UP/OFF/DOWN) using the 3-position Stabilizer Direction Selector switch (1).

16.4

Tigercat 250C Loader

Stabilizers ROTARY MANIFOLD VALVE

CR

VR VC

COUNTERBALANCE VALVE ATTACHED TO CYLINDER

7

1

8

2

9

4

10

5

11

6 3

VR

CR VC

1

7

2

8

4

9

6

10

5

11

3

RETRACT

FRONT FRONT LEFT STABILIZER CYLINDER

CR

VR VC

RETRACT FRONT RIGHT STABILIZER CYLINDER

COUNTERBALANCE VALVE ATTACHED TO CYLINDER

VR

CR VC

RETRACT

RETRACT REAR LEFT STABILIZER CYLINDER

MAIN CONTROL VALVE

REAR RIGHT STABILIZER CYLINDER

YS

TO OIL COOLER (PL) TEST PORT

SV4

E

SV3

D

SV2

MAIN PUMP OIL SUPPLY

STABILIZER MANIFOLD

C

SV1

(PX) TEST PORT

B

A

250B-026

STABILIZER CIRCUIT COMPONENTS 16.5

Tigercat 250C Loader

Stabilizers

LOWERING STABILIZERS

valve, the rotary manifold, the stabilizer control valve and back to tank.

Place Stabilizer Direction Selector switch in DOWN position. Press and hold one of the stabilizer control switches. Electrical current flows through a series of diodes and energizes the DOWN solenoid operated pilot valve on the main control valve. Pilot oil is then directed to the stabilizer control valve spool DOWN pilot end cap, to shift the spool.

To raise or lower all of the stabilizers at the same time, press and hold the center (ALL) switch.

Electrical current flows through all of the diodes to supply electrical current to all four solenoidoperated pilot valves on the stabilizer pilot manifold, Current also goes through the direction switch and energizes the solenoid-operated pilot valve on the pilot manifold. Hydraulic oil then flows as described above for either UP or DOWN, except that all cylinders operate at the same time.

Current also flows to energize a solenoid pilot valve on the stabilizer pilot manifold to allow pilot oil, through internal porting, to shift a spool in a directional valve in the manifold.

In this condition, hydraulic oil flows from the DOWN side of stabilizer control valve, through the stabilizer pilot manifold, through the rotary manifold and on to the cylinder pilot-operated check valve, where it flows to the base end of the selected cylinder. Return oil from the rod end of the cylinder flows through the counterbalance 71-GR MAIN VALVE

DOWN

UP

A

2

B

2

1

70-GR

1 STABILIZERS GRAP. SAW

OPEN

A

2

B

2

1

1 DELIMBER

CCW

A

1 BASE

G70-BK

2

STABILIZERS LR

STABILIZERS LF

STABILIZERS RR

STABILIZERS RF

OUTRIGGER MANIFOLD

1

15

T3

T4

3

2B

17

73B-GR

19

69B-GR

20

85A-TN

3D-RD

STAB. LF 74-GR

3

2B

74A-GR 75B-GR

21

2

3C-RD 2B

72A-GR

69A-TN

16 18

1

72-GR T2

11

DIODE #3

FRAME GROUND STUD

14

13

2

3

STAB. RF

9

T1

10

T2

8

G72-BK

12

1

3B-RD

STAB. ALL 85-TN

7

G73-BK

HOIST

DIRECTION 3

69-TN

22

2B

1

23 24

72-GR

26 27 28 29

69B-GR

30 31

VOLTAGE REF. +5V

CAN-L (A), BLANK

CAN-L (A), FROM JOYSTICKS

RESERVED

RESERVED

GRAPPLE CW, PWMRET E-

BLANK, DOUT F

SAW CUT, PWMRET D-

DELIMBER OPEN HOLD, DOUT E

GRAPPLE CLOSE, PWMRET C-

RESERVED, PWMRET F-

VOLTAGE REF. GROUND

STICK BASE, PWMRET B-

CAN-H (A), BLANK

HOIST BASE, PWMRET A-

CAN-H (A), TO JOYSTICKS

STABILIZER ACTIVATION, DIN F

BATTERY SUPPLY (24V)

