Tigercat T250 Loader SERVICE MANUAL – PDF DOWNLOAD

SERVICE MANUAL Tigercat T250 Loader TABLE OF CONTENTS

ISSUE 1.1, MARCH 2004

SECTION INTRODUCTION .............................................................................................................. iii NON-APPROVED FIELD PRODUCT CHANGES ............................................................ iv SAFETY ............................................................................................................................ 1 CONTROLS AND OPERATION ............................. See separate OPERATOR'S MANUAL LUBRICATION AND MAINTENANCE ............................................................................... 3 HYDRAULIC SYSTEM/ LOAD SENSE CONTROL ........................................................... 4 PILOT SYSTEM ................................................................................................................ 5 ELECTRICAL, GAUGES AND ALARMS ........................................................................... 6 ENGINE START AND STOP ............................................................................................. 7 ENGINE ANTI-STALL ....................................................................................................... 9 TRACK DRIVE ................................................................................................................ 11 BOOM FUNCTIONS ....................................................................................................... 12 SWING ............................................................................................................................ 15 GRAPPLE ....................................................................................................................... 17 *DELIMBER*/SLASHER .................................................................................................. 18

NOTE: The DELIMBER function on the *T250 Loader is an OPTIONAL installation.

250T-SM00

T250 Available Literature Operator's Manual ............................... Part No. 18878A Service Manual .................................... Part No. 18879A Parts Catalog ....................................... Part No. 18877A Hydraulic Adapters Book ....................... Part No. 1472A Hydraulic Hose assemblies Book ......... Part No. 3707A

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

®

Tigercat 250 Loader

Introduction

ii

Tigercat 250 Loader

Introduction

Tigercat T250 Loader

INTRODUCTION An Operator's manual, Service manual and a Parts catalog are provided by Tigercat to assist the dealer, customer and operator in becoming familiar with the features of the Tigercat T250 Loader.

The operator's manual will assist the operator with the techniques of proper and safe operation of the T250 Loader. There is also important information regarding the safe operation of the saw head. 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.

T250-01

iii

Tigercat 250 Loader

Introduction

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

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

Authorization by any other person is unacceptable.

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

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

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

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

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

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

Tigercat Industries Inc.

iv

Tigercat T250 Loader

SECTION 1 - SAFETY OCTOBER 2003 Read and understand this Safety section prior to operating any equipment.

Read and understand all manuals for any attachments or accessories.

CONTENTS - SECTION 1 ANTI-STALL CONTROL MODULE IN CAB - DISCONNECT ........................ 1.7 BATTERY DISCONNECT SWITCH .............................................................. 1.6 COOLING SYSTEM ....................................................................................... 1.8 EXHAUST FUMES ......................................................................................... 1.8 FIRE PREVENTION ....................................................................................... 1.9 FIRE PREVENTION GUIDELINES ............................................................ 1.9 WHAT ELSE TO DO BEFORE YOU EXPERIENCE A FIRE ................... 1.10 WHAT TO DO AFTER A FIRE ................................................................. 1.11 WHAT TO DO IN CASE OF A MACHINE FIRE ....................................... 1.10 FIRST AID ...................................................................................................... 1.4 FLUID LEAKS ................................................................................................ 1.7 LOOSE CLOTHING ....................................................................................... 1.8 PROTECTIVE CLOTHING ............................................................................. 1.3 SAFETY PRECAUTIONS, GENERAL ........................................................... 1.3 SAFETY PRECAUTIONS, OPERATING ....................................................... 1.5 SAFETY PRECAUTIONS, SERVICING ......................................................... 1.7 SAFETY SYMBOLS ....................................................................................... 1.2 UNDERSTANDING SIGNAL WORDS ........................................................... 1.2 WELDING, PRIOR TO ................................................................................... 1.7

Tigercat T250 Loader

Safety

SAFETY SYMBOLS

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

Understanding Signal Words

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

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

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

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

1.2

Tigercat T250 Loader

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

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

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

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

KEEP BACK 500 FEET When approaching an operating machine on foot, stay at least 500 feet (150M) away from the machine and all related attachments including the grapple, delimber, topping saw and ground saws until the operator recognizes your presence.

Make sure that all equipment is shut down with grapple resting securely on stable ground before advancing to the machine.

Follow all instructions from safety inspector and supervisors.

Always avoid the discharge path of all saws.

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

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

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

Do not let an untrained person operate the machine.

Use the handrails and steps provided when mounting and dismounting from the machine. Do not climb onto or jump off the machine at any time. Do not use the seat armrest or joystick as handle when entering or leaving the cab.

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

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

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

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

Tigercat T250 Loader

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

GENERAL SAFETY PRECAUTIONS continued

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

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

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

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

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

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

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

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

Machine should be washed completely at every major service.

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

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

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

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

Do not operate the equipment with anyone in the cab, on platforms, or anywhere else within 300 feet the machine or related equipment. The machine is provided and approved with seating for the operator only.

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

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

Repair or replace malfunctioning parts and systems immediately.

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

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

WARNING Battery posts, terminals and related accessories contain lead and lead compounds.

Wash hands after handling.

1.4

Tigercat T250 Loader

Safety

OPERATING SAFETY PRECAUTIONS

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

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

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

Ensure that the windshield guard is installed and properly secured.

During refuelling do not leave the filler nozzle unattended.

Avoid over filling and immediately clean up spilled fuel.

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

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

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

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

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

Sound the machine horn before starting the machine.

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

Start the engine according to the instructions in this manual.

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

Use only prearranged and approved signalling practices.

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

1.5

Tigercat T250 Loader

Safety

OPERATING SAFETY PRECAUTIONS continued

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

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

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

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

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

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

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

Before transporting the machine: •

Secure the grapple to the trailer and raise the stabilizers.

•

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

•

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

1.6

Tigercat T250 Loader

Safety ENGINE ANTISTALL CONTROL MODULE

SERVICING SAFETY PRECAUTIONS

•

DISCONNECT MULI-PIN PLUG FROM THE ENGINE ANTI-STALL CONTROL MODULE

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

250-10

CONTROL MODULE IN CAB

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

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

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

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

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

This machine is equipped with sensitive electronic control equipment, prior to welding:Disconnect the multi-pin plug from the engine anti-stall controller located on the rear inside wall of the cab.

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

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

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

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.

1.7

Tigercat T250 Loader

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

SERVICING SAFETY PRECAUTIONS continued

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

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

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

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.

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

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

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

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

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

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

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

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

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

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

1.8

Tigercat T250 Loader

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

FIRE PREVENTION

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

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

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

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.

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

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

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

3. Remove debris and blow out dust regularly from the air intake doors, engine radiator, hydraulic oil cooler and A/C condenser core to prevent overheating of the engine and hydraulics. Refer to CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR in SECTION 2 of the OPERATOR’S MANUAL. 4. Blow off all debris and dust accumulated near hot engine exhaust components (turbocharger and exhaust manifold as well as exhaust pipes and muffler) at the completion of each work shift or more frequently depending on logging conditions. Visual inspection after blow off to ensure thorough cleanliness is vital. Engine exhaust systems provide numerous small pockets where saw dust, small wood chips and other flammable forest debris can gather. Even small accumulations close to hot exhaust components can ignite and smolder. If 1.9

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

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

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

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

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

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

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

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

Tigercat T250 Loader

Safety WHAT TO DO IN CASE OF A MACHINE FIRE

FIRE PREVENTION continued

•

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

•

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

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

•

Shut the engine off.

•

Activate the fire suppression system*

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

•

Radio or call for help (as appropriate).

•

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

•

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

•

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

•

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

•

Use the PASS method with most extinguishers.

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

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

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

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

•

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

•

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

•

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

•

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

•

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

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

•

Prevent the fire from happening by ensuring that the machine is cleaned regularly and all systems are well maintained. *NOTE: Dry chemical fire suppression systems are offered by Tigercat as an optional installation on some of the Tigercat product lines. Please disregard any references made to fire suppression systems if not installed on your machine.

1.10

•

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

•

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

•

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

•

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

Tigercat T250 Loader

Safety WHAT TO DO AFTER A FIRE

FIRE PREVENTION continued

20229A

TYPICAL FIRE EXTINGUISHER ACCESS HOLE

•

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

•

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

•

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

•

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

1.11

•

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

•

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

•

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

•

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

Tigercat T250 Loader

Safety

1.12

Tigercat T250 Loader

SECTION 3 - LUBRICATION & MAINTENANCE MARCH 2004

CONTENTS - SECTION 3 AIR CLEANER ...........................................................................................................

AIR CONDITIONING SYSTEM A/C SYSTEM TOTAL CAPACITIES .....................................................................

CHECKING SYSTEM ............................................................................................

AIR INTAKE MAINTENANCE AIR CLEANER .......................................................................................................

AIR CLEANER UNLOADER VALVE .....................................................................

FILTER RESTRICTION INDICATOR ....................................................................

INTAKE TUBING AND JOINTS .............................................................................

3.18 3.11 3.11 3.18 3.19 3.19 3.19

CYCLE TIMES, CYLINDERS, FACTORY SETTINGS .................................... 3.27, 3.29 FILTERS ENGINE AIR FILTER ............................................................................................ 3.18 ENGINE FILTERS ................................................................................................. 3.12 FUEL FILTER/WATER SEPARATOR .................................................................. 3.12 FUEL FILTER/WATER SEPARATOR, REMOTE ................................................. 3.12 HYDRAULIC OIL RETURN FILTERS ................................................................... 3.14 PILOT RETURN PRESSURE FILTER ................................................................. 3.16 REMOVE AND REPLACE ..................................................................................... 3.12 SERVICING GUIDELINES FOR OIL FILTERS .................................................... 3.15 FIRE PREVENTION .................................................................................................... 3.3 GENERAL MAINTENANCE ........................................................................................ 3.3 HYDRAULIC OIL RETURN FILTERS ....................................................................... 3.14 HYDRAULIC OILS, APPROVED ................................................................................ 3.7 HYDRAULIC TANK PRESSURIZATION SYSTEM EARLIER DESIGN ................................................................................................. 3.20 LATER DESIGN .................................................................................................... 3.22 LUBRICATING CYLINDER PINS AND BOOM JOINTS ............................................ 3.4 LUBRICATION POINTS .............................................................................................. 3.8 NEW MACHINE MAINTENANCE ...............................................................................

FIRST 50-100 HOUR INSPECTION AND SERVICE REPORT .............................

INITIAL PRE-DELIVERY INSPECTION ..................................................................

TIGHTENING POINTS ............................................................................................

3.2 3.2 3.2 3.2

OIL LOST FROM LEAKAGE CHART .......................................................................... 3.2 PILOT RETURN PRESSURE FILTER ...................................................................... 3.16 PRESSURE SETTING PROCEDURES. SEE SERVICE MANUAL PRESSURE SETTINGS, S/N 250T0111 TO 250T0115 ........................................... 3.26 PRESSURE SETTINGS, S/N 250T0131 AND UP ................................................... 3.28 PREVENTIVE MAINTENANCE SCHEDULE .............................................................. 3.2 SCHEDULED MAINTENANCE EVERY 8 HOURS: ................................................................................................... 3.4 EVERY 24 HOURS: ................................................................................................ 3.4 EVERY 125 HOURS ............................................................................................... 3.4 EVERY 250 HOURS ............................................................................................... 3.5 EVERY 500 HOURS: .............................................................................................. 3.5 EVERY 1000 HOURS ............................................................................................. 3.6 EVERY 2000 HOURS ............................................................................................. 3.6 EVERY 3000 HOURS ............................................................................................. 3.6 SERVICE AND LUBRICATION POINTS .................................................................... 3.8 SWING DRIVE GEARBOX LUBRICATION .............................................................. 3.10 TORQUE CHART, GENERAL ................................................................................... 3.25 TORQUE SETTINGS, RECOMMENDED ................................................................. 3.24 VACUUM PUMP (LATER DESIGN ONLY) ............................................................... 3.23

Tigercat T250 Loader

Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE FOR T250 LOADER NEW MACHINE MAINTENANCE

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

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

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

Tightening points:~

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

All hydraulic connections Hose clamps All cylinder and boom pin retainers

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

Boom pin nuts Check swing bearing bolt torque Engine mounting bolts Pump mounting bolts

IMPORTANT

Track shoe bolts Track roller retaining bolts

BEFORE DRIVING MACHINE ENSURE THAT THE TRACK TENSION (SAG) IS SET CORRECTLY.

Track sprocket retaining bolts

TRACK SAG MAY BE SET LESS THAN SPECIFIED FOR SHIPPING PURPOSES.

Track drive gearbox mounting bolts

REFER TO SECTION 11 IN THE SERVICE MANUAL FOR THIS PROCEDURE.

Track drive motor mounting bolts Swing gearbox mounting bolts

OIL LOST FROM LEAKAGE

Swing motor mounting bolts Cab securing bolts

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

Any other loose nut, bolt or fitting

3.2

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

Tigercat T250 Loader

Lubrication and Maintenance

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

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.

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

CAUTION Clean around filler caps before checking or adding fluids.

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

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

Clean up spills as soon as possible.

Always release pressure in hydraulic tank Before breaking a connection.

1. Pine needles and bark when allowed to accumulate, form a fuel source that when Always use clean oil and containers. ignited is extremely difficult to extinguish. A Drain dirty oil while still warm. thorough program of regular cleaning and washing will reduce the possibility of a fire Do not exceed recommended fluid levels. starting. In the event a fire does start, the Service all hydraulic filters after the failure of a regular cleaning program will improve the pump, motor, cylinder or valve. Failures of chances of successfully extinguishing a fire. this nature could contaminate the entire 2. Pay close attention to wiring and plumbing hydraulic system. routings during maintenance, ensure that ALL Top up diesel fuel at each shift to reduce wiring harnesses or hydraulic hoses are contamination by condensation. properly restrained and clamped to prevent damage from chaffing.

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

3. Read the fire suppression system manual and have the system serviced regularly by qualified personnel.

Before welding on machine, be sure the negative battery terminal is disconnected.

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

Before welding on machine, disconnect the multi-pin plug from the engine anti-stall controller and the two engine CPU multi-pin plugs from the left side of the engine.

Also refer to the SAFETY section of this manual for additional information on how to prevent fires from starting on the machine.

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

Clean away all branches, bark and chips.

Clean up all traces of oil to avoid fires.

Always have a fire extinguisher at hand.

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

Always install roof safety strut when working in engine compartment.

Clean fire suppression system sensors.

3.3

Tigercat T250 Loader

Lubrication and Maintenance

SCHEDULED MAINTENANCE • For loose nuts, bolts and fittings

EVERY 8 HOURS:~ • Check engine coolant level

• Condition and tension of engine belts

• Check engine oil level

• Visually inspect condition of track components

• Drain fuel/water separator

• Conduct an overall visual inspection.

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

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

• Check hydraulic oil level

EVERY 24 HOURS:~

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

• Perform 8 hour maintenance And in addition:~ • Lubricate grapple rotate bearing; 1-fitting - 4 shots, rotate 90° after each shot

• Swing pinion; 1-fitting - 10 shots while swinging • *Boom joint; 2-fittings - purge

EVERY 125 HOURS:~

• *Stick joint; 2-fittings - purge

• Perform 8 hour maintenance

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

• Perform 24 hour maintenance

*Lubricating cylinder pins and boom joints:1. Ensure machine is on level ground 2. Fully extend stick boom cylinder

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

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

• Check return filter restriction gauge is in GREEN zone with engine running at high idle with oil flow and oil at operating temperature

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

• Check track gearboxes oil level with level plug at 9 O'clock and other plug at 6 O'clock.

NOTE: This procedure will allow grease to flow to the normally "loaded side" of the pin/bearing surfaces.

• Check fluid level in batteries unless maintenance free • Check engine rpm

• Yoke pins; 2-fittings - purge

• Check hydraulic pump and motor securing bolts

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

• Check torque tightening points as per new machine maintenance

• Grapple arm pins; 6-fittings - purge

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

• Grapple cylinder pins; 4-fittings - purge

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

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

• Tracks, track frames and carbody

• Remove potentially damaging limbs or sticks and all debris

• Swing bearing area

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

Make repairs immediately

• Attachment

3.4

Tigercat T250 Loader

Lubrication and Maintenance

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

EVERY 500 HOURS:~ • Perform 8 hour maintenance

NOTE: Neglecting the proper maintenance of these items can result in fire.

• Perform 24 hour maintenance • Perform 125 hour maintenance

• Wear in any other components Clean/replace:~ • Air conditioner re-circulation filter • Cab fresh air filter

• Perform 250 hour maintenance And in addition:~ • Replace engine oil and filter§.

• Replace engine fuel filter§.

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

• Replace engine coolant filter§.

• Replace filter in remote mounted fuel filter/ water separator§ (all machines).

• Replace air cleaner safety element.

EVERY 250 HOURS:~

• Replace hydraulic oil pre-fill filter§. †

• Perform 8 hour maintenance

• Replace hydraulic oil return filters. †

• Perform 24 hour maintenance

• Replace hydraulic oil pilot pressure filter§. †

• Perform 125 hour maintenance

§ Refer to FILTERS - REMOVE AND REPLACE in THIS SECTION.

And in addition:~ • Check all hydraulic pressures • Lubricate swing drive gearbox lower bearing; 2 fitting - 5 shots.* Do not use power grease gun. *With swing gearbox at operating temperature slowly add 5 shots of lithium based EP2 to each side of the gearbox. Note: During cold weather the swing function must be operated 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.

Lubricate:~ • Door and cover hinges; 8 fittings - 1 shot • Other door hinges; apply oil liberally Check:~ • Torque on swing bearing and swing gearbox retaining bolts.

• Torque on track drive gearboxes and motor mounting bolts.

• Check track rollers for leakage. Earlier rollers were filled with oil and later rollers filled with grease, both cases are considered to be maintenance free. If a lubricant leakage is detected the rollers must be removed, repaired and replaced.

• Check fire extinguisher and turn it to mix contents

• Check track idler assembly for leakage, the bearing is filled with oil and is considered to be maintenance free. If a lubricant leakage is detected the idler must be removed, repaired and replaced.

• Replace air cleaner primary element*.

• 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.

3.5

Tigercat T250 Loader

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 1000 HOURS:~

EVERY 3000 HOURS:~

• Perform 8 hour maintenance

• Perform frequently maintenance

• Perform 24 hour maintenance

• Perform 8 hour maintenance

• Perform 125 hour maintenance

• Perform 24 hour maintenance

• Perform 250 hour maintenance

• Perform 125 hour maintenance

• Perform 500 hour maintenance

• Perform 250 hour maintenance • Perform 500 hour maintenance

And in addition:~ • Replace oil in track drive gearboxes with drain plug at 6 O'clock position and fill plug at 9 O'clock.

• Perform 1000 hour maintenance • Perform 2000 hour maintenance And in addition:~

• Check in-tank fuel strainer. Drain tank, clean or replace as necessary.

• Clean/replace filter element in fitting at P1. port on main pump anti-stall valve. (Main pump AP011 (160cc) only)

• Replace air cleaner unloader valve.

EVERY 2000 HOURS:~ • Perform 8 hour maintenance • Perform 24 hour maintenance • Perform 125 hour maintenance • Perform 250 hour maintenance • Perform 500 hour maintenance • Perform 1000 hour maintenance And in addition:~ • Replace turbocharger rubber inlet coupling, High temperatures in this area can cause the rubber to harden. See AIR INTAKE MAINTENANCE in THIS SECTION • Check ALL air intake tubing, rubber couplings and band clamps for signs of wear and leakage • Drain and refill hydraulic oil tank with recommended hydraulic oil. See APPROVED HYDRAULIC OILS in THIS SECTION It is strongly recommended that a program of regular oil testing be used. Oil change intervals can be established from oil test results

3.6

Tigercat T250 Loader

Lubrication and Maintenance

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

Chevron

Mechanism LPS 68 (summer)

Citgo

Mystik HVI-68 (summer)

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

Tellus T68 (summer) Tellus T22 (winter)

Texaco

Rando HDZ 68 (summer)

3.7

Tigercat T250 Loader

Lubrication and Maintenance

SWING BEARING 1 FTG/8

14

DOOR HINGES 2 FTG/500

6

4 SHOTS WHILE SWINGING

5 1 2

SWING PINION 1 FTG/8

4 3

10 SHOTS WHILE SWINGING

7 8

DOOR HINGES 2 FTG/500

SWING GEARBOX LOWER BEARING 2 FTG/250

9

5 SHOTS EACH FITTING (FITTINGS LOCATED UNDER BOOM)

12

10

STICK JOINT 2 FTG/8

10

BOOM JOINT 2 FTG/8

DOOR HINGES 4 FTG/500

YOKE PINS 2 FTG/8

CYLINDER PINS 4 FTG/8 GRAPPLE ROTATE BEARING 1 FTG/24 4 SHOTS ROTATE 90˚ AFTER EACH SHOT

13

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

GRAPPLE ARM PINS 6 FTG/8 CYLINDER PINS 4 FTG/8

16

14025B.AI.R1

3.8

11

15

Tigercat T250 Loader

Lubrication and Maintenance

Tigercat® T250 Loader On Tracks SERVICE AND LUBRICATION POINTS REFER TO Tigercat OPERATOR’S MANUAL FOR ADDITIONAL INFORMATION ®

CHANGE COOLANT EVERY 2 YEARS

34

9

24

6.3

60% ANTIFREEZE ** 40% DISTILLEDWATER

1

COOLING SYSTEM

CHK

2

ENGINE OIL AND FILTER CUMMINS 'C'

CHK

3

FUEL FILTER (ENGINE)

REP

4

ENGINE COOLANT FILTER

REP

1

5

FUEL/WATER SEPARATOR

REP

1

6

INTANK FUEL STRAINER

REP

DRN

1

1

CHK REP

1

7 AIR CLEANER SAFETY ELEMENT

REP

8

AIR CLEANER UNLOADER VALVE

CHK

9

HYDRAULIC TANK

CHK

10

RETURN FILTERS † (4 ELEMENTS)

11

PRESSURE FILTER, PILOT †

12

MAIN PUMP PILOT FILTER SCREEN

13

1

1

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

REP

4

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

REP

1

D/R

15

TRACK DRIVE GEARBOX

16

TRACK ROLLERS & IDLERS

350

92

REP

1

FILTER SCREEN LOCATED IN FITTING AT 'P1' PORT CONNECTION ON CONTROL VALVE ON MAIN PUMP

SEE LUBRICATION POINTS DIAGRAM SEE MANUFACTURER'S MAINTENANCE SCHEDULE

GRAPPLE, OTHER MANUFACTURERS FIRE EXTINGUISHER

CHECK AIR CLEANER FILTER RESTRICTION INDICATOR AT FULL ENGINE RPM REFER TO OPERATOR'S MANUAL SECTION 2 FOR DETAILS

GRAPPLE, Tigercat

14

DRAIN TANK, CLEAN OR REPLACE AS NECESSARY

1

REP

CHK

SEE ENGINE MANUFACTURER'S SERVICE MANUAL

1

CHK

AIR CLEANER PRIMARY ELEMENT

DESCRIPTION

QTY

US GAL

3000

2000

1000

500

250

125

8

SERVICE POINT NO.

ITEM

LITER

CAPACITY

SERVICE EVERY

CHK

CHK

D/R

CHK

1

TURN TO MIX CONTENTS

6

1.5

2

CHECK IN HORIZONTAL POSITION FILL WITH SAE 75W90 SYNTHETIC GEAR OIL

7.6

2

1

CHECK FOR OIL LEAKAGE. FILL WITH SAE 30 OR 40 IF REQ'D

LEGEND 2 FTG/125

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

† Use of filters other than genuine Tigercat replacement filters is not recommended T250LUBCHART.XLS

3.9

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

Tigercat T250 Loader LUBRICATION OF SWING DRIVE GEARBOX

Lubrication and Maintenance

UPPER GEARING LUBRICATION The swing gearbox upper gearing is lubricated by hydraulic oil which flows from one of two return ports on the auxiliary valve into the swing brake 'U' port on the swing drive gearbox. A 1/16 inch orifice/connector installed in the 'U' port regulates the flow of oil through the gearbox at approximately 1 GPM. Oil is returned to tank via flushing port 'T'.

ALTERNATE BRAKE RELEASE PORT 'Z' (PLUGGED)

STEEL DISC FLUSHING PORT 'T'

FRICTION DISC

FLUSHING PORT 'U'

• •

• •

•

CONNECTOR/ ORIFICE 0.062" DIA

•

• BRAKE RELEASE PORT 'Y'

BK005-8

CROSS SECTION OF SWING BRAKE 2-GREASE FITTINGS FOR LOWER BEARING LUBRICATION

• • BELOW MAIN BOOM ON UPPER FRAME

381-3A LOWER BEARING LUBRICATION LOWER BEARING LUBRICATION The cavity in the lower portion of the gearbox where the two lower bearings are housed is completely filled with grease.

Using a hand grease gun, pump 5 shots of grease into each grease fitting located at the front of the upper frame below the main boom mount. Follow the lubricating procedure on the label located beside the grease fittings and also refer to SCHEDULED MAINTENANCE - 250 HOURS in THIS SECTION. For additional information refer to SECTION 15 in the SERVICE MANUAL.

3.10

Tigercat T250 Loader CHECKING THE AIR CONDITIONING SYSTEM

Lubrication and Maintenance IMPORTANT It is recommended that during cold weather when the A/C system is not in use, that it be run for a period of 5 minutes every 2 weeks.

This will circulate oil to all components of the A/C system.

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

CAUTION

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

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

2 OZ.

The compressor and charge valves are accessed on the right side of the engine. The receiver dryer is mounted to the outside back of the cab.

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

i.

Check to see that compressor clutch will engage.*

j.

Inspect sight glass on receiver dryer with A/C ON. A constant stream of bubbles indicates system requires charging.* SIGHT GLASS INDICATES CONDITION OF CHARGE

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

•• ••

CHECK A/C CONDENSER CORE

BINARY SWITCH, SYSTEM PROTECTION

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

• • UPPER FRAME

A/C RECEIVER/DRYER 206-6A

CHECK A/C CONDENSER CORE

b. Check the condenser core for dirt and debris.

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

A/C RECEIVER/DRYER Check colour in moisture indicator; BLUE is OK. PINK indicates desiccant material in dryer is saturated with moisture. In this situation replace receiver/dryer, evacuate system and recharge system with both refrigerant and PAG oil.*

870-D43

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

* Indicates that these repairs must only be carried out by a certified A/C technician.

e. Check all A/C hoses for kinks.* f.

Run air conditioning system for 3 - 5 minutes.

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

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

3.11

Tigercat T250 Loader

Lubrication and Maintenance ENGINE FILTERS

FILTERS - REMOVE AND REPLACE IMPORTANT Failure to service and replace filters at the proper intervals specified in the manufacturer's manuals, could cause damage to the machine and result in the product warranty becoming NULL and VOID. Check Tigercat parts catalog for replacement filters.

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

FUEL FILTER/WATER SEPARATOR, REMOTE MOUNTED

IMPORTANT Refer to the appropriate engine manufacturers operation and maintenance manual for correct procedures and time intervals when servicing the engine coolant, oil and fuel filters.

ENGINE OIL FILTER

1" INNER GASKET & OUTER GASKET

SHUT-OFF VALVES, ENGINE COOLANT FILTER

••

CLOSE BOTH VALVES WHEN REMOVING FILTER. OPEN BOTH VALVES AFTER INSTALLING NEW FILTER ELEMENT.

••

FILTER ELEMENT INCLUDES 3-GASKETS

WATER SEPARATOR BOWL

•• ••

WATER BOWL GASKET

• ENGINE COOLANT FILTER, CORROSION RESISTOR CARTRIDGE

870-D19

ENGINE OIL AND COOLANT FILTERS FUEL FILTER/WATER SEPARATOR ELEMENT

••

•• FUEL FILTER ELEMENT

T250-D01

WATER/SEDIMENT DRAIN VALVE

••

ENGINE FUEL FILTER/WATER SEPARATOR Cummins 6CTAA8.3 engine filters shown above.

CAUTION When changing coolant filter, wait until engine coolant temperature is below 50°C (122°F) before removing radiator cap.

FUEL LINE WATER SEPARATOR (REMOTE MOUNTED)

DRAIN TAP

• •

383-18

The fuel filter/water separator is a combination unit, with a replaceable fuel filter and a removable water sediment bowl on the bottom of the unit. The water sediment bowl is only replaced if it becomes damaged or non-functional. For service and replacement intervals see SERVICE AND LUBRICATION CHART in THIS SECTION. Changing the filter: 1. Park machine on level ground with felling head resting on the ground.

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

3. Remove engine front access panel.

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

5. Place a suitable container below to catch the spilt fuel.

6. Wearing face protection (in case of a fuel squirt) and unscrew the old filter.

7. Remove and discard the small 1” I.D. gasket from the threaded extension on the filter head.

3.12

Tigercat T250 Loader

Lubrication and Maintenance

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

9. Clean the water sediment bowl.

10. Check the seating area for the gaskets on the filter head and the water sediment bowl and wipe clean.

11. Lubricate gasket for bottom of filter and water sediment bowl with clean engine oil and carefully hand tighten the water sediment bowl onto the new filter. It is plastic and will break if over tightened. Close the water drain valve.

12. Lubricate the new 1” I.D. gasket with clean engine oil and install onto the threaded extension on the filter head.

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

14. Screw the new filter on to the filter head until the gasket makes contact with the seat and then hand tighten an additional 3/4 turn only.

15. If fuel priming is necessary, refer to the appropriate engine manufacturers maintenance manual.

16. Start the engine and check for leaks.

3.13

Tigercat T250 Loader

Lubrication and Maintenance Changing the filters:

RETURN MANIFOLD

DOUBLE FILTER HEADS

1. Ensure Loader is on firm level ground. Lower grapple to ground and stop engine.

••

•

2. Turn battery disconnect switch OFF. 3. Release air from hydraulic tank by opening the air vent ball valve.

••

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

5. Place rags below to catch the spillage of oil.

•

• 1-WATER ABSORBING RETURN FILTER (COLOUR BLUE) 358-17

••

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

••

7. 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-HYDRAULIC RETURN FILTERS

HYDRAULIC RETURN FILTERS

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

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

3.14

Tigercat T250 Loader

Lubrication and Maintenance •

FILTER HEAD

HYDRAULIC FILTER SERVICING GUIDELINES

• GASKET

•

IMPORTANT

FILTER ELEMENT

NEVER PRE-FILL ANY HYDRAULIC FILTERS ON 200, 700, 800 AND 1000 SERIES MACHINES NEVER PRE-FILL CHARGE PRESSURE FILTERS ON 600 SERIES SKIDDERS

SQUARE SECTION GASKET INSTALLATION FILTR_SEALS 2

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

Apply clean oil to new gasket surfaces.

Install new gasket into groove in filter head.

Do not prefill filter *. Screw on new filter until gasket makes contact with filter head.

Tighten filter an additional 3/4 turn.

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

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

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

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

FILTER HEAD

• •

ALWAYS PRE-FILL DUAL HEAD HYDRAULIC FILTERS ON 600 SERIES SKIDDERS

GASKET

•

FILTER ELEMENT

Dual head hydraulic filters on 600 series skidders must always be pre-filled with clean oil as noted specifically in the manuals for each of these machines.

'O' RING GASKET INSTALLATION 'O' Ring Gasket

FILTR_SEALS 2

z

Remove used gasket and clean gasket seat in head.

Apply clean oil to new gasket surfaces.

All 600 series hydraulic circuits direct oil from the dual head filters to the main and drive pump inlets. Air must not be allowed to enter the inlets of these pumps. Entry of air directly into pump inlets can cause significant and costly damage to pumps. In this particular case the risk of damage to pumps caused by entry of air into the circuit is considered to be greater than the risk of damage caused by unfiltered oil. Prefiltering of any hydraulic oil used to pre-fill these filters is strongly recommended to eliminate the risk of damage caused by unfiltered oil.

Install new gasket on inside lip of filter.

Do not prefill filter *. Screw on new filter until gasket makes contact with filter head.

Tighten filter an additional 3/4 turn.

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.

8. Close air vent ball valve.

9. Start the engine and check for leaks. *Refer to HYDRAULIC FILTER SERVICING GUIDELINES on PREVIOUS PAGE. 3.15

Tigercat T250 Loader

Lubrication and Maintenance 10. 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. *Refer to HYDRAULIC FILTER SERVICING GUIDELINES on PREVIOUS PAGE.

••

PILOT FILTER ELEMENT

LOCATED LOWER LEFT SIDE OF ENGINE COMPARTMENT

383-11

HYDRAULIC PILOT FILTER

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

For service and replacement intervals see SERVICE AND LUBRICATION CHART in THIS SECTION. Changing the filter: 1. Ensure Loader is on firm level ground. Lower grapple to ground and stop engine.

2. Turn battery disconnect switch OFF. 3. Release air from hydraulic tank by opening the air vent ball valve.

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

5. Place rags below to catch the spillage of oil.

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

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

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

9. Do not prefill filter *. Screw on new filter until gasket makes contact with filter head.

3.16

Tigercat T250 Loader

Lubrication and Maintenance

3.17

Tigercat T250 Loader AIR INTAKE MAINTENANCE

Lubrication and Maintenance

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

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

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

The most common and most damaging air intake servicing problems are:

AIR CLEANER UNLOADER VALVE

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.

382-12A

••

AIR CLEANER

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.

205-19AC

AIR CLEANER PRIMARY ELEMENT

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

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

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

205-22AC

AIR CLEANER SAFETY ELEMENT

8. Check connection and ducts for air tight fit.

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

4. Always clean the inside of the outlet tube.

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

6. Inspect the new filter for damage.

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

3.18

Tigercat T250 Loader

Lubrication and Maintenance

AIR CLEANER UNLOADER VALVE

AIR INTAKE TUBING

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.

RUBBER TURBO INLET CHARGER JOINT

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.

•

• 250-04

••

FILTER RESTRICTION INDICATOR

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

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

See SCHEDULED MAINTENANCE in THIS SECTION.

RESET BUTTON

• FILTER RESTRICTION INDICATOR

240B-D26

••

••

FILTER RESTRICTION INDICATOR

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

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

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

3.19

Tigercat T250 Loader SERVICING HYDRAULIC PRESSURIZATION SYSTEM, ENGINE TURBO AIR (EARLIER DESIGN)

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

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

REGULATED PRESSURE LINE TO TANK

REGULATOR

•

PRESSURE GAUGE

•

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

•

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

LOCATION: INSIDE REAR ACCESS DOOR 381-15A

VENT FILTER AND RELIEF VALVE

• •

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

• ••

AIR VENT BALL VALVE

HYDRAULIC TANK

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

LOCATION: INSIDE FRONT ACCESS PANEL

383-4

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

HYDRAULIC TANK PRESSURIZATION SYSTEM BY ENGINE TURBO AIR (EARLIER DESIGN)

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

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

PRESSURE GAUGE

RUBBER NIPPLE

•

HYDRAULIC TANK

•

•

REGULATOR ADJUSTING HANDLE

•

•

• •

AIR FILTER

• LOCKING NUT

RELIEF VALVE

•

BALL VALVE, AIR VENT

REGULATOR

TURBO AIR FROM ENGINE 845-41

REGULATOR SET-UP PROCEDURE (EARLIER DESIGN ONLY) 3.20

Tigercat T250 Loader

Lubrication and Maintenance

5. Close the ball valve.

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

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

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

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

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

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

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

IMPORTANT When servicing the hydraulic system, always de-pressurize the hydraulic tank by opening the air vent ball valve .

Do not attempt to START the engine unless the hydraulic tank has been pressurized.

Refer to HYDRAULIC PRESSURIZATION SYSTEM (EARLY DESIGN) in SECTION 2 of the OPERATOR'S MANUAL

3.21

Tigercat T250 Loader SERVICING HYDRAULIC PRESSURIZATION SYSTEM (LATER DESIGN)

Lubrication and Maintenance RELIEF VALVE

PRESSURE GAUGE AIR VENT BALL VALVE

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

SET HYDRAULIC TANK RELIEF VALVE WITH AIR COMPRESSOR CHARGING SYSTEM

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

The gauge should now read 0 psi.

••

•

VENT FILTER

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

•

••

•• PUMP SWITCH

HYDRAULIC TANK

•• AIR COMPRESSOR/ VACUUM PUMP

•• 250-P05

HYDRAULIC PRESSURIZATION SYSTEM (LATER DESIGN)

AIR COMPRESSOR/VACUUM SOLENOID VALVE

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

••

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

VENT FILTER

AIR COMPRESSOR/ VACUUM PUMP

••

•

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

Tighten the relief valve locking nut.

250-04

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

RELIEF VALVE

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

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

PRESSURE GAUGE

AIR COMPRESSOR/ VACUUM PUMP

AIR VENT BALL VALVE

•• •

•• VENT FILTER

•• ••

250-05

3.22

HYDRAULIC PRESSURIZATION SYSTEM (LATER DESIGN/LATER MACHINES)

Tigercat T250 Loader VACUUM PUMP (LATER MACHINES) Later machines are equipped with a vacuum pump to "hold" the oil in the hydraulic tank when work is being done on the hydraulic system. This eliminates the need to drain the hydraulic reservoir before servicing pumps and other hydraulic components. The air compressor used for hydraulic reservoir pressurization also acts as a vacuum pump for this purpose.

Lubrication and Maintenance 5. Turn the vacuum pump switch OFF. 6. Relieve the vacuum in the hydraulic tank by OPENING and CLOSING the air vent ball valve.

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

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

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

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

IMPORTANT REMOVE KEY FROM KEY SWITCH

Do not attempt to START the engine unless the hydraulic tank has been pressurized.

Refer to HYDRAULIC PRESSURIZATION SYSTEM (EARLY DESIGN) in SECTION 2 of the OPERATOR'S MANUAL

•• 250-P02

When servicing the hydraulic system, always de-pressurize the hydraulic tank by opening the air vent ball valve .

REMOVE KEY

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

VACUUM TANK SWITCH

•

T250-D13

VACUUM TANK SWITCH

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

4. Perform all required work on the hydraulic system.

3.23

Tigercat T250 Loader

Lubrication and Maintenance

TORQUE CHART LOCATION

Cylinders Hoist, Piston nut Hoist, Keeper plate bolts Stick, Piston nut Stick, Keeper plate bolts Heel, Piston nut Heel, Keeper plate bolts Grapple, Piston nut Grapple, Gland Cab Tilt, Piston nut Cab Tilt, Gland Boom joint and cylinder pin retaining bolts Main and Stick boom pin retaining nut Heel to Stick boom pin retaining nut Cab securing bolts Swing bearing bolts Swing bearing bolts, Track machine Swing gearbox mounting bolts Swing motor mounting bolts Engine mounting Bolts, bracket/mount to chassis Bolts, bracket to engine Flex drive coupling hub setscrew Engine cooling fan mounting bolts Pump drive Drive plate to flywheel Bell housing to engine Under carriage Track shoe bolts (D6) Roller mounting bolts Sprocket bolts Gearbox mounting bolts Drive motor mounting bolts

THREAD DIAMETER

TORQUE (LUBRICATED) lbf-ft Nm

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

3200 315-347 3200 315-347 2250 315-347 1750 80-88 930 450

4320 427-470 4320 427-470 3050 427-470 2355 109-119 1260 610

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)

450-500

610-680

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

450-500 450-500 160-175 200

610-680 610-680 215-235 275

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

450-500 75 90 40

610-680 100 122 54

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

33-36 47

45-49 63

3/4" UNC (Special) 7/8"-9 UNC (G8) M20 (10.9) M20 (10.9) M12 (10.9) M20 (10.9)

T/T 450 380 380 95 380

**

**

T/T 610 515 515 130 515

**T/T represents Torque -turn, this is a method of torquing the track shoe bolts which is fully described in SECTION 11 of the Tigercat SERVICE MANUAL.