FUEL LEVEL SWITCH, DIN E

ANTI-STALL, PWMRET F+

SWING BRAKE, DOUT D

PILOT RESET, DOUT C

GRAPPLE CCW, PWMRET E+ SAW RETRACT, PWMRET D+

GRAPPLE OPEN, PWMRET C+

STICK ROD, PWMRET B+

HOIST ROD, PWMRET A+

BATTERY GROUND

SAW CUT POWER, PWMOUT D

ID TAG, ADDR-L

GRAPPLE ARM POWER, PWMOUT C

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 SWING ACTIVATION, VIN B

STICK POWER, PWMOUT B

8

HYD. OIL TEMP, VIN D

HOIST POWER, PWMOUT A

7

HYD. OIL LEVEL, VIN C

ID TAG, ADDR-H

6

ANTI-STALL POWER, PWMOUT F

5

CHARGE FILTER SERVICE, VIN A

4

GRAPPLE SAW, DOUT B

3

GRAPPLE ROTATE POWER, PWMOUT E

2

DELIMBER OPEN, DOUT A

1

70-GR

25

75-GR

74-GR

73-GR

XA2-A0 - VALVE MODULE

250C-078

3A-RD

2B

6

G74-BK

2

DIODE #2

A

1

2

T4

5

1

1

T3

4

T1

B

2

G75-BK

BASE

T3

STICK

3

3

73A-GR

1 2

1 ROD

73-GR

74B-GR

2

T4

A

T2

B

1

DIODE #1

ROD

2

2B

STAB. RR

72B-GR G71-BK

T1

GRAPPLE

STAB. LR 3

75A-GR

2

1

AUX LIGHTS

B

2

15A

CLOSE

KEY INPUT

OPEN

75-GR

PILOT RESET

3-RD

1 SAW

5A

2

1

5A

A

STABLIZERS

CUT

B

FUEL HEATER

RETRACT

2

10A

FAN (OPT)

1 GRAPPLE ROTATE

WIPER/WASH

5A

2

10A

B

1

10A

A

2

CW

STABILIZER ELECTRICAL CIRCUIT SCHEMATIC 16.6

71-GR

Tigercat 250C Loader

REAR STABILIZER CYLINDER

Stabilizers

REAR STABILIZER CYLINDER

FRONT STABILIZER CYLINDER

FRONT STABILIZER CYLINDER

ROTARY MANIFOLD VALVE

STABILIZER MANIFOLD

STABILIZER SECTION OF THE MAIN DIRECTIONAL CONTROL VALVE (OTHER SECTIONS HIDDEN FOR CLARITY)

234-075

STABILIZER HYDRAULIC CIRCUIT SCHEMATIC 16.7

Tigercat 250C Loader

Stabilizers

STABILIZER CYLINDERS AND COUNTERBALANCE VALVES

250C-080

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.

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

The purpose of the counterbalance valve assembly is to: (a) To prevent the raised stabilizers from creeping down when transporting the loader.

COUNTERBALANCE VALVE SCHEMATIC

(b) To prevent the build-up of pressure caused by thermal expansion.

COUNTERBALANCE VALVE OPERATION When lowering the stabilizers (extending the cylinders), oil enters the (VC) port and opens the counterbalance valve through 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 (CR) port and through the open counterbalance valve to the (VR) port and back to tank through the stabilizer control valve.

COUNTERBALANCE VALVE CARTRIDGE CHECK VALVE CARTRIDGE

250B-044

When raising the stabilizers (retracting the cylinders), oil enters the (VR) port and has free flow through the valve to the (CR) port, and to the rod end of the cylinder. The counterbalance valve is also opened by oil pressure through 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 through the (VC) port.

STABILIZER CYLINDER COUNTERBALANCE VALVE

The counterbalance cartridge relief pressure range is adjustable and factory set to 69 bar (1000 psi). This relief valve opens either when system pressure is applied to the (VC) port, or when pressure in the rod end of a cylinder exceeds the 69 bar (1000 psi) setting.

The purpose of the pilot-to-open check valve cartridge is to make sure that the stabilizers remain firmly placed on the ground during the loading/unloading operation, by preventing oil from leaving either end of the cylinders. 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.

16.8

Tigercat 250C Loader

Stabilizers

SAFE REMOVAL OF COUNTERBALANCE AND CHECK CARTRIDGES WARNING When the stabilizers are extended to 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.

CR

VC

VR

LOWER FRAME

VERTICAL CENTERLINE COUNTERBALANCE VALVE

CYL

STABILIZER UP IN VERTICAL POSITION

250B-008

COUNTERBALANCE VALVE & CYLINDER CYLINDER

230-06A

COUNTERBALANCE/CHECK CARTRIDGE REMOVAL

If it becomes necessary to remove either the counterbalance or check cartridge from the housing, raise the stabilizer until it is in the overcenter position, and stop the engine. In this position, the weight of the stabilizer does 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.

16.9

Tigercat 250C Loader

Stabilizers

CIRCUIT PRESSURE SETTINGS

gauge on the (PL) test port at the inlet section of the main valve.

IMPORTANT!

4. Have an assistant start the engine and place throttle control at IDLE.

CAUTION

5. Place stabilizer direction selector switch in the UP position.

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

6. Press one of the stabilizer switches to raise stabilizer. While holding stabilizer switch in UP position, record gauge pressure reading.

CAUTION

7. Adjust stabilizer up feed reducer on main control valve section to achieve proper setting. The pressure is increased by turning the screw in. Tighten the locknut while making sure adjusting screw does not turn.

Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

8. Place stabilizer direction selector switch in DOWN position.

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

9. Press one of the stabilizer switches to lower stabilizer. While holding stabilizer switch in DOWN position, check gauge pressure reading.

SET STABILIZER PORT RELIEFS VALVES For system pressure values, refer to PRESSURE SETTINGS in Section 3.

NOTE: The counterbalance valve cartridge is factory set to 69 bar (1000 psi). It cannot be set in the field without removing it from the cylinder and using special test equipment. If this valve is suspect (for example, stabilizers do not stay in the raised position) it should be replaced with a new one.

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

10. Adjust down feed reducer on main control valve section to achieve proper setting. The pressure is increased by turning the screw in. Tighten the locknut while making sure adjusting screw does not turn.

11. Repeat steps 9 and 10 to verify settings.

12. Shut engine off, remove gauge and wipe up any spilled oil.

INLET SECTION

250BT-031

B

B

B

OPEN

RET

UP

B

B

B

B

A

A

A DOWN

A

CUT

A

CW

CUT

A

OPEN

CLOSE

A

CCW

OUT

STABILIZER SECTION

IN

3. Install a 0–350 bar (0–5000 psi) pressure

UP

2. Make sure the hydraulic oil is at operating temperature.

Be aware of machine stability.

It may be necessary to lower all stabilizers to the end of the cylinder stroke in order to develop enough pressure to set the relief valves.

DOWN

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

CAUTION

STABILIZER DOWN FEED REDUCER

INLET SECTION

250C-048

16.10

STABILIZER UP FEED REDUCER

STABILIZER FEED REDUCERS

Tigercat 250C Loader SECTION 17 – GRAPPLE CONTENTS – SECTION 17

JUNE, 2014

C

CIRCUIT DESCRIPTION......................................................................................................................... 17.4 CIRCUIT DIAGRAM................................................................................................................................. 17.5 CIRCUIT PRESSURE SETTINGS........................................................................................................... 17.6 GRAPPLE OPEN/CLOSE RELIEF VALVE SETTING.......................................................................... 17.6 GRAPPLE ROTATE RELIEF VALVE SETTING.................................................................................... 17.8 HYDRAULIC SCHEMATICS................................................................................................................. 17.7 G

GRAPPLE CONNECTIONS TO BOOM................................................................................................... 17.4 GRAPPLE QUICK REVERSAL FEATURE.............................................................................................. 17.9 QUICK REVERSAL STATUS................................................................................................................ 17.9 GRAPPLE SYSTEM COMPONENTS...................................................................................................... 17.2 HYDRAULIC PUMP.............................................................................................................................. 17.2 JOYSTICK CONTROLS....................................................................................................................... 17.2 MAIN DIRECTIONAL CONTROL VALVE............................................................................................. 17.2 VALVE SPOOL CROSS-SECTION DRAWINGS.............................................................................. 17.3

Tigercat 250C Loader

Grapple

GRAPPLE SYSTEM COMPONENTS

JOYSTICK CONTROLS The grapple open/close functions are controlled by the left-hand joystick. Tilt the joystick to the left to open the grapple, and tilt it to the right to close the grapple.

ENGINE BELL HOUSING

The grapple rotate functions are controlled by the right-hand joystick. Tilt the joystick to the left to rotate the grapple counterclockwise, and tilt it to the right to rotate the grapple clockwise.

MAIN PUMP

SWING PUMP

250B-035

NOTE: Joystick configurations vary, so for a detailed description of the joystick controls, refer to Section 2 in the OPERATOR’S MANUAL.

MAIN DIRECTIONAL CONTROL VALVE

HYDRAULIC PUMPS

The main control valve is made up of seven spool sections. There are proportional solenoid controls on all sections. The valve assembly is made up of two different types of valve section, due to flow requirements of each function. The four larger sections of the valve are capable of supplying larger oil volume for functions that require it. The Valve Spool Cross-section drawings on the next page illustrate the differences in the two types.

HYDRAULIC PUMP The main pump is an axial-piston, variabledisplacement pump with load sensing, pressure compensating, and horsepower limiting controls.

The grapple circuit utilizes the main pump to supply hydraulic oil to the grapple open/close control valve spool section and the grapple rotate control valve spool section in the main control valve.

The main control valve is located in the upper frame below the floor plates inside the valve compartment.

For a more detailed description of the main pump, refer to Section 4.

For a detailed description of the main control valve, refer to Section 4

GRAPPLE ROTATE SECTION

250C-048

UP

B

B

B

A

A

A DOWN

IN

B

CUT

B

B

OPEN

B

CW

CUT

A

CCW

CLOSE

A

RET

OUT

A

OPEN

UP

A

DOWN

GRAPPLE OPEN/ CLOSE SECTION

MAIN CONTROL VALVE 17.2

Tigercat 250C Loader

Grapple

VALVE SPOOL CROSS-SECTION DRAWINGS

FEED REDUCERS

PORT RELIEF (B) SIDE

24V PROPORTIONAL ELECTRO-HYDRAULIC SPOOL ACTUATORS

PORT RELIEF (A) SIDE

SPOOL

234-068

PRESSURE COMPENSATOR

GRAPPLE ROTATE SPOOL SECTION

FEED REDUCTION SIDE (B)

PORT RELIEF (B) SIDE

PORT RELIEF (A) SIDE

FEED REDUCTION SIDE (A)

24V PROPORTIONAL ELECTRO-HYDRAULIC SPOOL ACTUATORS

250C-069

SPOOL PRESSURE COMPENSATOR

GRAPPLE OPEN/CLOSE SPOOL SECTION 17.3

Tigercat 250C Loader

Grapple

GRAPPLE CIRCUIT DESCRIPTION

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

Refer to Grapple Circuit diagram on the next page.