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

3.24

Tigercat T250 Loader

Lubrication and Maintenance

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

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

IMPERIAL

GRADE 5 BOLTS

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

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

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

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

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

METRIC

SIZE

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

M6 M8 M10

4.8 12 23

3.5 8.5 17

6 15 29

4.5 11 21

9 22 43

6.5 16 32

11 28 55

8.5 20 40

13 32 63

9.5 24 47

17 40 80

12 30 60

15 37 75

11.5 28 55

19 47 95

14.5 35 70

M12 M14 M16

40 63 100

29 47 73

50 80 125

37 60 92

75 120 190

55 88 140

95 150 240

70 110 175

110 175 275

80 130 200

140 225 350

105 165 225

130 205 320

95 150 240

165 260 400

120 190 300

M18 M20 M22

135 190 260

100 140 190

175 240 330

125 180 250

260 375 510

195 275 375

330 475 650

250 350 475

375 530 725

275 400 540

475 675 925

350 500 675

440 625 850

325 460 625

560 800 1075

410 580 800

M24 M27 M30

330 490 675

250 360 490

425 625 850

310 450 625

650 950 1300

475 700 950

825 1200 1650

600 875 1200

925 1350 1850

675 100 1350

1150 1700 2300

850 1250 1700

1075 1600 2150

800 1150 1600

1350 2000 2700

1000 1500 2000

M33 M36

900 1150

675 850

1150 1450

850 1075

1750 2250

1300 1650

2200 2850

1650 2100

2500 3200

1850 2350

3150 4050

2350 3000

2900 3750

2150 2750

3700 4750

2750 3500

ISSUE 3 800

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

3.25

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

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

Tigercat T250 Loader

Lubrication and Maintenance

PRESSURE SETTINGS, Machine serial numbers 250T0111 to 250T0115 ENGINE RPM WITH CUMMINS 6CT8.3-C (215 HP @ 2200 RPM) FULL THROTTLE, NO LOAD, MAX .................................... 2400 RPM IDLE, NO LOAD ..................................................................... 950 RPM RATED WORKING .............................................................. 2200 RPM L.H. FINAL DRIVE CROSSLINE RELIEFS .......................................................... 4700 PSI (CRACKING PRESSURE) BEGIN OF REGULATION ..................................................... 3100 PSI BRAKE RELEASE ................................................................... 500 PSI SPEED: LOW .................................................................... 14.5 RPM (TRACK DRIVE SPROCKET) DRIVE .................................................................... 28 RPM (TRACK DRIVE SPROCKET) R.H. FINAL DRIVE CROSSLINE RELIEFS ........................................................... 4700 PS (CRACKING PRESSURE) BEGIN OF REGULATION ..................................................... 3100 PSI BRAKE RELEASE ................................................................... 500 PSI SPEED: LOW .................................................................... 14.5 RPM (TRACK DRIVE SPROCKET) DRIVE .................................................................... 28 RPM (TRACK DRIVE SPROCKET) MAIN PUMP (LINDE) START OF ANTI-STALL OUTPUT (MODULE AX159) .............. 2100 RPM MAIN VALVE (LINDE) HIGH PRESSURE LIMITING CONTROL MAIN RELIEF ........................................................................................ NONE ADJUSTABLE LOAD SENSE RELIEF P1 .................................................................... SCREW IN FULLY (LOCKED OUT) LOAD SENSE RELIEF P2 (AT ‘P’ PORT) ............................ 4500 PSI @ FULL THROTTLE MARGIN PRESSURE (‘P’ TO ‘LS’ DIFFERENCE) ............. ¶ 300 PSI @ FULL THROTTLE MAIN VALVE PORT RELIEFS LEFT TRACK FORWARD AND REVERSE SPOOL SECTION ........... NO PORT RELIEF PORT RELIEF HEEL IN (OPTION) ..................................... *4900 PSI @ 1200 RPM PORT RELIEF HEEL OUT (OPTION) ................................. *4900 PSI @ 1200 RPM PORT RELIEF GRAPPLE SAW (OPTION) ....................... ***3600 PSI @ FULL THROTTLE or DELIMBER OPEN ..................................... ***2500 PSI @ FULL THROTTLE PORT RELIEF SLASHER CUT ...................................... § ***2700 PSI @ FULL THROTTLE PORT RELIEF STICK IN ..................................................... *4900 PSI @ 1200 RPM PORT RELIEF STICK OUT ................................................. *4900 PSI @ 1200 RPM RIGHT TRACK FORWARD AND REVERSE SPOOL SECTION ......... NO PORT RELIEF PORT RELIEF HOIST DOWN ............................................. *4900 PSI @ 1200 RPM PORT RELIEF HOIST UP .................................................... *4900 PSI @ 1200 RPM SWING SPOOL SECTION ................................................................... NO PORT RELIEF PILOT SUPPLY MAIN RELIEF ............................................................................... 425 PSI @ FULL THROTTLE SWING MOTOR CROSSLINE RELIEFS ............................................................ ***3600 PSI @ FULL THROTTLE AUXILLIARY PUMP COMPENSATOR POR ............................................................. **2900 PSI @ FULL THROTTLE COMPENSATOR STANDBY VALVE .......................................................... SCREW IN FULLY (LOCKED OUT) MINIMUM DISPLACEMENT ....................................................................... DO NOT ADJUST MAXIMUM DISPLACEMENT ...................................................................... TURN ADJUSTING SCREW IN UNTIL IT JUST TOUCHES THE SWASHPLATE, THEN TURN IN 1/2 TURN MORE. AUXILLIARY VALVE MAIN RELIEF AUXILLIARY VALVE ....................................... 3300 PSI @ IDLE PORT RELIEF GRAPPLE ROTATE CCW .......................... †1750 PSI @ FULL THROTTLE PORT RELIEF GRAPPLE ROTATE CW ............................. †1750 PSI @ FULL THROTTLE PORT RELIEF SLASHER CUT .......................................... § 2500 PSI @ FULL THROTTLE PORT RELIEF SAW RETRACT ............................................ 1500 PSI @ FULL THROTTLE PORT RELIEF GRAPPLE OPEN .......................................... 3500 PSI @ IDLE PORT RELIEF GRAPPLE CLOSE ........................................ 3500 PSI @ IDLE CAB TILT VALVE MAIN RELIEF ......................................................................... 2000 PSI @ IDLE

ALL PRESSURES MUST BE SET WITH HYDRAULIC OIL AT OPERATING TEMPERATURE. NOTE: The above values are for reference purposes only, 13918B-R4.10/08/03 SEE SERVICE MANUAL FOR SETTING PROCEDURE. 3.26

Tigercat T250 Loader

Lubrication and Maintenance

PRESSURE SETTINGS, Machine serial numbers 250T0111 to 250T0115 * With Load Sense relief temporarily set at 4900 psi. Set port relief to a point just above the point when the engine stops lugging. ** Turn pump compensator POR valve all the way out to set at 2900 psi. *** Set pressure with gauge on 'LS' port † Tigercat grapple set to 1750 psi.

Hultdins grapple set to 2900 psi. § Slasher cut port relief valve on "auxiliary" valve must be turned up above 2800 psi before setting port relief on "main valve". ¶ Set MARGIN PRESSURE while holding SWING over relief.

CYCLE TIMES, FACTORY SETTINGS Main Valve Flow Adjustment LEFT track speed Forward and Reverse ........................................

Heel IN (option) ........................................................................... 4 Heel OUT (option) ....................................................................... 4 Grapple SAW (option) ................................................................... 9 Delimber OPEN ........................................................................... 8 Slasher CUT ................................................................................ 8 Stick IN ........................................................................................ 6 Stick OUT ............................................................................... 6.75 RIGHT track speed Forward and Reverse ......................................

Hoist DOWN ............................................................................... 8 Hoist UP ................................................................................... 8.5 Swing CCW ................................................................................. 9 Swing CW ................................................................................... 9

See service manual seconds seconds turns ‡ turns ‡ turns ‡ seconds seconds See service manual seconds seconds rpm rpm

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

NOTE: •

All cycle times are set at full throttle.

•

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

•

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

13918B-R4.10/08/03

3.27

Tigercat T250 Loader

Lubrication and Maintenance

PRESSURE SETTINGS, Machine serial numbers 250T0131 and up ENGINE RPM WITH CUMMINS 6CTAA8.3 (205 HP @ 2200 RPM) FULL THROTTLE, NO LOAD, MAX .................................... 2400 RPM IDLE, NO LOAD ..................................................................... 950 RPM RATED WORKING .............................................................. 2200 RPM L.H. FINAL DRIVE CROSSLINE RELIEFS .......................................................... 4700 PSI (CRACKING PRESSURE) BEGIN OF REGULATION ..................................................... 3100 PSI BRAKE RELEASE ................................................................... 500 PSI SPEED: LOW .................................................................... 14.5 RPM (TRACK DRIVE SPROCKET) DRIVE .................................................................... 28 RPM (TRACK DRIVE SPROCKET) R.H. FINAL DRIVE CROSSLINE RELIEFS ........................................................... 4700 PS (CRACKING PRESSURE) BEGIN OF REGULATION ..................................................... 3100 PSI BRAKE RELEASE ................................................................... 500 PSI SPEED: LOW .................................................................... 14.5 RPM (TRACK DRIVE SPROCKET) DRIVE .................................................................... 28 RPM (TRACK DRIVE SPROCKET) MAIN PUMP (LINDE) START OF ANTI-STALL OUTPUT (MODULE AX159) .............. 2100 RPM MAIN VALVE (LINDE) HIGH PRESSURE LIMITING CONTROL MAIN RELIEF ........................................................................................ NONE ADJUSTABLE LOAD SENSE RELIEF P1 .................................................................... SCREW IN FULLY (LOCKED OUT) LOAD SENSE RELIEF P2 (AT ‘P’ PORT) ............................ 4500 PSI @ FULL THROTTLE MARGIN PRESSURE (‘P’ TO ‘LS’ DEFERENCE) .............. ¶ 300 PSI @ FULL THROTTLE MAIN VALVE PORT RELIEFS LEFT TRACK FORWARD AND REVERSE SPOOL SECTION ........... NO PORT RELIEF PORT RELIEF HEEL IN (OPTION) ..................................... *4900 PSI @ 1200 RPM PORT RELIEF HEEL OUT (OPTION) ................................. *4900 PSI @ 1200 RPM PORT RELIEF GRAPPLE OPEN ...................................... ***2500 PSI @ IDLE PORT RELIEF GRAPPLE CLOSE .................................... ***2500 PSI @ IDLE PORT RELIEF STICK IN ..................................................... *4900 PSI @ 1200 RPM PORT RELIEF STICK OUT ................................................. *4900 PSI @ 1200 RPM PORT RELIEF SLASHER CUT ...................................... § ***2700 PSI @ FULL THROTTLE PORT RELIEF GRAPPLE SAW (OPTION) ....................... ***3600 PSI @ FULL THROTTLE PORT RELIEF HOIST DOWN ............................................. *4900 PSI @ 1200 RPM PORT RELIEF HOIST UP .................................................... *4900 PSI @ 1200 RPM RIGHT TRACK FORWARD AND REVERSE SPOOL SECTION ......... NO PORT RELIEF PILOT SUPPLY MAIN RELIEF ............................................................................... 425 PSI @ FULL THROTTLE SWING MOTOR CROSSLINE RELIEFS .............................................................. µ2000 PSI @ IDLE "SWING" PUMP COMPENSATOR POR ............................................................. **3600 PSI @ FULL THROTTLE COMPENSATOR STANDBY VALVE .......................................................... SCREW IN FULLY (LOCKED OUT) MINIMUM DISPLACEMENT ....................................................................... DO NOT ADJUST MAXIMUM DISPLACEMENT ...................................................................... TURN ADJUSTING SCREW IN UNTIL IT JUST TOUCHES THE SWASHPLATE, THEN TURN IN 1/2 TURN MORE. "SWING" VALVE MAIN RELIEF ......................................................................... 4000 PSI @ IDLE PORT RELIEF SWING CCW ............................................................... TURN ADJUSTING SCREW IN PORT RELIEF SWING CW .................................................................. TURN ADJUSTING SCREW IN PORT RELIEF SLASHER CUT .......................................... § 2500 PSI @ FULL THROTTLE PORT RELIEF SAW RETRACT ............................................ 1500 PSI @ FULL THROTTLE PORT RELIEF GRAPPLE ROTATE CCW .......................... †1750 PSI @ FULL THROTTLE PORT RELIEF GRAPPLE ROTATE CW ............................. †1750 PSI @ FULL THROTTLE CAB TILT VALVE MAIN RELIEF ......................................................................... 2000 PSI @ IDLE

ALL PRESSURES MUST BE SET WITH HYDRAULIC OIL AT OPERATING TEMPERATURE. NOTE: The above values are for reference purposes only, 16294B-R4.10/08/03 SEE SERVICE MANUAL FOR SETTING PROCEDURE. 3.28

Tigercat T250 Loader

Lubrication and Maintenance

PRESSURE SETTINGS, Machine serial numbers 250T0131 and up * With Load Sense relief temporarily set at 4900 psi. Set port relief to a point just above the point when the engine stops lugging. ** Turn pump compensator POR valve all the way out to set at 2900 psi. *** Set pressure with gauge on 'LS' port † Tigercat grapple set to 1750 psi.

Hultdins grapple set to 2900 psi. § Slasher cut port relief valve on "SWING" valve must be turned up above 2800 psi before setting port relief on "main valve". ¶ Set MARGIN PRESSURE while holding SWING over relief. µ For 36 ft. reach boom, set to 3000 psi.

CYCLE TIMES, FACTORY SETTINGS Main Valve Flow Adjustment LEFT track speed Forward and Reverse ........................................

Heel IN (option) ........................................................................... 4 Heel OUT (option) ....................................................................... 4 Grapple OPEN .......................................................................... 8.5 Grapple CLOSE ........................................................................ 8.5 Stick IN ........................................................................................ 6 Stick OUT ............................................................................... 6.75 Slasher CUT ............................................................................. 7.5 Grapple SAW (option) ................................................................... 9 Hoist DOWN ............................................................................... 8 Hoist UP ................................................................................... 8.5 RIGHT track speed Forward and Reverse ......................................

See service manual seconds seconds turns ‡ turns ‡ seconds seconds turns ‡ turns ‡ seconds seconds See service manual

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

NOTE: •

All cycle times are set at full throttle.

•

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

•

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

16294B-R4.10/08/03

3.29

Tigercat T250 Loader

Lubrication and Maintenance

3.30

Tigercat T250 Loader

SECTION 4 - HYDRAULIC SYSTEM CONTENTS - SECTION 4 DIFFUSERS/STRAINERS CLEANING ................................................................................................. 4.5 HIGH PRESSURE LIMITING CONTROL VALVE SET LOAD SENSE RELIEF VALVE ......................................................... 4.26 HYDRAULIC OIL RESERVOIR DESCRIPTION ........................................................................................... 4.4 RESERVOIR ............................................................................................... 4.4 HYDRAULIC PUMPS AUXILIARY OR SWING PUMP .................................................................. 4.7 GENERAL DESCRIPTION ......................................................................... 4.6 MAIN PUMP MAIN PUMP CONTROL VALVE ........................................................... 4.25 SWING OR AUXILIARY PUMP .................................................................. 4.7 HYDRAULIC RESERVOIR STRAINER/DIFFUSER ............................................................................... 4.5 HYDRAULIC SYSTEM OPERATION AUXILIARY OR SWING SYSTEM ............................................................. 4.3 BOOM CYLINDERS ................................................................................... 4.2 MAIN CIRCUIT DESCRIPTION ............................................................... 4.12 FLOW ON DEMAND AND LOAD COMPENSATION ............................ 4.12 MAIN HYDRAULIC CIRCUIT ................................................................... 4.13 MAIN HYDRAULIC SYSTEM ..................................................................... 4.2 PILOT CIRCUIT .......................................................................................... 4.3 SWING OR AUXILIARY SYSTEM ............................................................. 4.3 SWING SYSTEM ........................................................................................ 4.2 TRACK DRIVE SYSTEM ............................................................................ 4.2 LOAD SENSING BASIC DESCRIPTION CLOSED CENTRE SYSTEM ................................................................ 4.10 OPEN CENTRE SYSTEM ...................................................................... 4.9 BASIC PRINCIPALS ................................................................................... 4.8 OPERATING TIPS ................................................................................... 4.11 SET LOAD SENSE RELIEF VALVE ......................................................... 4.26 SET MARGIN PRESSURE ....................................................................... 4.25 MAIN CONTROL VALVE CONTROL VALVE SECTIONS ................................................................ 4.16 CONTROL VALVE SPOOL OPERATION ................................................ 4.19 DESCRIPTION ......................................................................................... 4.14 HIGH PRESSURE LIMITING CONTROL VALVE .................................... 4.24 PORT RELIEF AND ANTICAVITATION VALVE ...................................... 4.18 ADJUSTING PROCEDURE .................................................................. 4.18 SCHEMATIC DIAGRAMS LOAD SENSING (FLOW ON DEMAND) .................................................... 4.8 LOAD SENSING SYSTEM ....................................................................... 4.13 MAIN PUMP SCHEMATIC ......................................................................... 4.7 MAIN VALVE MANIFOLD VALVE SECTION WITH H.P. RELIEF . 4.14, 4.24 STRAINERS/DIFFUSERS CLEANING ................................................................................................. 4.5

OCTOBER 2003

Tigercat T250 Loader

Hydraulic system

HYDRAULIC SYSTEM OPERATION

Linde valve base manifold. This provides a back pressure in these passages and reduces the possibility of cavitation in the components of the load sensing system. A check valve is installed in the fitting at the 'T3' port to prevent tank oil flowing from the main Linde valve in the reverse direction.

The hydraulic system has three separate circuits; 1. Main hydraulic circuit with load sensing for the track drive, boom, stick and some grapple functions.

On earlier machines the swing function was also in the main hydraulic circuit.

Boom cylinders

2. Auxiliary hydraulic circuit for the grapple rotate, grapple open/close and slasher functions.

On later machines the swing function is also in the auxiliary hydraulic circuit.

The boom hydraulic circuits are incorporated in the main hydraulic load sensing system. All hoist and stick cylinders have cushions at both ends. All cylinder rods are ground, heat treated, chrome plated and polished.

3. Closed-centre pilot circuit to supply oil to the pilot system.

For a detailed description of the BOOM SYSTEM, refer to SECTION 12 of THIS MANUAL.

1. THE MAIN HYDRAULIC SYSTEM

Track drive system

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

This feature improves fuel economy and reduces heat generation as compared to other types of hydrostatic systems. Energy is not wasted by producing unnecessary pump flow for systems that don't require it. Refer to LOAD SENSING in THIS SECTION.

The track drive hydraulic circuit is incorporated in the main hydraulic load sensing system and utilizes high-torque, axial-piston hydraulic motors. The motors are mounted to a three stage planetary drive gearbox and each is completely housed within the width of the track shoes. The gearboxes include wet, multiple-disc, spring-apply, hydraulicrelease brakes which automatically release when driving and apply when stationary. Independent control of each track permits counter rotation.

For a detailed description of the TRACK DRIVE SYSTEM, refer to SECTION 11 of THIS MANUAL. Swing system

The horsepower limiting control ensures that the engine will not lug down below the full load rpm (engine anti-stall set point) by signalling the main pump to de-stroke. This reduces the output from the main hydraulic pump to lighten the load on the engine. Refer to ENGINE ANTI-STALL in SECTION 9 of this manual.

On machine serial numbers 250T0131 and up the swing circuit is in the auxiliary or "swing" hydraulic system.

The main control valves associated with this system are pressure and flow compensated to provide independent and load independent operation for all functions. The control valves are mounted on a common supply/return base manifold. Two 'P' (pressure) ports on the back of the manifold receive supply oil from the main pump. The return oil from the main control valves exits the base manifold at two 'T' ports and 75 psi internal check valves. From there the oil is returned directly to tank via the return manifold and return filters.

This swing system has a piston motor with crossover relief valves and a double reduction planetary gearbox which provides variable swing speeds from 0 to 9 rpm. A rotary manifold provides hydraulic connection to the subframe of the vehicle and permits continuous 360 degree swing. A multidisc wet brake is installed between the motor and gearbox and is controlled with a switch on the instrument panel. The brake is spring-apply hydraulic-release and will apply whenever the pilot oil supply is shut off. Refer to SWING in SECTION 15 of THIS MANUAL.

A return line connects a 'T3' tank port on the main Linde valve to the 'PB' port on the swing valve or auxiliary valve as it is known as on earlier machines. This connection maintains a supply of oil in the 'T' tank passages of the main

For a detailed description of the SWING SYSTEM, refer to SECTION 15 of THIS MANUAL.

On machine serial numbers 250T0111 to 250T0115 the swing circuit is in the main hydraulic load sensing system.

4.2

Tigercat T250 Loader

Hydraulic system

2. AUXILIARY OR SWING SYSTEM This open centre circuit uses a variabledisplacement pressure-compensated piston pump which delivers oil to the three section spool valve. This valve controls the Slasher, Grapple rotate and Grapple Open/Close on machine serial numbers 250T0111 to 250T0115 and the Slasher, Swing and Grapple Rotate on machine serial numbers 250T0131 and up.