The grapple hydraulic circuit is supplied with oil from the main pump. The grapple valve sections in the main control valve receive oil at the inlet section of the valve, and direct it through the spool sections when either of the grapple functions are activated.

Return oil from the hydraulic cylinders and rotate motor is directed back through the spool sections of the main valve to the outlet section, then to the return oil filters and back to tank.

When operating a grapple function, the joystick sends an electronic signal to the MD3 computer, which transmits the signal on to the XS2 cab module, then to the XA2 valve module. From there, the signal is directed to the solenoid control on the main valve to shift the valve spool and supply system oil for the grapple function activated.

277-8

Moving the L.H. joystick in the right or left direction sends the electronic signal to the solenoid on the Main Directional Control Valve to shift the Grapple Open/Close spool. Hydraulic oil from the pump is then directed through the shifted spool to the Grapple Hydraulic Cylinders, to open or close the grapple arms.

Moving the R.H. joystick in the right or left direction sends the electronic signal to the solenoid on the Main Directional Control Valve to shift the Grapple Rotate spool. Hydraulic oil from the pump is then directed through the shifted spool to the Grapple Rotate Motor, to turn the grapple in either a clockwise or counterclockwise direction.

17.4

GRAPPLE CONNECTIONS

Tigercat 250C Loader

RETRACT

Grapple

GRAPPLE CYLINDERS

RETRACT GRAPPLE ROTATE

MAIN DIRECTIONAL CONTROL VALVE

TO OIL COOLER

(PX) TEST PORT

MAIN HYDRAULIC PUMP

(PL) TEST PORT

JOYSTICKS

MD3 COMPUTER DISPLAY SUCTION LINE FROM RESERVOIR

XA2 VALVE MODULE

XS2 CAB MODULE

RETURN FILTERS

TO TANK

FROM (YS) PORT ON MAIN CONTROL VALVE PILOT PRESSURE FILTER

PILOT MANIFOLD LEGEND PRESSURE LINE RETURN LINE PILOT LINE ELECTRICAL WIRE

250C-082

GRAPPLE CIRCUIT 17.5

TO TANK

HAND FILL PUMP

Tigercat 250C Loader

Grapple

CIRCUIT PRESSURE SETTINGS

4. Have an assistant start the engine, and set the throttle control to the IDLE position. Lower left arm rest and depress the pilot reset switch to activate the pilot system.

GRAPPLE OPEN/CLOSE RELIEF VALVE SETTINGS

5. Hold the L.H. joystick in the GRAPPLE OPEN position (cylinders fully retracted). Record gauge pressure reading.

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

6. Hold the L.H. joystick in the GRAPPLE CLOSE position (cylinders fully extended).

Record gauge pressure reading.

7. Compare gauge readings to values shown in PRESSURE SETTINGS – MAIN VALVE PORT RELIEFS, in Section 3.

CAUTION Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

8. If the pressure reading is less than set value, adjust feed reducer. Turn adjusting screw in to increase pressure or turn screw out to decrease pressure.

WARNING

NOTE: Relief valves are not adjustable. If less than set value in one direction but OK in the other direction, the relief valve for the low pressure circuit must be replaced.

Make sure no one is standing near the grapple during this procedure.

IMPORTANT! Avoid pushing oil over relief longer than 5 seconds. Doing so causes excessive heating of the hydraulic fluid.

9. Tighten the locknut while making sure adjusting screw does not turn.

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

For system pressure values, refer to PRESSURE SETTINGS in Section 3.

Procedure: 1. Position machine on flat level ground.

2. Make sure that the hydraulic oil is at operating temperature.

3. Connect a 0–350 bar (0–5000 psi) pressure gauge to the main control valve (PL) test port on the inlet section of the main control valve.

GRAPPLE OPEN CLOSE SECTION

250BT-031

B

B

IN

OPEN

RET

UP

B

B

B

B

A

A

A DOWN

B

CUT

CUT

A OPEN

CLOSE

A

CW

OUT

A

CCW

UP

A

DOWN

GRAPPLE ROTATE SECTION

250C-048

GAUGE INSTALLATION

MAIN CONTROL VALVE 17.6

Tigercat 250C Loader

Grapple

HYDRAULIC SCHEMATICS GRAPPLE ROTATE MOTOR GRAPPLE OPEN/CLOSE CYLINDERS CROSS-LINE RELIEF VALVE

MAIN DIRECTIONAL CONTROL VALVE (OTHER VALVE SECTIONS NOT SHOWN FOR CLARITY)

250C-081

GRAPPLE ROTATE CIRCUIT

GRAPPLE OPEN/CLOSE CIRCUIT 17.7

Tigercat 250C Loader

Grapple

GRAPPLE ROTATE RELIEF VALVE SETTINGS

6. Hold the R.H. joystick in the ROTATE CLOCKWISE position. Record gauge pressure reading.

For system pressure values, refer to PRESSURE SETTINGS in Section 3.

7. Hold the L.H. joystick in the ROTATE COUNTERCLOCKWISE position. Record gauge pressure reading.

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

8. Compare gauge readings to values shown in PRESSURE SETTINGS – MAIN VALVE PORT RELIEFS, in Section 3.

9. If pressure reading is less than set value, adjust feed reducer. Turn adjusting screw in to increase pressure or turn screw out to decrease pressure.

CAUTION Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

NOTE: Relief valves are not adjustable. If less than set value in one direction but OK in the other direction the relief valve for the low pressure circuit must be replaced.

WARNING

10. Tighten the locknut while making sure adjusting screw does not turn.

Make sure no one is standing near the grapple during this procedure.

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

IMPORTANT! Avoid pushing oil over relief longer than 5 seconds. Doing so causes excessive heating of the hydraulic fluid.

Procedure: 1. Position machine on flat level ground.

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

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

4. Connect a 0–350 bar (0–5000 psi) pressure gauge to the main control valve (PL) test port on the inlet section of the main control valve.

250BT-031

GAUGE INSTALLATION

5. Have an assistant start the engine, and set the throttle control to the IDLE position. Lower left arm rest and depress the pilot reset switch to activate the pilot system.

17.8

Tigercat 250C Loader

Grapple

GRAPPLE QUICK REVERSAL FEATURE Grapple Quick Reversal provides a quick-open feature for the grapple. When enabled, the quickopen-then-close movement of the grapple arms allows unwanted material (roots etc.) to be quickly dropped, without losing the load.

Turn the feature on or off from the menu on the MD3 computer display.

QUICK REVERSAL STATUS From the main Menu screen, press F1 to access the Adjust menu.

From there, select the Machine Parameters menu.

Use the down arrow button to scroll to Grapple Quick Reversal Status. Press OK to accept the selection.

Use the up or down arrow buttons to turn the feature ON or OFF. Press OK to accept.

Press the Back button to return to the Machine Parameters menu or press it again to return to the Main menu.

17.9

Tigercat 250C Loader

Grapple

17.10

Tigercat 250C Loader SECTION 18 – DELIMBER/SLASHER CONTENTS – SECTION 18

JUNE, 2014

C

CIRCUIT DESCRIPTION......................................................................................................................... 18.4 DELIMBER OPEN/DUMP VALVE......................................................................................................... 18.7 DELIMBER/SLASHER CONNECTIONS.............................................................................................. 18.7 CIRCUIT DIAGRAM................................................................................................................................. 18.5 CIRCUIT PRESSURE SETTINGS........................................................................................................... 18.8 D

DELIMBER/SLASHER CIRCUIT COMPONENTS................................................................................... 18.2 MAIN DIRECTIONAL CONTROL VALVE............................................................................................. 18.2 H

HYDRAULIC PUMP................................................................................................................................. 18.2 J

JOYSTICK CONTROLS........................................................................................................................... 18.2 P

PRESSURE SETTINGS DELIMBER ARMS RELIEF VALVE SETTINGS.................................................................................... 18.9 SAW CUT RELIEF VALVE SETTING................................................................................................... 18.8 SAW RETRACT RELIEF VALVE SETTING.......................................................................................... 18.9 S

SAW RETRACT TIME/DELIMBER STATUS.......................................................................................... 18.11 AUTO SLASHER SAW RETRACT TIME............................................................................................ 18.11 DELIMBER STATUS........................................................................................................................... 18.13 GRAPPLE SAW AUTO RETRACT TIME............................................................................................ 18.12 TOP SAW AUTO RETRACT TIME..................................................................................................... 18.12 SAW SPEED ADJUSTMENT SLASHER SAW FLOW %.................................................................................................................. 18.10 TOP SAW FLOW %............................................................................................................................ 18.10

Tigercat 250C Loader

Delimber/Slasher

DELIMBER/SLASHER CIRCUIT COMPONENTS

JOYSTICK CONTROLS The delimber and slasher saw functions are electronically controlled using the thumb switches located on the right- and left-hand joystick control levers in the cab.

ENGINE BELL HOUSING

NOTE: Joystick configurations vary, so for a detailed description of specific switch functions and joystick controls, refer to Section 2 in the OPERATOR’S MANUAL.

MAIN PUMP

MAIN DIRECTIONAL CONTROL VALVE

SWING PUMP

250B-035

The main control valve is made up of seven spool sections. There are proportional solenoid controls on all sections. The valve assembly is made up of two different types of valve section, due to flow requirements of each function. The four larger sections of the valve are capable of supplying larger oil volume for functions that require it. The Valve Spool Cross-section drawings on the next page illustrate the differences in the two types.

HYDRAULIC PUMPS

HYDRAULIC PUMP The main pump is an axial-piston, variabledisplacement pump with load sensing, pressure compensating, and horsepower limiting controls.

The main control valve is located in the upper frame below the floor plates inside the valve compartment.

The delimber and slasher circuits utilize the main pump to supply hydraulic oil to the delimber and slasher control valve spool sections in the main directional control valve.