The return oil from the auxiliary/swing open centre circuit is directed to tank via the oil cooler. A smaller proportion of return oil is returned to tank via the swing brake and the 'T3' port on the main Linde valve. All return oil from this system flows to the hydraulic tank via the return oil filters.

For a detailed description of the AUXILIARY SYSTEM, refer to GRAPPLE and DELIMBER/SLASHER in SECTIONS 17 and 18 of this manual and for SWING SYSTEM refer SECTION 15.

3. PILOT CIRCUIT The pilot circuit is supplied with oil from the pilot pump which is driven by the auxiliary drive off the left side of the engine. Oil from the pilot pump is filtered by the pilot pressure filter prior to entering the pilot manifold.

On machines with a cab tilt function, pilot oil is directed through the open centre cab tilt valve on it's way to the pilot filter and the pilot manifold.

The pilot manifold contains a pressure reducing valve on the INPUT side of the manifold which maintains the pilot OUTPUT oil pressure at 425 psi. The pilot manifold also contains up to eight solenoid operated pilot valve cartridges that control such functions as the swing brake, low speed travel and grapple rotate etc. The output 'PB' port in the manifold supplies oil to the joysticks and swing foot pedal. A pilot shut-off solenoid valve cartridge located at the INPUT side of the manifold will shut down or deactivate the pilot system whenever the left armrest is in the raised position.

Refer to SECTION 5 in THIS MANUAL for a complete description of the PILOT SYSTEM.

4.3

Tigercat T250 Loader

Hydraulic system PRESS. GAUGE, HYD. TANK

AIR COMPRESSOR/ VACUUM PUMP

TANK RELIEF VALVE

•

•

•

•

•

VACUUM SWITCH 9 INS. HG

•

•

PRESSURE SWITCH 6 PSI.

HYDRAULIC TANK PRESSURIZATION/ VACUUM SYSTEM

•

AIR COMPRESSOR/ VACUUM SOLENOID VALVE

BALL VALVE, AIR VENT

FILTER/ BREATHER

• VACUUM SWITCH 9 INS. HG

RETURN MANIFOLD

DUAL FILTER HEADS (2)

'A'

PRESSURE SWITCH 4 PSI.

• • •

• • • •

RETURN TUBES

•

•

RETURN FILTERS (4) OIL LEVEL SIGHT GAUGE

• •

• • CROSS SECTION 'A' 'A'

•

OIL TEMP. SENDERS PUMP CONNECTIONS

•

HAND FILL PUMP

••

•

TO PILOT PUMP

RETURN STRAINERS (4)

•• ••

•

OIL LEVEL SIGHT GAUGE PILOT SHUT OFF VALVE

ACCESS COVER WITH 'O' RING SEAL

•

•

ACCESS COVER WITH 'O' RING SEAL

• •

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

250-01

CASE DRAIN FROM MAIN PUMP

HYDRAULIC RESERVOIR

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

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

Hydraulic oil is drawn from the tank by the pumps through the suction manifold at the base of the tank. The bulk of the oil returning to the tank is directed to the return manifold and the four return filters and from there to the return tubes in the hydraulic tank. There is a bypass valve built into

• •

• 'A'

• SUCTION MANIFOLD TO PUMPS

each filter head preset at 25 psi. which will open in the event the elements become restricted. A strainer/diffuser is attached to the end of each of the two return tubes. The reusable return strainers with a 250 micron particle retention, screen oil prior to re-entering the tank.

Case drain oil from the main pump, swing pump & motor and stabilizer manifold return to the tank via two hose connections at the base of the tank. This return oil also flows through two strainer/diffusers before re-entering the tank.

4.4

Tigercat T250 Loader

Hydraulic system

The hydraulic tank is pressurized to assist pump suction, this pressure is referred to as PUMP INLET PRESSURE. On later machines, the hydraulic tank is pressurized, before machine start-up, by an air compressor to 4 psi. A 10 psi. relief valve located at the top of the hydraulic tank serves to protect the tank from over-pressurization.

IMPORTANT: Before disconnecting any hoses, release the pressure in the hydraulic tank by opening the air vent ball valve.

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

On earlier machines the pump is also used to initially pressurize the hydraulic reservoir to 3 psi.

Refer to HYDRAULIC PRESSURIZATION SYSTEM, EARLIER DESIGN in SECTION 2 OF THE OPERATORS MANUAL for this procedure.

HYDRAULIC TANK PRESS/VAC CIRCUIT DIAGRAM

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

250T-16

RELAY 31

RELAY 30

RELAY 32

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

•

••

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

••

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

250T-D02 1

LE 3

RELAY 1

RELAY 2

RELAY 3

RELAY 4 2

LOW ENG. OIL PRESS.

PILOT LOCK-OUT

A/CHEATER

LOW HYD. OIL

3 4 5

RELAY 5

RELAY 30

RELAY 31

RELAY 32 6

WORK LIGHTS

CHARGE TANK

CHARGE TANK

VACUUM TANK

7

GAUGES 5A SAFETY 15A ANTI-STALL 2A JOYSTICKS 15A BK-UP ALRM 15A WIPER/WASH 15A FUEL 10A

8 RAD 1 9 LIG 2 10 H 2 11 AC/H 2 12 WOR 2 13 SER 1 14 AUX 2

LOACATION OF RELAYS IMPORTANT: DO NOT start the engine unless the hydraulic tank is pressurized to 4 psi. Starting the engine before pressurizing the tank will result in damage to pumps and other hydraulic components.

The air compressor/vacuum pump is used to perform two functions in the hydraulic pressurization system. First it is used as an air compressor to provide the required 4 psi pressure for the hydraulic tank. Second it is used as a vacuum pump to "hold" the oil in the hydraulic tank when work is being done on the hydraulic system. Two sensor switches located at the top of the tank control the pressure or the vacuum in the hydraulic tank.

Refer also to HYDRAULIC PRESSURIZATION SYSTEM in SECTION 3 and SECTION 2 of the OPERATOR'S MANUAL. 4.5

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

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

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

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

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

9. Reinstall the strainers using the hex on end.

10. Reinstall access cover with a NEW “O” ring.

11. Refill and check for leaks.

12. Ensure that the air vent valve is closed.

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

Tigercat T250 Loader

Hydraulic system

ENGINE BELL HOUSING

PILOT PUMP

AUXILIARY (SWING) PUMP (LINDE)

••

• MAIN PUMP

• • 240B-D23

PILOT PUMP

HYDRAULIC PUMPS HYDRAULIC PUMPS (LINDE)

250-07

AUXILIARY PUMP (PARKER)

ENGINE BELL HOUSING

All hydraulic functions are powered by three pumps.

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

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

• •

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

••

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

MAIN PUMP

250-06

HYDRAULIC PUMPS (LINDE/PARKER)

ENGINE BELL HOUSING

••

•

MAIN PUMP

•

AUXILIARY PUMP (KAWASAKI)

250-14

HYDRAULIC PUMPS (LINDE/KAWASAKI) 4.6

Tigercat T250 Loader

Hydraulic system

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

L.S. GAUGE TEST CONN.

•

LINDE MAIN VALVE MANIFOLD

•

HIGH PRESSURE LIMITING CONTROL (HPLC)

••

••

'P' GAUGE TEST CONN.

103-17A

GAUGE TEST PORTS

•

LOAD SENSING RELIEF VALVE (P2)

•

increases to the point where it is equal to the work port pressure and it shifts the LS control valve.The pump then adjusts its output volume until the pump output pressure exceeds the LS pressure by a small amount. This difference is known as MARGIN PRESSURE (Also known as differential pressure Delta P).

MAIN PUMP SCHEMATIC

845B-45

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

Refer to SET MARGIN PRESSURE in this section.

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

MARGIN PRESSURE When a function control lever is moved, i.e. joystick, to activate a function, LS pressure

••

HORSEPOWER CALIBRATION DO NOT ADJUST

ENGINE ANTI-STALL SOLENOID VALVE

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

GAUGE TEST PORT 'X1' ANTI-STALL SIGNAL PRESSURE GAUGE TEST PORT 'L.S.'

••

••

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

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

••

PILOT SUPPLY 'P1'PORT WITH OIL FILTER

•• 822-D65

••

••

MAIN PUMP

MARGIN PRESSURE ADJUSTING SCREW

AUXILIARY OR SWING PUMP For the operation and adjustments of this pump refer to SECTION 15 of THIS MANUAL.

MAIN PUMP CONTROLLER (LS CONTROL) 4.7

Tigercat T250 Loader LOAD SENSING

Hydraulic system

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

853SM18

Figs. 3 & 4 In an attempt to recover some of the wasted energy, variable volume pumps evolved. These pumps are power regulated or FIG. 1 horsepower controlled and since they reduce the pumps output to maintain a constant system FIXED DISPLACEMENT PUMP hp, oil flow over the relief valve is less, therefore reducing the wasted power losses and heat generation. SEE FIGS. 3 & 4.

FLOW

WASTED WASTED

W USED PRESSURE 853SM16

FIG. 2

HP =CO

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.

NS TAN T

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

FLOW

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

WASTED WASTED

W USED PRESSURE

853SM19

HP REGULATED PUMP

FIG. 3

FIG. 4

853SM16

HP =C ON STA

FLOW

NT

∆p LS W USED PRESSURE

853SM17 FIG.5

LOAD SENSING (FLOW ON DEMAND) 4.8

FIG.6

853SM16

Tigercat T250 Loader LOAD SENSING BASIC DESCRIPTION

Hydraulic system

OPEN CENTRE VS. CLOSE CENTRE OPEN CENTRE SYSTEM:

853SM21

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

853SM20

With the control valve in neutral all of the oil from the pump “bypasses” through the open centre 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 centre passage is blocked off in proportion to the amount the lever is moved. This creates back pressure forcing oil into the valve work port to move the load.

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

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

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

853SM20

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

4.9

Tigercat T250 Loader CLOSED CENTRE SYSTEM: Load sensing systems use variable flow pumps and only flow oil when required. Unlike the open centre system, the control valve does not have an open centre passage. When in neutral, no oil flows through the control valve to tank and the pump output flow is zero. The pump’s output flow is controlled by a “stroking piston” which is connected to the pump output, and to the valve’s work port or “load”. This sense line to the actual working load defines the system as load sensing.

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

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

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

853SM22

853SM22

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

853SM22

The following are key differences from open centre systems;

853SM22

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

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

1. The load sensing valve’s maximum flow is not equal to the pumps maximum flow as with the open centre system. The valves maximum flow is determined by the maximum size of opening or “orifice” it provides.

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

Moving the lever further will not increase the lifting force.

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

4.10

Tigercat T250 Loader

Hydraulic system

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

Load sensing systems respond to rough operation by amplifying these movements. If you find the boom is jerky or always giving “feedback”, you’re probably too active on the controls. If slowing down doesn’t eliminate the roughness, the margin pressure setting may be too high and can be reduced to calm down the machine’s response.

Refer to SET MARGIN PRESSURE in this section.

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

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

4.11

Tigercat T250 Loader MAIN HYDRAULIC CIRCUIT CIRCUIT DESCRIPTION (S/N 250T0111 TO 250T0115) The main hydraulic circuit controls the hoist, stick, delimber, grapple rotate, slasher and swing functions.

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

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

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

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

CIRCUIT DESCRIPTION (S/N 250T0131 AND UP) The main hydraulic circuit controls the hoist, stick, delimber, grapple open/close, slasher and stabilizer functions.

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

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

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

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

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

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

Without this system, an operator moving control levers halfway on the boom up and stick out controls would find that the lowest pressure function would move and the other would not move. To make both functions move the operator would have to move the high load lever much more than the low load lever. In other words, the operator would have to restrict oil flow to one function while opening up the valve fully to the other. This is what the load compensation system does automatically as will be explained further below.

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

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

4.12

Tigercat T250 Loader

250T-19

Hydraulic system

LOAD SENSING SYSTEM CIRCUIT DIAGRAM 4.13

Tigercat T250 Loader

Hydraulic system DELIMBER OPEN/ GRAPPLE SAW

LH. TRACK DRIVE

•

STICK CYLINDER

RH. TRACK DRIVE

•

•

•

HOIST CYLINDER

•

SWING

•

• VIEWED FROM BELOW

•

HIGH PRESSURE LIMITING CONTROL

CONTROL VALVE MANIFOLD

MAIN CONTROL VALVE (S/N 250T0111 TO 250T0115)

250T-02

GRAPPLE OPEN/CLOSE

LH. TRACK DRIVE

•

DELIMBER OPEN/ STICK CYLINDER GRAPPLE SAW

•

•

•

HOIST CYLINDER

•

RH. TRACK DRIVE

•

• VIEWED FROM BELOW

• 250T-03

HIGH PRESSURE LIMITING CONTROL

CONTROL VALVE MANIFOLD

MAIN CONTROL VALVE (S/N 250T0131 AND UP)

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

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

2 3 1 SCHEMATIC DIAGRAM, VALVE MANIFOLD/VALVE SECTION WITH H.P. RELIEF

853SM24

4.14

Tigercat T250 Loader

Hydraulic system

4.15

Tigercat T250 Loader

Hydraulic system

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

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

The drive control valve sections and the swing control valve section on earlier machines utilize make-up valves for anti-cavitation. See FIG. 90919.

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

4.16

Tigercat T250 Loader

Hydraulic system

MAKE UP OR ANTICAVITATION VALVE

MAKE UP OR ANTICAVITATION VALVE

WORK PORTS

•

•

PILOT CHECK

•

PILOT END CAP AIR BLEED PLUG

•

•

• •

•

•

•

BALL AND SPRING

90919

SPOOL TRAVEL STOP (ADJUSTABLE)

LOAD SENSING 'LS'

•

COMPENSATOR VALVE PUMP 'P' RETURN 'T'

RETURN 'T'

LOAD SENSING 'LS'

CONTROL VALVE SECTION "MOTOR" TYPE SPOOL - DRIVE AND ON EARLIER MACHINES THE SWING FUNCTION WORK PORTS

ANTICAVITATION RELIEF VALVE MAX. FLOW ADJUSTING SCREW

•

ANTICAVITATION RELIEF VALVE

• •

•

• • • MAIN CONTROL SPOOL COMPENSATOR RETURN 'T'

90744

90744-2

PUMP 'P'

RETURN 'T'

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

CONTROL VALVE SECTION "CYLINDER" TYPE SPOOL - TYPICAL FOR HOIST, STICK, GRAPPLE AND DELIMBER FUNCTIONS (SHOWN IN FLOW POSITION) 4.17

Tigercat T250 Loader PORT RELIEF AND ANTICAVITATION VALVE OPERATION

Hydraulic system MEDIUM SYSTEM PRESSURE

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

WORK PORT

• •

•

• RETURN

ORIFICE 'A'

NORMAL OPERATION

90744-4A

(Step 2) The piston seats against the poppet.

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

MEDIUM SYSTEM PRESSURE

HIGHEST SYSTEM PRESSURE

•

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

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

PILOT POPPET 'D'

•

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

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

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

•

WORK PORT

• RETURN

RELIEF OPERATION

90744-6A

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

LOW WORK PORT PRESSURE

ADJUSTING PROCEDURE 1. Loosen locknut.

•

WORK PORT

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

• RETURN

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

90744-5A

ANTICAVITATION OPERATION

4. Re-check pressure gauge reading.

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

PORT RELIEF VALVE

LOCKNUT • 17mm WRENCH

• • • • MAIN VALVE BODY

90744-4

4.18

ADJUSTING SCREW • 5mm ALLEN KEY

MAIN VALVE PORT RELIEF VALVE

Tigercat T250 Loader

Hydraulic system

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

PILOT END CAP

SHUTTLE COMPENSATOR CONTROL VALVE VALVE SPOOL

COMPENSATOR VALVE

SHUTTLE VALVE

PILOT END CAP

•

•

•

• CENTERING SPRING

•

•

• •

•

•

• •

• •

•

•

LOAD SENSING WORK WORK PASSAGE 'LS' PORT 'A' PORT 'B' SUPPLY RETURN RETURN PASSAGE 'P' PASSAGE 'T' PASSAGE 'T'

LOAD SENSING PASSAGE 'LS'

CENTERING SPRING

(A) CONTROL VALVE SECTION ~ IN NEUTRAL

853SM25

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

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

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

PILOT OIL

LS PORT JUST OPENED

SHUTTLE VALVE

CONTROL SPOOL

• •

(B) CONTROL VALVE SECTION ~ • CONTROL SPOOL STARTING TO MOVE TO RIGHT • LS PORT JUST OPENED • ONLY SPOOL ACTUATED 853SM26

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

4.19

Tigercat T250 Loader

Hydraulic system

PILOT OIL

SHUTTLE VALVE

•

BALANCE VALVE

•

CONTROL SPOOL

•

WORK PORT 'A' JUST OPENED

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

853SM27

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

PILOT OIL

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

CONTROL SPOOL

TANK PORT 'T' (RETURN)

(1) ANGLED VENT PORT OPENS

• •

•

•

• •

(4) OIL FLOWS TO 'LS' PASSAGE

(3) PRESSURE PORT OPENED SLIGHTLY

(2) WORK PORT 'B' OPENS

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

• PRESSURE PORT OPENED SLIGHTLY • HIGHEST WORKING PRESSURE

(D) The next port to open is the angled vent port (1) on the right side of the control spool which connects to the tank port, ‘T’. This connects all passages in the compensator spool to return pressure. There is no movement at this time but as soon as the work port ‘B’ opens (2) and oil flows, the returning oil will push the compensator valve to the right and connect ‘B’ to ‘T’.

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

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

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

4.20

Tigercat T250 Loader PILOT OIL

Hydraulic system

(1) COMPENSATOR VALVE

CONTROL SPOOL FULLY SHIFTED TO RIGHT

SHUTTLE VALVE

•

•• •

•

•

•

•

•

•

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

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

853SM29

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

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

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

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

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

PILOT OIL

LS PORT JUST OPENED

COMPENSATOR (2) SHUTTLE VALVE MOVES TO RIGHT VALVE

(1) CONTROL SPOOL STARTS TO MOVE

CENTERING SPRING

• ••

•

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

• LS PORT JUST OPENED • LOWER WORKING PRESSURE

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

4.21

Tigercat T250 Loader

Hydraulic system SHUTTLE VALVE

PILOT OIL

CONTROL SPOOL

COMPENSATOR VALVE

•

•

•

WORK PORT 'A' JUST OPENED

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

853SM31

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

PILOT OIL

SHUTTLE VALVE

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

•

CONTROL SPOOL

•

TANK PORT 'T' (RETURN)

(1) ANGLED VENT PORT OPENS

• •

• •

OIL FLOWS TO 'LS' PASSAGE

(3) PRESSURE PORT OPENED SLIGHTLY

(2) WORK PORT 'B' OPENS

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

• PRESSURE PORT OPENED SLIGHTLY • LOWER WORKING PRESSURE

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

4.22

Tigercat T250 Loader PILOT OIL

Hydraulic system (1) CONTROL SPOOL FULLY SHIFTED TO RIGHT

(2) COMPENSATOR VALVE SETTLES IN A BALANCE POSITION

•

• •

•

•

•

•

•

•

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

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

• LOWER WORKING PRESSURE

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

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

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

4.23

Tigercat T250 Loader HIGH PRESSURE LIMITING CONTROL VALVE The main pump is protected by a High Pressure Limiting Control which consists of three relief valve cartridges. The H.P.L. control is attached to the main control valve manifold and contains three relief valves: The first relief valve (P2) limits L.S. pressure to approx. 4200 psi, (Gauge at 'L.S.' test port) which in turn limits the pump output pressure to 4500 psi. (Gauge at 'P' test port) The 300 psi differential is known as margin pressure. See SET MARGIN PRESSURE in THIS SECTION.