For a detailed description of the main control valve, refer to Section 4.

For a more detailed description of the main pump, refer to Section 4.

250C-048

UP

B

B

A

A

A DOWN

B

CUT

B

B

OPEN

B

CW

B

DELIMBER OPEN SECTION

CCW

CUT

A

RET

CLOSE

A

OPEN

OUT

A

IN

A

DOWN

UP

SAW CUT RETRACT SECTION

MAIN CONTROL VALVE 18.2

Tigercat 250C Loader

Delimber/Slasher

VALVE SPOOL CROSS-SECTION DRAWINGS

FEED REDUCERS

PORT RELIEF (B) SIDE

24V PROPORTIONAL ELECTRO-HYDRAULIC SPOOL ACTUATORS

PORT RELIEF (A) SIDE

SPOOL

234-068

PRESSURE COMPENSATOR

DELIMBER OPEN/GRAPPLE SAW SPOOL SECTION

FEED REDUCTION SIDE (B)

PORT RELIEF (B) SIDE

PORT RELIEF (A) SIDE

FEED REDUCTION SIDE (A)

24V PROPORTIONAL ELECTRO-HYDRAULIC SPOOL ACTUATORS

250C-069

SPOOL PRESSURE COMPENSATOR

SAW CUT/RETRACT SPOOL SECTION 18.3

Tigercat 250C Loader

Delimber/Slasher

CIRCUIT DESCRIPTION

Pilot oil shifts the spool in the saw cut valve section. System oil flows through the Rotary Manifold to the pilot-operated Three-Way Valve.

Because the delimber knives are closed, there is no pressure to shift the Three-Way Valve, and the system oil flows 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.

Refer to Delimber/Slasher Circuit diagram on the next page.

The delimber/slasher circuit is supplied with hydraulic oil by an axial-piston, variabledisplacement pump. Two spool sections in the main control valve hydraulically control the delimber and slasher functions.

SLASHER SAW – CUT

The joystick switches, the MD3 computer module, the XS2 cab module and the XA2 valve module electronically control the delimber and slasher functions, using proportional electro-hydraulic solenoid controls on the main control valve.

Press the Slasher Saw Cut switch and an electronic signal is sent to the MD3 computer which then sends a signal on to the XA2 valve module. The signal is then sent to open Delimber Knives and to energize the Slasher Cut solenoid on the Main Directional Control Valve.

DELIMBER ARMS – OPEN Press the Delimber Open switch and an electronic signal is sent to the MD3 computer, which then sends a signal on to the XA2 valve module. The signal is then sent to energize the Delimber Open solenoid (B) on the Pilot Manifold and allow pilot oil to shift the valves in the Delimber Open Dump Valve and the Three-Way Valve. At the same time, a signal is also sent to energize the Delimber Open Solenoid on the delimber valve section of the Main Control Valve. Internal pilot oil shifts the spool and directs system oil to flow through the Rotary Manifold to the base end of the delimber arm cylinders, to open the arms.

The solenoid on the Slasher Cut valve section allows pilot oil to shift the spool in the main valve and allow system oil to flow through the Rotary Manifold to the pilot operated Three-Way Valve. Because the delimber knives are open, oil pressure shifts the Three-Way Valve and the system oil flows to the Slasher Saw Motor and the rod end of the Bar Cylinder to run the saw motor and cut with the bar saw.

DELIMBER TOP SAW OR SLASHER SAW – RETRACT Press the Delimber Top Saw or Slasher Saw switch and an electronic signal is sent to the MD3 computer which then sends a signal on to the XA2 valve module. The signal is then sent to energize the Top Saw/Slasher Saw Retract solenoid on the Main Directional Control Valve.

When the switch is released, the Delimber Open Solenoid on the Main Control Valve is deenergized, stopping the flow of oil. The solenoid remains energized to hold the delimber open.

DELIMBER ARMS – CLOSE

The solenoid on the Top Saw/Slasher Saw Retract valve section directs pilot oil to shift the spool in the main valve and 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).

Press the Delimber Close switch and an electronic signal is sent to the MD3 computer, which then sends a signal on to the XA2 valve module. The XA2 module then de-energizes the Delimber Open solenoid (B) on the Pilot Manifold, removing pilot pressure from the Delimber Open/Dump Valve.

Oil enters the rod end of the cylinders from the delimber accumulator to close the arms. Oil from the base end of the delimber arms cylinder is returned to tank through the Delimber Open/Dump Valve.

DELIMBER TOP SAW – CUT Press the Delimber Top Saw switch and an electronic signal is sent to the MD3 computer which then sends a signal on to the XA2 valve module. The signal is then sent to energize the solenoid on Saw Cut Retract section on the Main Control Valve.

18.4

Tigercat 250C Loader

Delimber/Slasher

DELIMBER OPEN/ DUMP VALVE

D V

T

ROTARY MANIFOLD

TO TOP SAW MOTOR AND BAR CYLINDER ROD END (CUT)

1 2 4 3

TO SLASHER MOTOR AND BAR CYLINDER ROD END (CUT)

7

1

8

2

9

5

10

4

11

3 6

12

THREEWAY VALVE

4

7

5

FRONT BULKHEAD

8

1

9

3

10

2

11

6

12

TO DELIMBER ARMS CYLINDER BASE END (OPEN) TO TOP SAW CYLINDER BASE END (RETRACT) TO SLASHER SAW CYLINDER BASE END (RETRACT)

RETURN

MAIN DIRECTIONAL CONTROL VALVE

PS A

B

A

A

B

A

B

B

B

A

A

A

TO OIL COOLER

B

B

(PX) TEST PORT

MAIN HYDRAULIC PUMP

(PL) TEST PORT

MD3 COMPUTER DISPLAY

JOYSTICKS

SUCTION LINE FROM RESERVOIR XA2 VALVE XS2 CAB MODULE MODULE RETURN FILTERS

PILOT SHUT OFF

LEGEND PRESSURE LINE RETURN LINE PILOT LINE ELECTRICAL WIRE

DELIMBER OPEN

P2

TO TANK TO TANK P1

P3 C

B

A

INLET

FROM (YS) PORT ON MAIN CONTROL VALVE PILOT PRESSURE FILTER

T3

PILOT MANIFOLD 250C-083

HAND FILL PUMP

DELIMBER/SLASHER CIRCUIT 18.5

Tigercat 250C Loader

Delimber/Slasher RETURN

TOP SAW RETRACT

DELIMBER OPEN

SAW RETRACT

SLASHER CUT

FRONT BULKHEAD

TOP SAW CUT

ROTARY MANIFOLD VALVE

RETURN TO TANK

GRAPPLE SAW CUT (OPTION)

DELIMBER OPEN/GRAPPLE SAW CUT VALVE SECTION

SAW CUT/RETRACT VALVE SECTION

MAIN DIRECTIONAL CONTROL VALVE (OTHER VALVE SECTIONS NOT SHOWN FOR CLARITY)

PILOT VALVE

250C-084

DELIMBER/SLASHER HYDRAULIC SCHEMATIC 18.6

Tigercat 250C Loader

Delimber/Slasher

DELIMBER OPEN/DUMP VALVE

DELIMBER/SLASHER CONNECTIONS

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

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 3–#12 JIC elbows and 1–#16 JIC elbow. The slasher connections, located at the rear of the lower frame consist of 2–#16 JIC fittings and 1–#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.

240B-039

For information on the Delimber or Slasher attachment, please refer to the component manufacturer's manual.

DELIMBER OPEN/DUMP VALVE

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

TOP SAW RETRACT

TOP SAW CUT

TANK

240B-027

DELIMBER OPEN/DUMP VALVE SCHEMATIC

DELIMBER OPEN

In the neutral position with the pilot de-activated, port (D) is open to tank port (T), allowing oil to flow from the base end of the delimber arms cylinder and return 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.

DELIMBER CONNECTIONS

240B-039

When the switch is pressed to open the delimber arms, a solenoid on the pilot valve directs pilot oil to the valve cartridge on the Open/Dump Valve.

The valve cartridge shifts to block the connection between ports (D) and (T) and allow system oil to flow from port (V). The oil flows through the check valve to port (D) and to the base end of the cylinder, to open the delimber arms.

SLASHER RETRACT TANK

275-16

18.7

SLASHER CUT

SLASHER CONNECTIONS

Tigercat 250C Loader

Delimber/Slasher

CIRCUIT PRESSURE SETTINGS

SAW CUT RELIEF VALVE SETTING Procedure: 1. Position machine on level ground.

For system pressure values, refer to PRESSURE SETTINGS in Section 3.

2. Make sure the hydraulic oil is at operating temperature.

CAUTION

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

3. Connect a 0–345 bar (0–5000 psi) pressure gauge to the main control valve (PL) test port on the inlet section of the main control valve.

4. Have an assistant start the engine and set the throttle control to the IDLE position. Lower left arm rest and depress the pilot reset switch to activate the pilot system.

CAUTION Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

5. Press and hold the Saw Extend switch.

Record gauge pressure reading at (PL) connection.

6. If the pressure reading is less than set value shown in Section 3, adjust feed reducer. Turn adjusting screw in to increase pressure or turn screw out to decrease pressure.

WARNING Make sure no one is standing near the grapple during the following procedure.

7. Tighten the locknut while making sure adjusting screw does not turn.

IMPORTANT! Avoid pushing oil over relief for longer than 5 seconds. Doing so can cause excessive heating of the hydraulic fluid.

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

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

250BT-031

B

B

IN

OPEN

RET

UP

B

B

B

B

A

A

A DOWN

B

CUT

CUT

A OPEN

CLOSE

A

CW

OUT

A

DELIMBER OPEN SECTION

CCW

UP

A

DOWN

SAW CUT RETRACT SECTION

250C-048

GAUGE INSTALLATION

MAIN CONTROL VALVE 18.8

Tigercat 250C Loader

Delimber/Slasher DELIMBER ARMS RELIEF VALVE SETTINGS

SAW RETRACT RELIEF VALVE SETTING Procedure: 1. Position machine on level ground.