Hydraulic system P2 L.S. PRESSURE LIMIT, SET AT 4200 PSI. WITH GAUGE ON 'LS' TEST PORT • 4MM ALLEN KEY • 13MM WRENCH MAIN CONTROL VALVE MANIFOLD

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

853SM24

••

••

•

• SYSTEM RELIEF VALVE NON-ADJUSTABLE

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

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

P1. SCREWED FULLY IN NOT USED

HIGH PRESSURE LIMITING CONTROL

845B-D20

•

HIGH PRESSURE LIMITING CONTROL VALVE

SCHEMATIC DIAGRAM OF H.P.L. CONTROL, MANIFOLD & A VALVE SECTION WITH PORT RELIEFS 4.24

Tigercat T250 Loader

Hydraulic system

PILOT PRESSURE 11.3 MM

ENGINE ANTI-STALL PROPORTIONAL SOLENOID VALVE

•

•

• ANTI-STALL CALIBRATION

TANK

DO NOT ADJUST REQUIRES TEST BENCH FOR READJUSTMENT GAUGE TEST PORT 'X1'

•

•

•

•

•

LOAD SENSE PRESSURE 8 MM

•

•

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

PUMP OUTLET PRESSURE PUMP SWASH CONTROL PASSAGE

TANK

MAIN PUMP CONTROL VALVE The margin pressure adjustment is made at the SET MARGIN PRESSURE main pump controller attached to the main pump. The pressure gauge connections are the MARGIN PRESSURE is the difference between 'L.S.' and 'P' gauge test ports on the Linde main the LOAD SENSE pressure and the PUMP valve manifold.

OUTPUT pressure while a function is being operated. For the load sensing system to operate correctly the differential pressure between L.S. and 'P' should be 300 psi. 'P' being higher than LINDE MAIN HIGH PRESSURE L.S. GAUGE VALVE LIMITING TEST CONN. L.S. MANIFOLD CONTROL (HPLC) 90669

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

••

HORSEPOWER CALIBRATION DO NOT ADJUST

•

ENGINE ANTI-STALL SOLENOID VALVE

••

••

••

'P' GAUGE TEST CONN.

GAUGE TEST PORT 'X1' ANTI-STALL SIGNAL PRESSURE

••

••

•• 103-17A

•• •• 822-D65

••

MAIN PUMP

MARGIN PRESSURE ADJUSTING SCREW

GAUGE TEST PORTS

•

GAUGE TEST PORT 'L.S.'

LOAD SENSING RELIEF VALVE (P2)

PILOT SUPPLY 'P1'PORT WITH OIL FILTER

The margin pressure is set at the factory to 300 psi. The margin pressure can be adjusted however the flow stops on the valves must be reset in order to maintain the same speed of the functions. Refer to CYCLE TIMES in SECTION 3 of THIS MANUAL.

MAIN PUMP CONTROLLER (LS CONTROL)

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

4.25

Tigercat T250 Loader

*

DO NOT use a single pressure gauge to set the margin pressure, a small difference in this pressure value (less than 50 psi.) can make a significant difference in machine performance.

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

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

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

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

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

4. Lower left armrest, press PILOT RESET button to activate pilot system and turn anti-stall switch OFF.

L.S. GAUGE TEST CONN.

5. S/N 250T0111 TO 250T0115: Turn swing brake ON and place SWING foot pedal in FULL position (left or right).

S/N 250T0131 AND UP: Hold LH joystick in the GRAPPLE CLOSE position.

•

LINDE MAIN VALVE MANIFOLD

••

••

HIGH PRESSURE LIMITING CONTROL (HPLC)

••

'P' GAUGE TEST CONN.

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

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

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

103-17A

GAUGE TEST PORTS

•

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

LOAD SENSING RELIEF VALVE (P2)

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

3. Lower left armrest, press PILOT RESET button to activate pilot system and turn antistall switch OFF. 4. While holding R.H. joystick in the STICK OUT position (fully extended), loosen locknut on P2 relief valve cartridge and turn adjusting screw until pressure gauge reads 4500 psi. Tighten locknut on adjusting screw and re-check pressure reading on gauge.

5. Stop engine and remove pressure gauge.

4.26

Tigercat 250 Loader

SECTION 5 - PILOT SYSTEM NOVEMBER 2003

CONTENTS - SECTION 5 CAB TILT ....................................................................................................... 5.6 CIRCUIT DIAGRAM ....................................................................................... 5.7 ELECTRICAL CIRCUIT ................................................................................. 5.5 PILOT SYSTEM COMPONENTS .................................................................. 5.2 JOYSTICKS AND FOOT PEDALS ............................................................. 5.4 PILOT MANIFOLD ...................................................................................... 5.3 PRESSURE SETTINGS ................................................................................ 5.5

Tigercat T250 Loader PILOT SYSTEM COMPONENTS The pilot circuit is supplied with oil from the pilot pump which is driven by the auxiliary drive off the left side of the engine. Oil from the pilot pump is

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

LEFT SIDE OF ENGINE

HYDRAULIC TANK BALL VALVE (SHOW OPEN)

• PILOT PUMP

240B-D23

PLASTIC TIE

•

TO PILOT PUMP

On machines with a cab tilt function, pilot oil is directed through the open centre cab tilt valve on it's way to the pilot filter and the pilot manifold.

A pilot pressure relief valve built into the pilot manifold maintains the pilot system pressure at 425 psi. Pilot oil is then distributed by the pilot manifold to the various pilot actuated functions of the machine. Solenoid operated pilot valve cartridges within the pilot manifold control the flow of pilot oil to various functions, See list on following page. Joysticks and foot pedals are also supplied with pilot oil which in turn distribute the oil to shift spools in the corresponding control valves.

••

•• •

PILOT PUMP

filtered by the pilot pressure filter prior to entering the pilot manifold.

••

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

240B-D21

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

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

FILTER ELEMENT

•

NOTE: Low pilot pressure can influence machine controls causing slow or sluggish response times, If this symptom occurs, first check hydraulic oil level in reservoir, if the level is correct, verify that the pilot relief valve setting is 425 psi. Refer to SET PILOT PRESSURE in THIS SECTION.

LOCATED BELOW PUMPS

206-5A

PILOT FILTER

valve will bypass the pilot oil back to the tank.

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

5.2

Tigercat T250 Loader

Pilot system

PILOT MANIFOLD

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

PILOT SHUT "IN" CONNECTION OFF VALVE FROM PILOT FILTER

"T" TANK CONNECTIONS

•• • PILOT MANIFOLD PILOT MANIFOLD

•

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

• •

The pilot manifold distributes oil to the following circuits through the ports in the manifold listed below for S/N 250T0131 and up shown: • • • • • • • • • • • •

Joysticks (both) Swing control foot pedal Plugged Gauge test port Slasher saw, cut Slasher saw, retract Grapple saw option or..... delimber open option Drive enable or Swing brake§ Blank (when no live heel) Blank (when no live heel) Swing brake or Drive enable§ Low speed travel

GAUGE TEST PORT CONNECTION

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

RELIEF VALVE

PILOT MANIFOLD labelled (2/PB and G) and to the eight solenoid operated pilot valves. The pilot shut off valve is activated by pressing the pilot reset switch in cab (with the left armrest down).

240B-D22

(3) solenoid valve (4) solenoid valve (5) solenoid valve (6) solenoid valve (7) solenoid valve (8) solenoid valve

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

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

A relief valve maintains the pilot pressure at 425 psi. The pilot shut off valve, which is an integral part of the pilot manifold, controls the flow of oil from the INLET port to the three outlet ports OPTIONAL § DRIVE ENABLE FUNCTION SWING BRAKE LOW SPEED TRAVEL

•

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

SWING BRAKE § DRIVE ENABLE

OPTIONAL GRAPPLE FUNCTION SAW, CUT

•

•

•

•

•

••

PILOT MANIFOLD

Pilot oil enters the manifold through the inlet port.

'PB' PLUGGED

•

•

240B-D20

• •

•

'PB' TO JOYSTICK AND SWING FOOT PEDAL

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

•

INLET

•

•

RELIEF VALVE

• •

•

• •

RETURN OIL TO TANK 230B-04

•

§ INDICATES FUNCTIONS ON MACHINES S/N 250T0111 TO 250T0115

PILOT MANIFOLD ASSEMBLY, S/N 250T0131 AND UP 5.3

'T' RETURN OIL FROM JOYSTICKS AND FOOT PEDALS

Tigercat T250 Loader

Pilot system

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

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

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

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

RR-12

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

1

•

5

•

•

•

TANK PORT

3

• 4 8

• • WORK PORT

•

2

• PRESSURE PORT

WORK PORT

FOOT PEDAL PILOT VALVE (KAWASAKI) AW017

5.4

JOYSTICK PILOT VALVE

Tigercat T250 Loader PILOT SYSTEM ELECTRICAL CIRCUIT

Pilot system PILOT SHUT OFF VALVE

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

•

• • PILOT MANIFOLD

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

••

GAUGE TEST PORT CONNECTION PILOT RELIEF VALVE 240B-D22

PILOT RELIEF VALVE

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

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

3. Start engine and set throttle in FULL position.

4. Loosen locknut on relief valve and turn adjusting screw IN until pressure gauge at pilot manifold reads 425 psi.

5. Stop engine, and remove pressure gauge.

PILOT MANIFOLD BODY

RELIEF VALVE CARTRIDGE

•

LOCKNUT ADJUSTING SCREW

•

•

•

OUT

IN

240B-01

5.5

PILOT PRESSURE RELIEF VALVE

Tigercat T250 Loader

Pilot system

CAB TILT CIRCUIT

ENGINE START SWITCH

Two cylinders are used to tilt the cab forward or backwards. Operating oil is supplied from the pilot pump to the inlet section of the cab tilt control

• •

•

•• CONTROL LEVER

BATTERY DISCONNECT SWITCH

HYDRAULIC OIL FILL PUMP

CAB TILT VALVE 248-26

WITH REMOTE START SWITCH

SET CAB TILT RELIEF VALVE 1. Park machine on level ground.

SPOOL SECTION

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

• • WORK PORT 'A'

••

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

RELIEF VALVE

248-4

3. "Tee" into work port 'A' on the cab tilt control valve and install a 0 - 5000 psi pressure gauge at the "Tee".

CAB TILT VALVE

valve. A relief valve is installed in the inlet section of the tilt control valve to protect the circuit components from abnormally high pressure spikes. A dual pilot operated check valve is installed in the tilt circuit between the cab tilt valve and the cylinders. The pilot operated check valve ensures that the cylinders will remain in any extended supporting position should a problem occur with the hydraulic system such as a leaking or broken hose. The cracking pressure for each of the two pilot operated check valve cartridges is pre-set to 20 psi.

5. Start the engine and put the throttle control to the FULL position.

6. With the cab tilt locking bolt still in place, push and hold the tilt lever in the FORWARD position, check the gauge reading, if less than set value, turn relief valve adjusting screw IN until 2000 psi is obtained on gauge.

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

8. Stop engine, remove pressure gauge and "Tee" fitting and reconnect hose to work port 'A'. Wipe up any excess oil from the gauge connection area.

During normal machine operating conditions the pilot oil from the pilot pump passes through the "open center" spool section of the cab tilt valve to supply the pilot system.

When the lever on the cab tilt valve is pulled forward to tilt the cab, oil is directed from the pilot pump via the control valve and pilot operated check valve to the base end of the two cab tilt cylinders to tilt the cab forward. A 1/32" dia. orifice is installed into each elbow at the cylinder port connections to control the rate of speed at which the cab will tilt.

See CAB TILTING PROCEDURE in SECTION 2 of the OPERATOR'S MANUAL. 5.6

Tigercat T250 Loader

250T-01

Pilot system

PILOT SYSTEM CIRCUIT DIAGRAM 5.7

Tigercat T250 Loader

Pilot system

5.8

Tigercat T250 Feller Buncher

SECTION 6 - ELECTRICAL, GAUGES & ALARMS OCTOBER 2003

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

Tigercat T250 Loader

250T-02 (13916B-R2)

Electrical, gauges and alarms

MACHINE SCHEMATIC DIAGRAM SHEET 1 OF 3 6.2

Tigercat T250 Loader

250T-03 (13916B-R2)

Electrical, gauges and alarms

MACHINE SCHEMATIC DIAGRAM SHEET 2 OF 3 6.3

Tigercat T250 Loader

250T-04 (13916B 02)

Electrical, gauges and alarms

MACHINE SCHEMATIC DIAGRAM SHEET 3 OF 3 6.4

Tigercat T250 Loader

Electrical, gauges and alarms

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

FUNCTION EXAMPLE Power ........................................ (protected and unprotected) Ground Engine control ........................... (fuel shut-off, start aid) Propulsion Control .................... (transmission/reverser solenoids) Monitor, electrical and mechanical systems ................. (air cleaner, alternator, wheel speed, engine speed) Electrical and electromechanical control ......... (park brake, alternator excitation) (power door motor, backup alarm) Monitors .................................... (flow, pressure, temperature, level) Standard monitor system .......... (logic module to monitor) Lights Electro-hydraulic control ........... (pilot solenoids) Accessories .............................. (horn, A/C, heater)

6.5

Tigercat T250 Loader

Electrical, gauges and alarms

FUSE AND RELAY PANEL

250T-D02

1

DIODE MODULE 1

DIODE MODULE 2

DIODE MODULE 3

RELAY 1

RELAY 2

RELAY 3

RELAY 4 2

LOW ENG. OIL PRESS.

PILOT LOCK-OUT

A/CHEATER

LOW HYD. OIL

3 4 5

DIODE MODULE 4

DIODE MODULE 5

RELAY 5

RELAY 30

RELAY 31

RELAY 32

WORK LIGHTS

CHARGE TANK

CHARGE TANK

VACUUM TANK

6 7

GAUGES 5A SAFETY 15A ANTI-STALL 2A JOYSTICKS 15A BK-UP ALRM 15A WIPER/WASH 15A FUEL 10A

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

16606B

250T-05 (16527B R0)

6.6

Tigercat T250 Loader

250T-06 (16527B R0)

Electrical, gauges and alarms

INSTRUMENT PANEL WIRING DIAGRAM 6.7

Tigercat T250 Loader GAUGES AND ALARMS

Electrical, gauges and alarms

The T250 Loader is monitored for proper operation by sensors located in the hydraulic system and on the engine. These sensors are connected to either gauges, warning lights and/or a panel buzzer.

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

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

SENSOR FUNCTION

GAUGE RANGE

LIGHT

0 - 100 psi

YES

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

Engine coolant temp.

100°F - 280°F

YES

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

Engine coolant level

NONE

YES

RED light comes ON when level in surge tank is LOW

0 - 9999.9

NONE

Total running hours

8v - 18v

NONE

Normal operating range 12 - 13.5 volts

Hydraulic oil temp.

100°F - 240°F

YES

RED light comes ON above 205°F *

Hydraulic oil level LOW

SIGHT GLASS

YES

RED light comes ON indicates 13 gallons below FULL *

Pump inlet pressure

NONE

YES

RED light comes ON below 2 psi.

Hyd. tank charge press.

NONE

YES

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

Light goes OFF when key in RUN position.

Safety alert HORN

NONE

NONE

Engine oil pressure

Engine hours Volts

INFORMATION

Switch on control panel

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

6.8

Tigercat T250 Loader

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

Electrical, gauges and alarms

SENDER- HYDRAULIC OIL TEMPERATURE (GAUGE) START SOLENOID RELAYS BATTERY DISCONNECT SWITCH SWITCHCOOLANT ENGINE TEMP. (RED SPEED LIGHT) SENSOR

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

DELIMBER 'OPEN' SOLENOID STABILIZER PILOT MANIFOLD

SWITCH, BTM.TANK PRESSURE

• TANK AIR COMPRESSOR/ VACUUM PUMP

•

PILOT MANIFOLD

• •

• • • •

•

•

•

• BOOM LIGHTS

SENDER COOLANT TEMPERATURE (GAUGE)

•

BATTERIES, LOCATED BELOW FAN PULLEY

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

• • •

•

•

•

LIMIT SWITCH, PILOT SHUT OFF

• • COOLANT LEVEL PROXIMITY SWITCH (RED LIGHT)

• •

HARNESS, ENGINE

• HARNESS, PILOT

HARNESS, ENGINE LOAD CONTROL

250T-07

• •

SENDER ENGINE OIL PRESSURE (GAUGE) JOYSTICKS

HARNESS, JOYSTICK

• •

SAFETY ALERT HORN (SWITCH ON CONTROL PANEL)

•

HARNESS, TANK/ PRESS. VACUUM

SWITCH AND SENSOR LOCATIONS 6.9

Tigercat T250 Loader

Electrical, gauges and alarms

6.10

Tigercat 250 Loader

SECTION 7 - ENGINE START AND STOP OCTOBER 2003

CONTENTS - SECTION 7 CIRCUIT DESCRIPTION ............................................................................... 7.2 ENGINE START CIRCUIT DESCRIPTION ................................................... 7.2 START CIRCUIT DIAGRAMS ........................................................................ 7.3 START CIRCUIT DIAGRAMS- SECONDARY START (CAB TILT) ............... 7.6

Tigercat T250 Loader ENGINE START CIRCUIT

Engine start and stop

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

FUEL CONTROL VALVE SOLENOID

The engine installed on the later Tigercat Loaders S/N 250T0181 and up is a Cummins Diesel 6CTAA8.3C 205 HP..

••

The engine installed on the earlier Tigercat Loaders S/N 250T0111 to 250T0170 is a Cummins Diesel 6CT8.3C 215 HP..

THROTTLE ARM

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

•• •• FUEL CONTROL VALVE

ENGINE FUEL CONTROL VALVE wire (13) to the fuel solenoid HOLD contact.

279-11A

Turn battery disconnect switch to the ON position.

Sound safty alert horn.

Turn ignition key to the START position and releasing it to the RUN position after the engine starts.

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

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

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

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

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

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

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

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

7.2

Tigercat T250 Loader

Engine start and stop

START CIRCUIT - AT REST

250T-08

START CIRCUIT - AT REST BATTERY DISCONNECT SWITCH - ON

250T-09

7.3

Tigercat T250 Loader

Engine start and stop

START CIRCUIT - START IGNITION KEY - START POSITION

250T-10

START CIRCUIT - RUN IGNITION KEY - RUN POSITION

250T-11

7.4

Tigercat T250 Loader

Engine start and stop

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

250T-12

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

250T-13

7.5

Tigercat T250 Loader

Engine start and stop

SECONDARY START CIRCUIT - START SECONDARY START SWITCH - START POSITION

250T-14

SECONDARY START CIRCUIT - START SECONDARY START SWITCH - RUN POSITION

250T-15

7.6

Tigercat T250 Loader

SECTION 9 - ENGINE ANTI-STALL OCTOBER 2003

CONTENTS - SECTION 9 CONTROL MODULE IN CAB .......................................................................... 9.2 CONTROL MODULE PIN CONNECTIONS ...................................................... 9.4 FAULT FINDING PROCEDURE ~ ANTI-STALL QUICK CHECK ...................... 9.5 FAULT FINDING PROCEDURES, ADDITIONAL ............................................. 9.6 HORSEPOWER LIMITING CONTROL ............................................................ 9.2 GENERAL DESCRIPTION ........................................... SEE ALSO SECTION 4 LOAD SENSE; SET MARGIN PRESSURE .............................. SEE SECTION 4 MAIN PUMP CONTROLLER (LS CONTROL) .................................................. 9.2 PILOT PRESSURE, SET .......................................................... SEE SECTION 5 SCHEMATIC DIAGRAMS ENGINE ANTI-STALL CIRCUIT DIAGRAM ................................................... 9.5 LOAD SENSING SYSTEM .......................................................................... 9.3 SPEED SENSOR ADJUSTING ....................................................................... 9.4 SPEED SENSOR ON ENGINE ....................................................................... 9.2

Tigercat T250 Loader

Engine anti-stall

HORSEPOWER LIMITING CONTROL

HPR REGULATOR VALVE

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

•

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

•

A solenoid valve mounted on the main pump.

•

A wiring harness.

•• • ••

WIRING HARNESS

••

MAIN PUMP CONTROLLER

MAIN PUMP

(LS CONTROL)

T250-D14

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

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

•• WIRING HARNESS WITH 25 PIN CONNECTOR

250-10

• SOLENOID VALVE

••

LOAD SENSE PRESS. PORT

CONTROL MODULE

•

•

••

TANK PORT

A Linde system is used and incorporates the following components: A control module mounted on the rear side wall of the cab interior.

PILOT SUPPLY 'P1' PORT WITH FILTER

•

GENERAL DESCRIPTION

•

GAUGE TEST PORT 'X1'

The control module in the cab receives and distributes signals through a 25 pin connector which is attached to the wiring harness. The control module is protected from power surges by a 2 amp. fuse, on earlier machines the fuse was an "in-line" type.

•

2 AMP FUSE (LATER MACHINES)

2 AMP IN-LINE FUSE (EARLIER MACHINES)

CONTROL MODULE IN CAB

SPEED SENSOR

••

••

T250-D15 105-2

SPEED SENSOR ON ENGINE 9.2

••

CONTROL MODULE FUSE LOCATION

Tigercat T250 Loader

250T-19

Engine anti-stall

LOAD SENSING SYSTEM CIRCUIT DIAGRAM 9.3

Tigercat T250 Loader

Engine anti-stall

CONTROL MODULE PIN CONNECTIONS

ADJUSTING SPEED SENSOR

Refer to Horsepower limiting control diagrams;

1. Stop engine.

•

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

•

Pin 13 is connected to ground.

•

Pin 6 is jumpered to Pin 17.

•

Pin 18 is jumpered to Pin 20.

•

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

•

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

•

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

2. Loosen locknut on speed sensor.

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

4. Turn speed sensor OUT one full turn.

5. Tighten locknut.

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

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

9.4

Tigercat T250 Loader

Engine anti-stall

FAULT FINDING ~ ANTI-STALL QUICK CHECK

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

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

2. Start engine.

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

4. Activate each function 1 at a time.

Expected Results:

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

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

•

All functions should operate normally.

•

X1 pressure should be less than 20 psi.

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

A. WHEN DOES THE PROBLEM OCCUR ?

•

•

2. Start engine and place throttle in minimum position.

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

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

Occurs only with the system ON.

Expected Results:

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

•

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

•

X1 pressure should be greater than 320 psi.

845-43

4. Fully activate MAIN BOOM UP function.

HORSEPOWER LIMITING CONTROL CIRCUIT 9.5

Tigercat T250 Loader

Engine anti-stall ADDITIONAL FAULT FINDING PROCEDURES

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

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

2. Start engine and place throttle in maximum position.

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

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

4. Fully activate MAIN BOOM UP function.

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

Expected Results: •

Boom up function should operate normally.

•

X1 pressure should be less than 20 psi.

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

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

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

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

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

3. Fully activate MAIN BOOM UP function.

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

2. Start engine.

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

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

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

Expected Results: •

The boom should not move initially.

•

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

•

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

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

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

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

2. Measure resistance of solenoid coil.

• The resistance should be 6.6 ±2 ohms.

Continued on page 7

9.6

Tigercat T250 Loader

Engine anti-stall

Continued from page 6

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

2. Start engine and place throttle in maximum position.

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

• The speed sensor output should be >5VAC. The speed sensor is non adjustable on the John Deere 6076 and 6081 engines (853 and 860). The speed sensor on the Cummins C engine (845/845B/250) should be a fixed distance from the flywheel. Do not use the voltage to adjust this distance. Refer to INSTALL OR ADJUST SPEED SENSOR in THIS SECTION. G. SPEED SENSOR WIRES 1. Remove connector from anti-stall control module.

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

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

3. Check for shorts from pin 14 to chassis.

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

2. Measure resistance of speed sensor coil.

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

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

9.7

Tigercat T250 Loader

Engine anti-stall

9.8

Tigercat T250 Loader

SECTION 11 - TRACK DRIVE CONTENTS - SECTION 11 CONTROL VALVE, MAIN ........................................................................... 11.3 DRIVE MOTOR BRAKE CIRCUIT DESCRIPTION ............................................................. 11.6 DESCRIPTION ......................................................................................... 11.5 START-UP PROCEDURE ........................................................................ 11.8 DRIVE MOTOR AND GEARBOX ASSEMBLY ........................................... 11.4 HYDROSTATIC DRIVE SYSTEM ............................................................... 11.3 PRESSURE SETTINGS, DRIVE SYSTEM BEGIN OF REGULATION, SET, FOR DRIVE MOTOR .......................... 11.10 BRAKE RELEASE PRESSURE ADJUSTMENT ON DRIVE MOT .......... 11.10 CROSSOVER RELIEF VALVES, FOR DRIVE MOTOR ........................... 11.9 SCHEMATIC DIAGRAMS DRIVE CIRCUIT ......................................................................... 11.12, 11.13 DRIVE MOTOR .................................................................... 11.4, 11.6, 11.7 TRACK COMPONENTS BOTTOM ROLLER RETAINING BOLTS ................................................ 11.22 MEASURING TRACK SAG .................................................................... 11.20 TRACK SAG ADJUSTMENT .............................................................. 11.21 OPERATING THE MACHINE ................................................................. 11.20 TORQUING UNDERCARRIAGE BOLTS ............................................... 11.21 TRACK DRIVE NOTES, IMPORTANT NEW MACHINE .................................................................................... 11.2 STRAIGHT TRAVEL ............................................................................. 11.2 TRACK SAG ......................................................................................... 11.2 TRACK SHOE RETAINING BOLTS ....................................................... 11.21 WEAR LIMITS BOTTOM ROLLER WEAR ................................................................. 11.23 BUSHING WEAR, OUTSIDE DIAMETER .......................................... 11.23 IDLER WEAR ...................................................................................... 11.24 PIN AND BUSHING WEAR ................................................................ 11.23 TRACK LINK WEAR ........................................................................... 11.22 TRACK SHOE GROUSER HEIGHT WEAR ....................................... 11.22 TRACK DRIVE ASSEMBLY ........................................................................ 11.2 TRACK SPEED SET-UP ADJUSTMENTS SEQUENCE ................................................................ 11.14 SET TRACK SPEED HIGH FORWARD (MOTOR MINIMUM DISPLACEMENT .................. 11.17 HIGH REVERSE (VALVE FLOW SETTING) ...................................... 11.17 LOW FORWARD (VALVE FLOW SETTING) ...................................... 11.16 SET MOTOR MAXIMUM DISPL. (SLOW SPEED) ............................. 11.15 SET STRAIGHT TRAVEL ................................................................... 11.18 SUMMERY OF PROCEDURE ............................................................ 11.18 TRACK SPEED TIMING CHART ........................................................ 11.15 UNDER CARRIAGE ASSEMBLY ................................................................ 11.2

MARCH 2004

Tigercat T250 Loader IMPORTANT TRACK DRIVE NOTES

Track drive STRAIGHT TRAVEL

NEW MACHINE

If the machine does not travel straight, the right and left track speeds are not set the same. Refer to TRACK SPEED SET-UP PROCEDURE in THIS SECTION.

Before driving a new machine ensure that track sag is set correctly. Track sag may be set less than specified for shipping purposes. The correct track sag must be adjusted once a machine has been delivered to the job sight and operating in the accumulated soil buildup in the undercarriage.

Check speeds of each track and follow the set-up procedures closely to obtain straight travel.

TRACK SAG The track sag dimension is very important and should be checked regularly. A 50% increase in the life of the track assembly can be realized, particularly in bushing O/D wear and 'track pitch' by maintaining the correct amount of track sag. A track that is too tight will wear out significantly faster due to increased tension in the chain. Refer to MEASURING TRACK SAG in THIS SECTION.

ROTARY MANIFOLD

TOP ROLLERS

••

IDLER ASSEMBLY

UNDERCARRIAGE LOWER HINGED ACCESS COVER

•• UNDERCARRIAGE

••

•• ••

•

•

INSPECTION COVERS

•

••

DRIVE MOTOR

DRIVE SPROCKET

240T-13

•

•

TRACK DRIVE GEARBOX

•

TRACK DRIVE ASSEMBLY 11.2

TRACK ACCESS COVER

LOWER ROLLERS

• TRACK ASSEMBLY

Tigercat T250 Loader

Track drive

HYDROSTATIC DRIVE SYSTEM The hydrostatic drive system is part of the main hydraulic system utilizing a variable piston pump (main pump) with load sensing and Horse Power (anti-stall) limiting control along with two pressure and flow compensated valve sections on the main Linde valve manifold.

The location of the RH. valve section on the Linde valve manifold varies depending on machine serial number. See figs. 250-08 and 250-09 below.

Refer to SECTION 4 in THIS MANUAL for a description of the MAIN HYDRAULIC SYSTEM.

DELIMBER OPEN/ GRAPPLE SAW

LH. TRACK DRIVE

•

•

STICK CYLINDER

RH. TRACK DRIVE

HOIST CYLINDER

•

•

•

SWING

•

• VIEWED FROM BELOW

•

HIGH PRESSURE LIMITING CONTROL

CONTROL VALVE MANIFOLD

MAIN CONTROL VALVE (S/N 250T0111 TO 250T0115)

T250-02

GRAPPLE OPEN/CLOSE

LH. TRACK DRIVE

•

•

DELIMBER OPEN/ STICK CYLINDER GRAPPLE SAW

•

•

HOIST CYLINDER

•

RH. TRACK DRIVE

•

• VIEWED FROM BELOW

• T250-03

HIGH PRESSURE LIMITING CONTROL

MAIN CONTROL VALVE (S/N 250T0131 AND UP) 11.3

CONTROL VALVE MANIFOLD

Tigercat T250 Loader

Track drive

A variable displacement swash plate piston motor transmits power to the tracks through a triple reduction planetary gearbox on each track frame.

The gearbox has an integral spring apply, hydraulic-release, multi-disc brake which is automatically released whenever the drive system is pressurized.

The valve will remain in the closed position as long as there is no oil pressure in the line from the main control valve. When the main control valve spool is shifted and oil flows to the motor, a check valve in the counterbalance valve (G) (Refer to motor schematic) opens and oil pressure builds up behind the motor pistons.

In order to control the vehicle movement in situations where the vehicle may roll down a grade, each motor is equipped with a counterbalance valve. These valves have a spool valve which controls the flow of oil out of the motor, See motor schematic diagram, it is shown in the centre, closed position.

The motor cannot move until the oil pressure shifts the counterbalance spool to permit the oil on the low pressure side of the motor to flow back through the counterbalance valve to the main control valve and then to tank.

845B-24

TRACK SPROCKET

PLANETARY TRACK DRIVE GEARBOX

•

MOTOR SCHEMATIC DIAGRAM (AQ019)

•

LOWER FRAME

•

TRACK DRIVE MOTOR (AQ019 SHOWN)

• ••

BRAKE ASSEMBLY

BK004-822

TRACK DRIVE MOTOR AND GEARBOX ASSEMBLY 11.4

Tigercat T250 Loader

Track drive (1) with nine pistons (2) and an output shaft (3) that is splined to the cylinder block.

DRIVE MOTOR DESCRIPTION The drive motor is a variable displacement swashplate design. The motor is interchangeable from side to side.

The motor rotating group consists of a cylinder block SLIPPER

RETAINER

Supply oil from the drive control valve enters the motor through the cover (4) to the pistons. During operation, high pressure supply oil enters the PISTON 2

BALL GUIDE

CYLINDER BLOCK

6

1

SWASHPLATE

PIN

5 SEAL

MAXIMUM DISPLACEMENT PISTON

8

•• ••

SPACER RETAINING RING

••••• ••

••

•• •• • •• ••

9 MINIMUM

•

•

SHIMS

••

••

4 COVER

•

•• •

SHAFT 3

DISPLACEMENT ADJUSTMENT STOP

••

•

10 MAXIMUM

DISPLACEMENT ADJUSTMENT STOP

WEAR SLEEVE

CROSS SECTION OF DRIVE MOTOR

AQ019-2

BEARING SHELL MINIMUM

SPRING

MINIMUM DISPLACEMENT ADJUSTMENT STOP

BRAKE RELEASE PRESSURE REDUCING VALVE ADJUSTMENT

BEGIN OF REGULATION ADJUSTMENT

9

7 DISPLACEMENT PISTON CROSSOVER

11 RELIEF VALVES 4 COVER

•

• •

•• ••

•• 'B' PORT

PRESSURE PORTS

•

'A' PORT

• PRESSURE REGULATOR VALVE BLOCK MAXIMUM 10 DISPLACEMENT ADJUSTMENT STOP

•

AQ019-1

COUNTERBALANCE VALVE

11.5

DRIVE MOTOR FRONT COVER

Tigercat T250 Loader piston bores in the cylinder block (1). This forces the pistons against an angled swashplate (5).

Piston sliding action causes the rotating group to turn. The cylinder block is splined to the output shaft (3) which causes the output shaft to turn.

During the second half of the motor rotation, low pressure is discharged as the pistons ride up to a higher position on the swashplate. To reverse rotation, oil flow is reversed. During operation a small amount of supply oil flows through the centre of each piston. This oil lubricates the piston to slipper (6) joint and the slipper to swashplate area.

Track drive BRAKE CIRCUIT DESCRIPTION Refer to motor schematic diagram Oil pressure entering ports 'A' or 'B' of the motor passes through supply shuttle valve 'F' and enters brake release pressure reducing valve 'D'. The pressure reducing valve output is adjustable. In this particular application it is limited to 500 psi., whenever 'A' or 'B' line pressure is above 500 psi., or 'A' or 'B' line pressure below 500 psi. The brake is fully released by 250 psi. and the maximum pressure the brake can stand without failure is 725 psi. The time required for the brake to release is approximately 1 to 3 seconds to apply.

High pressure supply oil also flows through a tube to lubricate the swashplate to bearing shell area.

Normal leakage and lubrication oil aid in flushing and cooling the motor during drive operation.

The swashplate (5) angle is changed by the minimum displacement piston (7) and maximum displacement piston (8). When supply oil acts on the minimum displacement piston (7), the motor runs at its highest speed. When supply oil acts on the maximum displacement piston (8), the motor runs at its slowest speed. The maximum displacement piston is larger than the minimum piston and will hold the motor in maximum displacement when equal pressure acts on both pistons.

NOTE: Swashplate angle (motor displacement) is limited by the minimum and maximum displacement pistons contacting the minimum (9) and maximum (10) displacement adjustment stops. For minimum displacement, the maximum displacement piston contacts the minimum displacement adjustment stop. For maximum displacement, the minimum displacement piston contacts the maximum displacement adjustment stop.

Refer to front cover illustration; The drive motor cover (4) consists of several components to operate the drive functions and regulate the release of drive brakes.

The minimum displacement adjustment stop (9) limits the minimum angle the swashplate can move. The maximum displacement adjustment stop (10) limits the maximum angle the swashplate can move. The crossover relief valve(s) (11) protects the motor circuit from pressure spikes.

845B-24

MOTOR SCHEMATIC DIAGRAM (AQ019)

The drive brake release pressure reducing valve (D) reduces the higher supply pressure to the lower pressure used to release the drive brake. The supply pressure comes from the supply shuttle valve (F) when a drive function is actuated.

The edge filter and pressure reducing valve orifice (J) are located in the pressure regulator housing in the passage from the supply shuttle valve (F) to the drive brake release pressure reducing valve (D).

The edge filter and orifice are accessible by removing the pressure regulator. The edge filter is used to break up small particles in the oil so they flow through the orifice. The orifice causes a pressure drop in supply oil flow to the reducing valve and dampens pressure oil fluctuation.

The drive speed change valve (H) routes supply oil to the maximum displacement piston to keep the drive motor in the lowest speed. A servo pressure reducing valve controls the pressure of the supply oil entering the drive speed change valve at 2000 psi. maximum.

11.6

Tigercat T250 Loader

Track drive

The flushing orifice (I) is located in the brake circuit to motor case passage. The orifice provides a passage for oil flow from the brake circuit to the motor case for cooling and flushing during drive operation. When the oil is cold the flow of oil is restricted by the orifice to prevent an excessive build up of pressure in the drive motor case. The orifice also provides a passage to release any residual pressure from the brake circuit to the motor case when not driving.

The drive motor may be operated in two ranges; MAXIMUM DISPLACEMENT = 105 cc/rev.

MINIMUM DISPLACEMENT = app. 50cc/rev.

These two ranges are controlled by a solenoid pilot valve on the pilot manifold which is operated by the TRACK (LOW/HIGH) switch in the cab. In the LOW position the solenoid on the pilot valve is energized and the motor is in its maximum displacement mode which will give the slowest speed and maximum tractive effort.

845B-24

For faster travelling modes the TRACK (LOW/ HIGH) switch can be put in the HIGH position and the motor will be in its minimum displacement position which will give the fastest speed. When in this high speed mode the motor will automatically de-stroke in the event that a high load is encountered, e.g. a short grade or obstacle. This de-stroking is controlled by the drive speed change valve. This valve controls the hydraulic pressure signal to the maximum displacement piston. The piston shifts the motor to maximum displacement when the supply oil pressure in the motor is above the drive speed change valve pressure setting.

11.7

MOTOR SCHEMATIC DIAGRAM (AQ019)

Tigercat T250 Loader DRIVE MOTOR START-UP PROCEDURE

Track drive

IMPORTANT: The drive motor will be damaged if is not filled with oil before operating the drive function. This procedure must be performed whenever a new drive motor or drive pump is installed or whenever oil has been drained from the motor.

1. Disconnect drive motor drain line on top of motor.

2. Install plug in line to minimize loss of oil.

3. Remove port adapter from motor drain port.

4. Fill motor with oil through the drain port. Add oil slowly until level is to the top of drain port.

5. Re-connect drain line.

6. Run each drive motor slowly with track off the ground for three track revolutions to remove air from the drive circuit.

DRAIN LINE

••

'U' PORT DRAIN CONNECTION

7. Check that the brake release pressure has not changed.

GAUGE TEST PORT 'Y1'

••

•

DRIVE MOTOR TOP VIEW

822-D61

PRESSURE REGULATOR VALVE BLOCK

GAUGE TEST PORT Y1 SYSTEM PRESSURE PORT 'A'

BRAKE LINE TO GEARBOX

•• MAXIMUM DISPLACEMENT ADJUSTMENT STOP

•

6mm ALLEN KEY 19mm WRENCH

••

SYSTEM PRESSURE PORT 'B'

MINIMUM DISPLACEMENT ADJUSTMENT STOP 6mm ALLEN KEY 19mm WRENCH

••

••

COUNTERBALANCE VALVE

••

'B' SIDE

• CROSSOVER RELIEF VALVES

'A' SIDE

6mm WRENCH 13mm WRENCH

•• 'L' PORT DRAIN CONNECTION (FOR L.H. SIDE)

5mm ALLEN KEY 17mm WRENCH 822-D62

BEGIN OF REGULATION ADJUSTING SCREW

DRIVE MOTOR (AQ019) - R.H. SIDE SHOWN 11.8

•

•• • BRAKE RELEASE PRESSURE ADJUSTING SCREW 5mm ALLEN KEY 17mm WRENCH

Tigercat T250 Loader

Track drive

DRIVE SYSTEM PRESSURE SETTINGS FOR DRIVE MOTOR

13. Set throttle to FULL

DRIVE MOTOR CROSSOVER RELIEF VALVES Pressure Setting: 4600 - 4800 psi (cracking pressure)

14. Activate LEFT drive foot pedal in FORWARD or REVERSE and temporarily set LS. relief valve to 4700 psi. on gauge at 'P' test port.

TEST PROCEDURE: Place boom attachment on the ground before performing any service work.

15. With the aid of an assistant; While holding the LEFT drive foot pedal in the FORWARD position

1. Ensure hydraulic oil is at operating temperature.

'B' SIDE FORWARD CROSSOVER RELIEF VALVE

'A' SIDE REVERSE CROSSOVER RELIEF VALVE

2. Remove both LEFT and RIGHT drive motor inspection covers.

•

3. Install a 0 to 10,000 psi gauge on 'P' test port on Linde main valve manifold.

'P' GAUGE TEST CONN.

• •

••

••

822-D60

DRIVE MOTOR - LEFT SIDE SHOWN

P2 L.S. PRESSURE LIMIT, SET AT 4500 PSI. WITH GAUGE ON 'P' TEST PORT • 4MM ALLEN KEY • 13MM WRENCH

103-17A

•

HIGH PRESSURE LIMITING CONTROL

L.S. GAUGE TEST CONN.

GAUGE TEST PORTS ON MAIN VALVE

...

'B' SIDE FORWARD CROSSOVER RELIEF VALVE

'A' SIDE REVERSE CROSSOVER RELIEF VALVE

5mm ALLEN KEY 17mm WRENCH

5mm ALLEN KEY 17mm WRENCH

•• ••

MAIN VALVE MANIFOLD

•

••

4. Disconnect LEFT brake line at port on final drive gearbox. Plug hose with size 04 JIC plug and cap port adapter on gearbox.

5.

From inside the cab close and latch the cab door.

6.

Start engine and set throttle speed to above 1500 RPM.

7.

Lower the LH. arm rest and press the PILOT RESET switch to activate the pilot system.

8.

Place ANTI-STALL switch to OFF position.