Procedure: 1. Position machine on level ground.

2. Make sure the hydraulic oil is at operating temperature.

2. Make sure the hydraulic oil is at operating temperature.

3. Connect a 0–345 bar (0–5000 psi) pressure gauge to the main control valve (PL) test port on the inlet section of the main control valve.

3. Connect a 0–345 bar (0–5000 psi) pressure gauge to the main control valve (PL) test port on the inlet section of the main control valve.

4. Have an assistant start the engine, and set the throttle control to the IDLE position. Lower left arm rest and depress the pilot reset switch to activate the pilot system.

4. Have an assistant start the engine, and set the throttle control to the IDLE position. Lower left arm rest and depress the pilot reset switch to activate the pilot system.

5. Press and hold the Saw Retract switch.

Record gauge pressure reading at (PL) test connection.

5. Press and hold the Delimber Open switch.

Record gauge pressure reading at (PL) test connection.

6. If the pressure reading is less than set value shown in Section 3, adjust feed reducer. Turn adjusting screw in to increase pressure or turn screw out to decrease pressure.

6. If the pressure reading is less than set value shown in Section 3, adjust feed reducer. Turn adjusting screw in to increase pressure or turn screw out to decrease pressure.

7. Tighten the locknut while making sure adjusting screw does not turn.

7. Tighten the locknut while making sure adjusting screw does not turn.

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

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

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

18.9

Tigercat 250C Loader

SAW SPEED ADJUSTMENTS Saw speeds can be adjusted through the MD3 computer display menus by changing the percentage of oil flowing to the attachment. Oil flow can be adjusted from 1 to 100% through the Attachment Flow Settings menu.

Delimber/Slasher Use the up or down arrow buttons to scroll to the desired selection. Press OK to set the selection.

TOP SAW FLOW %

From the main Menu screen, press F1 to access the Adjust menu. Under the Adjust menu, press OK to select Attachment Flow Settings menu.

Use the up or down arrow buttons to reset the value at 0% to 100%. Press OK to confirm the selection.

Press the Back button previous menu screen.

NOTE: Attachment Flow Settings only appears on this menu when the PIN code has been entered to permit access to this adjustment. For details on entering PIN code, see Saw Flow Adjustment under the Main Display screens in Section 6.

to return to the

SLASHER SAW FLOW %

IMPORTANT! Before making any adjustments, make sure you are aware of the oil flow requirements of your particular saw. Over-driving the saw motor with more flow than required can damage it.

Use the up or down arrow buttons to reset the value at 0% to 100%. Press OK to confirm the selection.

Press the Back button to return to the previous menu screen. Continue to press the Back button to return to the Adjust menu screen.

18.10

Tigercat 250C Loader

SAW RETRACT TIME/DELIMBER STATUS

Delimber/Slasher Use the up or down arrow buttons to change the value. Press OK to set the value.

Saw retract times can be adjusted through the MD3 computer display menus. From the Adjust menu, select the Accessories menu.

In the Accessories menu the following items can be selected.

• Auto Slasher Saw Retract Time • Top Saw Retract Time • Grapple Saw Retract Time • Delimber Status Use the up or down arrow buttons to scroll to the desired selection. Press OK to set the selection.

AUTO SLASHER SAW RETRACT TIME

Use the up or down arrow buttons to scroll to the next menu. Press OK to select the menu item.

Press the Back button Accessories menu.

In the Auto Slasher Saw Retract Time selection, the value can be adjusted from 0 to 5 seconds.

This sets the time for the slasher saw to auto retract once cutting has completed.

18.11

to return to the

Tigercat 250C Loader

Delimber/Slasher

TOP SAW AUTO RETRACT TIME

GRAPPLE SAW AUTO RETRACT TIME

In the Top Saw Retract Time selection, the value can be adjusted from 0 to 5 seconds. This sets the auto retract time after the saw has completed cutting.

In the Grapple Saw Retract Time selection, the value can be adjusted from 0 to 5 seconds.

This sets the auto retract time after the saw has completed cutting.

Use the up or down arrow buttons to change the value. Press OK to set the value.

Use the up or down arrow buttons to change the value. Press OK to set the value.

Use the up or down arrow buttons to scroll to the

next menu item. Press OK to select the menu item.

Press the Back button Accessories menu.

to return to the

Press the Back button main Menu screen.

again to return to the

Use the up or down arrow buttons to scroll to the next menu item. Press OK to select the menu item.

Press the Back button Accessories menu.

to return to the

Press the Back button main Menu screen.

again to return to the

18.12

Tigercat 250C Loader

Delimber/Slasher

DELIMBER STATUS

In the Delimber Status menu, 2 choices can be selected — Delimber or No Delimber. Select Delimber if the attachment is mounted on the machine.

Use the up or down arrow buttons to scroll to the desired selection. Press OK to set the selection.

Shown above, Delimber is the choice selected.

Press the Back button Menu screen.

to return to the main

18.13

Tigercat 250C Loader

Delimber/Slasher

18.14