822-D62

DRIVE MOTOR - RIGHT SIDE SHOWN loosen locknut on FORWARD crossover relief valve adjusting screw and unscrew slowly until engine begins to lug. Turn adjusting screw 1/8 of a turn in and tighten locknut.

9. Place HIGH/LOW switch to LOW.

16. Repeat step (15) for the LEFT REVERSE crossover relief valve.

10. Activate LEFT track drive foot pedal in both FORWARD and REVERSE directions to ensure that the track does not move.

17. Repeat steps (4) through (16) for RIGHT track drive motor.

11. With the aid of an assistant, activate LEFT track drive foot pedal in either FORWARD or REVERSE and check pressure reading on gauge at 'P' port. the gauge should show 4500 psi (Main system LS. relief pressure) 12. Loosen locknut on both crossover relief valve adjusting screws and turn both adjusting screws all the way in. Tighten locknuts.

18. Reset the LS. relief valve to 4500 psi. on gauge at 'P' test port. Refer to SET LOAD SENSE RELIEF VALVE in SECTION 4 of THIS MANUAL. 19. Re-connect brake line(s) to both gearboxes.

20. Remove pressure gauge and wipe up any spills.

21. Replace both LEFT and RIGHT drive motor inspection covers.

11.9

Tigercat T250 Loader

Track drive

SET BRAKE RELEASE PRESSURE ADJUSTMENT ON DRIVE MOTOR

BRAKE RELEASE PRESSURE ADJUSTING SCREW

Pressure setting: 500 psi. (cracking pressure)

•• ••

Place boom attachment on the ground before performing any service work.

5mm ALLEN KEY 17mm WRENCH

1. Ensure hydraulic oil is at operating temperature.

2. Remove both LEFT and RIGHT drive motor inspection covers.

•

3. Disconnect LEFT brake line at port on final drive gearbox.

••

DISCONNECT BRAKE LINE AT PORT ON FINAL DRIVE GEARBOX.

PRESSURE REGULATOR VALVE BLOCK

BEGIN OF REGULATION ADJUSTING SCREW 6mm WRENCH 13mm WRENCH

822-D62 DRIVE MOTOR - LEFT SIDE SHOWN 11. Remove pressure gauge from brake line and re-connect brake line to gearbox.

12. Repeat steps (3) through (11) for RIGHT track drive motor.

13. Replace both LEFT and RIGHT drive motor inspection covers.

•• GAUGE TEST PORT 'Y1'

•

SET BEGIN OF REGULATION (DRIVE SPEED CHANGE VALVE)

BRAKE LINE 822-D61

DRIVE MOTOR - R.H. SIDE SHOWN

4. Install a 0 to 1,000 psi gauge onto hose end (size 04 JIC).

5.

From inside the cab close and latch the cab door.

6.

Start engine and set throttle to FULL

7.

Lower the LH. arm rest and press the PILOT RESET switch to activate the pilot system.

8.

Place ANTI-STALL switch to OFF position.

1. Ensure hydraulic oil is at operating temperature.

2. Remove both LEFT and RIGHT drive motor inspection covers.

3. Install a 0 to 10,000 psi gauge on 'P' test port on Linde main valve manifold.

'P' GAUGE TEST CONN.

HIGH PRESSURE LIMITING CONTROL

L.S. GAUGE TEST CONN.

...

••

••

••

9. Place HIGH/LOW switch to HIGH position.

10. With the aid of an assistant; activate LEFT track drive foot pedal in either FORWARD or REVERSE direction and check pressure reading on gauge connected to brake line, the gauge should show 500 psi.

If adjustment is required, loosen locknut on brake release pressure adjusting screw and turn screw in to increase pressure or out to decrease pressure. Tighten locknut.

P2 L.S. PRESSURE LIMIT, SET AT 4500 PSI. WITH GAUGE ON 'P' TEST PORT • 4MM ALLEN KEY • 13MM WRENCH

103-17A

GAUGE TEST PORTS ON MAIN VALVE

•• ••

MAIN VALVE MANIFOLD

4. Disconnect LEFT brake line at port on final drive gearbox. Plug hose with size 04JIC plug and cap port adapter on gearbox.

5. Install a 0 to 5,000 psi gauge on drive motor gauge test port 'Y1', size 04JIC quick connect.

11.10

Tigercat T250 Loader

Track drive

6.

From inside the cab close and latch the cab door.

7.

Start engine and set throttle to FULL

8.

Lower the LH. arm rest and press the PILOT RESET switch to activate the pilot system.

9.

Place ANTI-STALL switch to OFF position.

...

10. Place HIGH/LOW switch to HIGH position.

11. Activate LEFT track drive foot pedal in both FORWARD and REVERSE directions to ensure that the track does not move.

12. With the aid of an assistant, activate LEFT drive foot pedal in FORWARD or REVERSE and temporarily set LS. relief valve to 3600 psi.** on gauge at 'P' test port on Linde main valve manifold.

13. With the aid of an assistant, activate LEFT track drive foot pedal in the FORWARD direction and check pressure reading on gauge at motor gauge test port 'Y1' it should show between 800 and 1,000 psi.

If adjustment is required, loosen locknut on begin of regulation adjusting screw and turn screw in to increase pressure or out to decrease pressure. Tighten locknut.

14. Stop engine.

15. Repeat steps (4) through (13) for the right drive motor.

16. Reset the LS. relief valve to 4500 psi. Refer to SET LOAD SENSE RELIEF VALVE in SECTION 4 of THIS MANUAL. 17. Re-connect brake line(s) to both gearboxes.

18. Remove pressure gauge and wipe up any spills.

19. Replace both LEFT and RIGHT drive motor inspection covers. **NOTE For begin of regulation; this pressure setting can be adjusted between 3100 psi and 3600 psi depending on the operator's requirements. The lower the begin of regulation setting the sooner the drive motors will automatically shift to LOW when encountering difficult terrain conditions.

11.11

Tigercat T250 Loader

250T-20

Track drive

TRACK DRIVE CIRCUIT DIAGRAM (S/N 250T0111 TO 250T0115) 11.12

Tigercat T250 Loader

250T-17

Track drive

TRACK DRIVE CIRCUIT DIAGRAM (S/N 250T0131 AND UP) 11.13

Tigercat T250 Loader

Track drive ADJUSTMENTS SEQUENCE:

TRACK TIMING CHART GEARBOX RPM

DESIRED LOW

DESIRED HIGH

DO NOT EXCEED

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

DRIVE ENGINE HIGH/LOW ADJUSTMENT MODE RPM SWITCH POS. FORWARD SLOW = FULL LOW FWD. SPOOL STOP FORWARD FAST = FULL HIGH MOTOR MIN. DISPL. REVERSE FAST = FULL HIGH REV. SPOOL STOP REVERSE SLOW = THIS DRIVE MODE WILL BE A PRODUCT OF THE ABOVE THREE ADJUSTMENTS. THERE IS NO CALIBRATION OR SPECIAL ADJUSTMENT REQUIRED.

NUMBER OF TRACK LINKS 45 47 51 TRACK REVOLUTION TIME (SECONDS) 23.48 21.34 19.57 18.06 16.77 15.65 14.67 13.81 13.04 12.36 11.74 11.18 10.67 10.21 9.78 9.39 9.03 8.70 8.39 8.10 7.83 7.57 7.34 7.11 6.91 6.71 6.52 6.35 6.18 6.02 5.87

24.52 22.29 20.43 18.86 17.52 16.35 15.33 14.42 13.62 12.91 12.26 11.68 11.15 10.66 10.22 9.81 9.43 9.08 8.76 8.46 8.17 7.91 7.66 7.43 7.21 7.01 6.81 6.63 6.45 6.29 6.13

26.61 24.19 22.17 20.47 19.01 17.74 16.63 15.65 14.78 14.00 13.30 12.67 12.09 11.57 11.09 10.64 10.23 9.86 9.50 9.18 8.87 8.58 8.32 8.06 7.83 7.60 7.39 7.19 7.00 6.82 6.65

1, Forward flow stop adjusting screw 2, Reverse flow stop adjusting screw 3, Motor minimum displacement adjustment stop SET TRACK SPEED Low speed 14.5 rpm**. High speed 28 rpm. **NOTE: This value is dependant on engine HIGH IDLE speed or FULL throttle. 14.5 rpm is based on 2400 rpm.

1. Ensure hydraulic oil is at operating temperature.

2. Remove both left and right final drive inspection covers to access track motors.

LEFT TRACK ADJUSTMENT POSITION MACHINE 3. Swing boom to LEFT side of machine.

T250 TRACKCHART.XLS

TRACK SPEED SET-UP PROCEDURE

SUPPORT BLOCK

IMPORTANT: EACH motor maximum displacement setting must be correctly set before making adjustments to the valve spool stops described here in. Refer to the following SET MOTOR MAX. DISPL. (SLOW SPEED) procedure.

240T-17

4. Place grapple on ground and by forcing down with boom controls, lift track clear of ground. (Hoist down and stick out)

Also note that changes in margin pressure will also affect track speeds.

NOTE: Both left and right T250 track drives have 4 (speed) settings which are dealt with in the following procedures, they are: 1, Forward-High 2, Forward-Low 3, Reverse-High 4, Reverse-Low. However, there are only 3 adjustments required to accomplish this;

LIFT LEFT TRACK

5. Use blocks to firmly support track frame in raised position.

WARNING DO NOT place arms, legs or body under track while in the raised position.

11.14

Tigercat T250 Loader

Track drive

SET MOTOR MAX. DISPL. (SLOW SPEED) NOTE: The motor maximum displacement setting is the SLOW speed setting and is factory set to:

13. Release drive pedal and turn screw IN an additional 1/4 turn = 105cc.

Tighten locknut while holding adjusting screw from turning.

MAXIMUM DISP. = 105CC/REV. NOTE: Turn the screw either IN (clockwise) to speed up or OUT (counterclockwise) to slow down the final drive.

14. LEFT drive motor maximum displacement (slow track speed) is now set to 105cc per revolution.

6. On LEFT track drive motor, unscrew the maximum displacement adjusting screw all the way OUT. 7.

From inside the cab close and latch the cab door.

8.

Lower the LH. arm rest and press the PILOT RESET switch to activate the pilot system.

9.

Place ANTI-STALL switch to OFF position.

10. Set TRACK (LOW/HIGH) switch to LOW. MINIMUM DISPLACEMENT ADJUSTING SCREW 6mm ALLEN KEY 19mm WRENCH

•• ••

MAXIMUM DISPLACEMENT ADJUSTING SCREW 6mm ALLEN KEY 19mm WRENCH

822-D60

LEFT TRACK DRIVE MOTOR MAXIMUM DISPLACEMENT ADJUSTING SCREW 6mm ALLEN KEY 19mm WRENCH

•• MINIMUM DISPLACEMENT ADJUSTING SCREW

••

6mm ALLEN KEY 19mm WRENCH 822-D61

RIGHT TRACK DRIVE MOTOR

11. Set throttle to FULL

...

12. With an assistant depressing LEFT TRACK drive pedal FORWARD, turn maximum displacement screw IN until the end of adjusting screw just makes contact with piston inside the motor.

11.15

Tigercat T250 Loader

Track drive

TRACK SPEED SET-UP PROCEDURE CONTINUED; LOW FORWARD (VALVE FLOW SETTING)

CONTROL REVERSE SPOOL VALVE STOP SCREW FOR MANIFOLD LEFT TRACK

•

15. Turn ‘HIGH/LOW’ switch to ‘LOW’ 16. Set throttle to FULL

...

••

17. With an assistant depressing ‘LEFT’ TRACK drive pedal ‘FORWARD’, record track drive sprocket speed.

B

LEFT DRIVE VALVE

SIDE A TIMING MARK, VISIBLE FROM THE CAB CAN ALSO BE PLACED ON THE TRACK

•• A SIDE

••

• ROTATION

TO RECORD TRACK SPEED, PLACE TIMING MARKS ON TRACK FRAME AND GEARBOX HOUSING

84-18

SET TRACK SPEED

FORWARD SPOOL STOP SCREW FOR LEFT TRACK T250-02

SPOOL STOP ADJUSTING SCREW • 19mm WRENCH • 6mm ALLEN KEY

•• MAIN CONTROL VALVE (LEFT TRACK SHOWN)

•

Track containing 47 links*: A reading of 15 RPM is desired which equals 1 complete revolution of the track every 16.3 seconds. *NOTE: Refer to TRACK TIMING CHART. 18. To obtain the 15 RPM value adjust FORWARD spool stop adjusting screw for the LEFT track drive control valve.

Turn the screw either IN (clockwise) to slow down or OUT (counterclockwise) to speed up the final drive. Tighten locknut on adjusting screw and re-check sprocket speed.

853MV-2

VALVE FLOW SETTING TRACK DRIVE MAIN CONTROL VALVE

11.16

Tigercat T250 Loader

Track drive

HIGH FORWARD (motor minimum displacement)

HIGH REVERSE (valve flow setting)

19. Turn ‘HIGH/LOW’ switch to ‘HIGH’ 20. Set throttle to FULL

23. Repeat steps 19 to 21 to set ‘LEFT’ HIGH REVERSE.

...

24. To obtain 28 RPM value adjust REVERSE spool stop adjusting screw for the LEFT track drive control valve. Turn the screw either IN (clockwise) to slow down or OUT (counterclockwise) to speed up the final drive. Tighten locknut on adjusting screw and re-check sprocket speed.

21. With an assistant depressing ‘LEFT’ TRACK drive pedal ‘FORWARD’, record track drive sprocket speed.

Track containing 47 links*: A reading of 28 RPM is desired which equals 1 complete revolution of the track every 8.8 seconds.

TRACK SPEED SET-UP PROCEDURE CONTINUED;

*NOTE: Refer to TRACK TIMING CHART. 22. To obtain the 28 RPM adjust the minimum displacement adjusting screw for the LEFT track drive motor. Turn the screw either IN (clockwise) to slow down or OUT (counterclockwise) to speed up the final drive. Tighten locknut on adjusting screw and re-check sprocket speed.

SUPPORT BLOCK

240T-17

MINIMUM DISPLACEMENT ADJUSTMENT STOP

LIFT RIGHT TRACK

WARNING DO NOT place arms, legs or body under track while in the raised position.

RIGHT TRACK ADJUSTMENT

••

25. Re-position machine to raise RIGHT track.

26. Repeat steps 3 through 13 to set RIGHT drive motor maximum displacement.

• MAXIMUM DISPLACEMENT ADJUSTMENT STOP 822-D60

LEFT TRACK DRIVE MOTOR IMPORTANT: DO NOT exceed the recommended track speed specified above, over speeding will damage the drive motor.

LOW FORWARD (valve flow setting) 27. Repeat steps 15 to 18 to set RIGHT TRACK valve flow setting.

HIGH FORWARD (motor minimum displ.)

28. Repeat steps 19 to 22 to set RIGHT drive motor minimum displacement.

HIGH REVERSE (valve flow setting) 29. Repeat steps 23 and 24 to set RIGHT TRACK valve flow setting.

30. Replace final drive inspection covers for both right and left track drives.

11.17

Tigercat T250 Loader

Track drive

TRACK SPEED SET-UP PROCEDURE CONTINUED;

SUMMERY OF PROCEDURE • REMOVE INSPECTION COVERS LEFT TRACK ADJUSTMENT • POSITION MACHINE, LEFT track off ground • LOW FORWARD (valve flow setting) • HIGH FORWARD (motor minimum displacement) • HIGH REVERSE (valve flow setting) RIGHT TRACK ADJUSTMENT • POSITION MACHINE, RIGHT track off ground • LOW FORWARD (valve flow setting) • HIGH FORWARD (motor minimum displacement) • HIGH REVERSE (valve flow setting) • REPLACE INSPECTION COVERS

SET STRAIGHT TRAVEL Following completion of TRACK SPEED SETUP PROCEDURE, drive the machine in both forward and reverse directions with the ‘HIGH/LOW’ switch in ‘HIGH’ and again with the switch in ‘LOW’ position. Ensure that both DRIVE pedals are equally and fully depressed.

If the machine continuously drifts to the left or to the right, the above set-up procedure should be reviewed. It is important that the LEFT and RIGHT track speeds are synchronized with each other to prevent unnecessary wear from occurring to the track components.

11.18

Tigercat T250 Loader

Track drive

11.19

Tigercat T250 Loader TRACK COMPONENTS

Track drive

IMPORTANT: New machine: Before driving a new machine ensure that track sag is set correctly. Track sag may be set less than specified for shipping purposes.

The correct track sag must be adjusted once a machine has been delivered to the job sight and operating in the accumulated soil build-up in the undercarriage.

TRACK SAG NOTE: The track sag dimension is very important and should be checked regularly, 50% increase in the life of the track assembly can be realized, particularly bushing O/D wear and track pitch by maintaining the correct amount of track sag. A track that is too tight will wear out significantly faster due to increased tension in the chain.

Track components operate under varying terrain conditions, most of which cause excessive wear.

Wear to one component can quickly spread to the rest of the track assembly.

SUPPORT BLOCK

•• 240T-17

MEASURING TRACK SAG 1. Swing boom to side of machine.

2. Place grapple on ground and by forcing down with boom controls, lift track clear of ground.

3. Rotate track in forward and reverse several times. Stop the track while in reverse. Do not clean the track.

4. Stop engine.

5. Measure distance between top surface of track shoe at centre of lower surface of track frame.

To ensure that the track components are always in good running order, a periodic inspection should be made to ensure that components have not come loose, that bolts are at the correct torque, that components are within the specified wear limits (discussed further in this section) and where applicable, check lubrication points.

For a guide on inspection, refer to the PERIODIC MAINTENANCE SCHEDULE in SECTION 3 OF THIS MANUAL.

UNDERSIDE OF TRACK GUARD

SAG DIMENSION

• •

UPPER SURFACE OF TRACK SHOE 853ILL8

MEASURING SAG DIMENSION

6. This dimension should be between 4" and 6" for normal operations.

DRIVE SPROCKETS IDLERS TOWARD FRONT

•

NOTE: If track sag is less than specified, track chain wear will be accelerated. If track sag is excessive, it is possible for the track to jump off the sprocket.

•

OPERATE MACHINE WITH GRAPPLE OVER IDLERS

240T-16

OPERATING THE MACHINE Whenever possible the machine should always be operated with the grapple over the IDLERS and not over the SPROCKETS. Operating over the sprockets will result in overloading of the contact surfaces between the sprocket and the track bushings. Bushings could crack during sprocket impact.

11.20

Tigercat T250 Loader IDLER ADJUSTING 4 CYLINDER

Track drive TORQUING UNDERCARRIAGE BOLTS

•

It is important to check the torque values of the track shoe retaining bolts and the bottom roller retaining bolts at the NEW MACHINE MAINTENANCE time period (first 100 hours) and the EVERY 125 HOURS SCHEDULED MAINTENANCE time period.

3

•

DO NOT REMOVE

•

•

CW001-3

• 1

2

When installing new components, all traces of paint and dirt must be removed from all mating surfaces including the contact area under the bolt head and nut.

TRACK ADJUSTMENT TRACK SAG ADJUSTMENT

Both the bolt and the nut on the track shoes should be lightly lubricated with SAE 30 oil and tightened using the Torque-turn method.

To tighten track, attach adjustment fitting adapter (3) onto valve body (1). Connect a grease gun to the grease fitting (2) on the adjustment fitting adapter (3). Add grease until track sag dimension is within recommended limits. Remove adjustment fitting adapter.

The torque-turn method involves torquing the bolt to an initial predetermined value, plus an additional 1/3 turn (not the value shown in the torque charts). This ensures a more accurate and consistent torquing of the bolts, with less likelihood of the bolt/nut coming loose later.

CAUTION: The grease is under very high pressure, DO NOT REMOVE the adjustment fitting valve body (1) from the idler adjusting cylinder (4).

When checking the torque values at the first 100 hours and every 125 hours thereafter use the CHECKING TORQUE values listed in the following paragraphs.

To loosen track, slowly loosen valve body (1) until grease begins to escape via a relief passage in the valve body housing, grease will be seen escaping from around valve body threads. When track sag is correct, tighten valve body.

If loose shoes or under torqued bolts are discovered during the FIRST 100 HOUR check, they should be removed, surfaces cleaned, and reused using the torque-turn method. If the shoe is not loose but a single bolt is low on torque, loosen the bolt and re torque-turn.

CW001-2

If loose or under torqued bolts are discovered any time after the 100 HOUR check, the bolts and nuts must be replaced with NEW ones, surfaces cleaned, and re torque-turned.

TRACK SHOE RETAINING BOLTS Track shoes must be fastened together applying the exact torque values shown below and using the Torque-turn method described in TORQUING UNDER CARRIAGE BOLTS earlier in this section.

TORQUE 1

TRACK COMPONENT TORQUE VALUES 11.21

Tigercat T250 Loader

Track drive

Track shoe bolts and nuts are designed specifically for this purpose and should not be substituted with standard off the shelf hardware.

Only bolts with grade '12.9' or '170' designation forged in the head are approved.

SINGLE GROUSER BERC-9

When checking the torque values at the first 100 hours and every 125 hours thereafter use the checking torque value.

DOUBLE GROUSER BERC-10

Track shoe bolts ~ 3/4" UNC TORQUE-TURN ........... 250 LBF-FT. + 1/3 TURN. CHECKING TORQUE ....................... 450 LBF-FT.

TRIPLE GROUSER

Track shoe bolts ~ M24 BERC-1

TORQUE-TURN ........... 340 LBF-FT. + 1/3 TURN.

GROUSER WEAR (HEIGHT)

CHECKING TORQUE ..................... 1040 LBF-FT.

WEAR LIMITS

BOTTOM ROLLER RETAINING BOLTS

TRACK SHOE GROUSER HEIGHT WEAR WEAR LIMITS New 75% wear 100% wear Single 2.82"(716.2mm) ... 1.37"(348mm) ........ 0.93" (236.2mm) Double 1.37"(348mm) ...... 0.71"(180.3mm) ..... 0.43" (109.2mm) Triple 1.06"(269.2mm) ... 0.51"(129.5mm) ..... 0.36" (91.4mm)

The bottom rollers must be fastened to the lower frame applying the exact torque values shown below.

When installing new rollers, apply "NEVER-SEEZ" to the bolt.

When checking the torque values at the first 100 hours and every 125 hours thereafter use the torque value(s) shown below.

NOTE: Allowable wear for soft ground conditions is 100%. Allowable wear for rocky ground conditions is 75%.

NOTE: Two sizes of bolts have been used to fasten the rollers to the lower frame; 3/4" UNC; and on later machines 7/8" UNC. Bottom roller bolts ~ 3/4" UNC TORQUE ......................................... 310 LBF-FT. Bottom roller bolts ~ 7/8" UNC TORQUE ......................................... 475 LBF-FT. BERC-2

For a complete maintenance check Refer to the PREVENTIVE MAINTENANCE SCHEDULE in SECTION 3 of this manual.

TRACK LINK WEAR (HEIGHT)

TRACK LINK WEAR WEAR LIMITS New link height ........................ 4.78" (121.5mm) 50% wear ................................ 4.60" (116.8mm) 75% wear ................................ 4.48" (113.8mm) 100% wear .............................. 4.34" (110.2mm)

11.22

Tigercat T250 Loader

Track drive

PIN AND BUSHING WEAR

BUSHING WEAR, OUTSIDE DIAMETER

To obtain the track internal wear, i.e., the wear between the pin and the internal diameter of the bushing, measure the track pitch over four sections of track (5 pins).

Use a calliper to measure the wear of the bushing O.D. in three places.

45°

45°

FORWARD SIDE VERTICAL WEAR WEAR BERC-3

MEASURING TRACK PITCH

To take this measurement, 1. Remove slack by placing a steel pin between sprocket and chain, then slowly move machine in reverse to tighten chain.

2. Measure pitch across two four link sections, except section on each side of the master pin, to find average chain wear.

INTERNAL PIN & BUSHING WEAR

ROTATION

MEASURING BUSHING WEAR

BERC-5

NOTE: Bushing outside diameter is measured at three places because of the forward and reverse travel of the machine and a vertical wear that takes place.

WEAR LIMITS New bushing O.D. ........................ 2.62" (66.6mm) 75% worn ..................................... 2.5" (63.5mm) 100% worn ................................... 2.43" (61.7mm) NOTE: Allowable wear in rocky ground is 75% BOTTOM ROLLER WEAR

180° EXTERNAL BUSHING WEAR

REVERSE SIDE WEAR

TURN PIN & BUSHING 180°

Measure the roller diameter on the tread contact surface with a large calliper to obtain the worst wear condition.

BERC-4 PIN/BUSHING INTERNAL WEAR NOTE: Wear to the pins and bushings only occurs in a small localised area, to extend the life of these components, the pins and bushings may be turned 180° or replaced provided other components are within specified wear limits:

1. Track link wear is 75% or less.

2. Change in track pitch is 32.50:" (825.5mm) per link or less.

3. Bushing external wear less than 100% or 75% or less in rocky ground.

BERC-6

MEASURING BTM. ROLLER WEAR

4. There is at least 0.008" (0.2mm) press fit available between pin and bushing and link.

If accessibility to the rollers is impaired by guards, then concentrate on the front and rear rollers, these will be the most worn.

WEAR LIMITS New length of four sections .............. 32" (813.0mm) 75% worn ......................................... 32.37"(822.2mm) 100% worn ....................................... 32.50"(825.5mm)

WEAR LIMITS New roller. ................................... 8.26" (210.0mm) 75% worn .................................... 7.64" (194.0mm) 100% worn .................................. 7.36" (187.0mm)

NOTE: Allowable wear in rocky ground is 75% NOTE: These wear limits are to be used as a guide for when to turn the pins and bushings. If pins and bushings are not to be turned, the chain can be run past the 100% wear limit, until chain failure.

11.23

Tigercat T250 Loader

Track drive

IDLER WEAR Measure the idler wheel side diameters (tread contact surface) at several points to obtain the worst wear condition. Position a depth gauge or measuring tape as close as possible toward the centre of the idler with the gauge flat on the centre flange and parallel to the idler shaft.

BERC-7

MEASURING IDLER WEAR

WEAR LIMITS New idler dimension ...................... 0.85"(22.0mm) 100% wear .................................... 1.18"(30.0mm)

11.24

Tigercat T250 Loader

SECTION 12 - BOOM FUNCTIONS NOVEMBER 2003

CONTENTS - SECTION 12 ADJUST OIL FLOW TO CYLINDERS (CYLINDER CYCLE TIMES ............ 12.6 BOOM CONTROL VALVE ........................................................................... 12.2 SEE ALSO SECTON 4 BOOM SYSTEM DESCRIPTION ................................................................. 12.2 CIRCUIT SCHEMATIC ................................................................................ 12.3 CYLINDER CYCLE TIMES, TYPICAL ......................................................... 12.6 ENGINE ANTI-STALL .................................................................................. 12.2 SEE ALSO SECTON 4 LOAD SENSING .......................................................................................... 12.2 SEE ALSO SECTION 9 PRESSURE SETTINGS .............................................................................. 12.4 PRESSURE SETTINGS, SUMMARY .......................................................... 12.6

Tigercat T250 Loader

Boom functions

BOOM SYSTEM DESCRIPTION

LOAD SENSING\ENGINE ANTI-STALL

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

The boom hydraulics along with the other circuits operated from the Linde main control valve are all included in the load sensing system incorporated into the main hydraulic circuit.

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

For a full description of the main hydraulic system including load sensing, the main pump and the main control valve, Refer to SECTION 4 in THIS MANUAL.

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

For a full description of the engine anti-stall, Refer to SECTION 9 in THIS MANUAL.

BOOM CONTROL VALVE

For a full description of the pilot system including the joystick handles, Refer to SECTION 5 in THIS MANUAL.

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

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

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

To adjust the relief valves, Refer to SET HOIST BOOM AND STICK PORT RELIEF VALVES in THIS SECTION. To adjust oil flow, Refer to ADJUST OIL FLOW TO CYLINDERS in THIS SECTION.

STICK 'IN' PORT RELIEF

FLOW ADJUSTING SCREW FOR PORT 'A' (TYPICAL)

HOIST 'DOWN' PORT RELIEF

• • •

B B B B

A

B A

B

A A A

A

• •

•

VIEWED FROM BELOW CONTROL VALVE MANIFOLD T250-03

HIGH PRESSURE LIMITING CONTROL

•

•

MAIN CONTROL

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

12.2

HOIST 'UP' PORT RELIEF

Tigercat T250 Loader

250T-18

Boom functions

BOOM HYDRAULIC CIRCUIT 12.3

Tigercat T250 Loader

Boom functions

PRESSURE SETTINGS

3.

Start engine and set throttle to 1200 rpm.

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

4.

From inside the cab close and latch the cab door.

5.

Lower the LH. arm rest and press the PILOT RESET switch to activate the pilot system.

6.

Place ANTI-STALL switch to OFF position.

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

CAUTION Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

SPOOL TRAVEL STOP • 19mm WRENCH • 6mm ALLEN KEY

•

•

ADJUSTING SCREW • 5mm ALLEN KEY

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

•

PORT RELIEF VALVE

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

MAIN VALVE BODY

• •

LOCKNUT • 17mm WRENCH

IMPORTANT

PILOT END CAP

•

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

1.

90744-3

7.

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

8.

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

With hydraulic oil at operating temperature,

L.S. GAUGE TEST CONN.

•

HIGH PRESSURE LIMITING CONTROL (HPLC)

LINDE MAIN VALVE MANIFOLD

•

••

• 'P' GAUGE TEST CONN.

2.

•

103-17A

GAUGE TEST PORTS

MAIN VALVE PORT RELIEF VALVE

LOAD SENSING RELIEF VALVE (P2)

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

12.4

Tigercat T250 Loader

Boom functions

HOIST BOOM PORT RELIEFS: NOTE: When making these relief adjustments, the upper frame should be positioned with the boom in the staight ahead position between the tracks.

9.

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

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

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

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

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

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

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

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

STICK PORT RELIEFS 17. Repeat steps 8 thru' 15 to set the port relief valves for the STICK 'IN' and 'OUT' functions.

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

18. Readjust L.S. pressure relief valve on Linde main valve manifold to read 4500 psi on pressure gauge at 'P' port (4200 psi at 'LS' port). Refer to SET LOAD SENSE RELIEF VALVE in SECTION 4 of THIS MANUAL.

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

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

19. Stop engine, remove all gauges and reinstall plugs and caps.

STICK 'IN' PORT RELIEF

FLOW ADJUSTING SCREW FOR PORT 'A' (TYPICAL)

HOIST 'DOWN' PORT RELIEF

• • •

B B B B

A

B A

B

A A A

A

• •

•

VIEWED FROM BELOW CONTROL VALVE MANIFOLD T250-03

HIGH PRESSURE LIMITING CONTROL

•

•

MAIN CONTROL 12.5

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

HOIST 'UP' PORT RELIEF

Tigercat T250 Loader

Boom functions

ADJUST OIL FLOW TO CYLINDERS (CYLINDER CYCLE TIMES)

FLOW ADJUSTING SCREW FOR PORT 'A' (TYPICAL)

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

1.

Hydraulic oil must be at operating temperature.

2.

Start engine and place engine throttle control in FULL position.

3.

From inside the cab close and latch the cab door.

4.

Lower the LH. arm rest and press the PILOT RESET switch to activate the pilot system.

5.

Place ANTI-STALL switch to OFF position.

6.

HOIST BOOM CYLINDER; Fully retract cylinder.

7.

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

8.

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

Record cycle time from start until cylinder hits cushion.

9.

HOIST 'DOWN' PORT RELIEF

• • B B B A A

A

• • (VIEWED FROM BELOW) T250-03

FLOW ADJUSTING HOIST 'UP' SCREW FOR PORT PORT RELIEF 'B' (TYPICAL)

MAIN CONTROL VALVE

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

STICK BOOM CYLINDER; Repeat steps (7) and (8) using STICK BOOM joystick lever.

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

** When extending or retracting the cylinders to record the time, it is better to stop the cylinder just before it gets to the end of it's stroke rather than let SUMMARY: it bottom out and impose unnecessary loads on the 1. Ensure hydraulic oil is at operating cylinder parts and boom structures.

temperature.

TYPICAL CYLINDER CYCLE TIMES

2. Connect gauge to 'LS' port.

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

3. Start engine, throttle to 1200 rpm..

4. Turn hoist and stick port reliefs in.

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

6. Set HOIST UP port relief.

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

7. Set HOIST DOWN port relief.

8. Set STICK UP port relief.

9. Set STICK DOWN port relief.

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

11. Set cylinder cycle times.

12. Stop engine.

12.6

Tigercat T250 Loader

SECTION 15 - SWING MARCH 2004

CONTENTS - SECTION 15 GEARBOX, SWING DRIVE ....................................................................... 15.13 SWING BEARING WEAR LIMITS ............................................................. 15.14 SWING DRIVE SERIAL NUMBER 250T0111 TO 250T0115 CIRCUIT DESCRIPTION ...................................................................... 15.3 CIRCUIT DIAGRAM .............................................................................. 15.6 CONTROL VALVE ................................................................................. 15.2 FOOT PEDAL CONTROL VALVE ......................................................... 15.2 MOTOR ................................................................................................. 15.3 MOTOR SCHEMATIC DIAGRAM ......................................................... 15.3 MOTOR SPEED, ADJUST OIL FLOW .................................................. 15.5 PILOT MANIFOLD ................................................................................ 15.2 PRESSURE SETTINGS ....................................................................... 15.4 PUMP .................................................................................................... 15.2 SUMMARY, PRESSURE SETTINGS .................................................... 15.5 SWING BRAKE ..................................................................................... 15.4 SERIAL NUMBER 250T0131 AND UP CIRCUIT DESCRIPTION .................................................................... 15.10 CIRCUIT DIAGRAM .............................................................................. 15.7 CONTROL VALVE ................................................................................. 15.9 FOOT PEDAL CONTROL VALVE ......................................................... 15.8 MOTOR ............................................................................................... 15.10 MOTOR SCHEMATIC DIAGRAM ....................................................... 15.10 PILOT MANIFOLD ................................................................................ 15.8 PRESSURE SETTINGS ..................................................................... 15.11 PUMP .................................................................................................... 15.8 SUMMARY, PRESSURE SETTINGS .................................................. 15.13 SWING BRAKE ................................................................................... 15.13

Tigercat T250 Loader

Swing

SWING DRIVE COMPONENTS

PILOT MANIFOLD

SERIAL NUMBER 250T0111 TO 250T0115

'PB' TO STABILIZER PILOT MANIFOLD

SWING PUMP

SWING BRAKE

MAIN (SWING) PUMP

PILOT SHUT OFF VALVE

•

PILOT RELIEF VALVE

•

•• • BELL HOUSING

•

RETURN OIL TO TANK (CASE DRAIN CON.)

••

230B-04

AUXILIARY PUMP

•

•

• GAUGE TEST PORT

PILOT MANIFOLD ASSEMBLY

One solenoid operated pilot valve (position 4) on the pilot manifold controls the flow of pilot oil to operate the swing brake function.

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

250-07

MAIN PUMP (SWING) S/N 250T0111 T0 250T0115 The hydraulic pump used for the swing system in this serial number range is the main pump. For a more detailed description of this pump, refer to MAIN PUMP in SECTION 4 of THIS MANUAL. FOOT PEDAL CONTROL VALVE The swing function is controlled by the center foot pedal valve which sends proportional pilot signals to the swing valve to supply oil to the swing motor.

SWING CONTROL VALVE SERIAL NUMBER 250T0111 TO 250T0115 The swing control valve is a spool section on the Linde main control valve which is described in detail in SECTION 4 of THIS MANUAL. The speed of rotation or swing speed can be increased or decreased by adjusting the spool travel stop screws in the end caps of each spool section. See ADJUST SWING MOTOR SPEED in THIS SECTION.

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

CONTROL VALVE MANIFOLD

SWING SPOOL SECTION

•

CCW ROTATION

B

••

•

A CW ROTATION

• VIEWED FROM BELOW

• T250-02

HIGH PRESSURE LIMITING CONTROL

MAIN CONTROL VALVE (S/N 250T0111 TO 250T0115) 15.2

FLOW ADJUSTING SCREW FOR PORT 'B' (TYPICAL)

Tigercat T250 Loader

Swing R.H. ROTATION

CROSSLINE RELIEF VALVES

MOTOR

•• •••

•

SWING MOTOR SERIAL NUMBER 250T0111 TO 250T0115 The swing motor is a fixed displacement piston motor with crossline relief valves mounted on the input end. The crossline relief valves provide a cushion to the high forces that occur during start and stop of the boom swing.

L.H. ROTATION

SWING CIRCUIT DESCRIPTION SERIAL NUMBER 250T0111 TO 250T0115 SWING BRAKE

1/16" DIA. ORIFICE CONNECTOR PORT 'U'

• •• GEARBOX

•• 845B-D32

SWING DRIVE GEARBOX CONNECTOR/ ORIFICE 0.062" DIA SWING BRAKE

•

GEARBOX FLUSHING OIL SUPPLY FROM OIL COOLER BYPASS/ RETURN MANIFOLD

FROM BRAKE RELEASE PILOT

•

The swing spool valve section on the main control valve receives oil from the main pump. When the swing foot pedal in the cab is pressed either to the left or right, pilot pressure acts on the end of the spool in the swing spool section of the main valve and shifts the spool to direct oil to the swing motor and cause rotation. The swing circuit is not part of the load sensing system due to the cross line relief valves on the motor being set at a lower value than the load sensing relief valve (P2) on the main valve HPLC valve.

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

Power is transmitted from the motor to a double reduction planetary gearbox which has a springapplied, hydraulic-release, multi-disc brake on the input shaft.

Continued on page 4

• CROSS LINE RELIEF VALVES

PRESSURE LINES FROM MAIN CONTROL VALVE

830-16

SWING DRIVE MOTOR SCHEMATIC

15.3

Tigercat T250 Loader

Swing PRESSURE SETTINGS

Continued from page 3

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

Placing the swing brake switch in the OFF position energizes the swing brake solenoid pilot valve on the pilot manifold and allows pilot oil pressure to flow to the swing brake via port 'Y', to release the brake.

ALTERNATE BRAKE RELEASE PORT 'Z' (PLUGGED)

•

STEEL DISC FLUSHING PORT 'T'

FRICTION DISC

• •

•

SET SWING RELIEF VALVES ON "MAIN" VALVE SERIAL NUMBER 25T00111 TO 250T0115 Main valve CW port relief setting .................. No relief Main valve CCW port relief setting ................ No relief Motor crossline relief valves (low setting) ...... 3000 psi SET CROSSLINE RELIEF VALVES 1. Park machine on level ground, lower grapple to the ground and stop engine.

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

CONNECTOR/ ORIFICE 0.062" DIA

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

FLUSHING PORT 'U'

• •

L.S. GAUGE TEST CONN.

• BRAKE RELEASE PORT 'Y'

BK005-8

LINDE MAIN VALVE MANIFOLD

••

••

HIGH PRESSURE LIMITING CONTROL (HPLC)

••

••

'P' GAUGE TEST CONN.

CROSS SECTION OF SWING BRAKE

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

The swing gearbox upper gearing is lubricated by hydraulic oil which flows from the 'PB' port on the auxiliary valve to the 'U' port on the gearbox. A 1/16 inch orifice/connector installed in the 'U' port regulates the flow of oil through the gearbox to approximately 1 GPM. Oil is returned to tank via flushing port 'T'.

WARNING Never drive machine with swing brake ON, If grapple makes contact with an imoveable object, forces could damage swing drive gearbox

103-17A

••

GAUGE TEST PORTS

LOAD SENSING RELIEF VALVE (P2)

4. Start engine and place throttle control in FULL. 5.

From inside the cab close and latch cab door.

6.

Lower the LH. arm rest and press the PILOT RESET switch to activate the pilot system.

7. Turn anti-stall switch OFF and the swing brake ON. 8. While operating the foot pedal fully in both the

CROSSLINE RELIEF VALVES R.H. ROTATION

•• ADJUSTING SCREWS 111-6

15.4

•••

L.H. ROTATION

• •• • • CROSSLINE RELIEF

Tigercat T250 Loader

Swing

LEFT and RIGHT directions, loosen locknut on each crossline relief adjusting screw and turn adjusting screw until the reading on pressure gauge in 'L.S.' test port is 3600 psi for each direction.

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

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

FLOW ADJUSTING SCREW FOR PORT 'A' (TYPICAL)

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

SWING SPOOL SECTION

•

CCW ROTATION

B

••

10. Stop engine, remove gauge and reinstall plug.

A

ADJUST OIL FLOW TO SWING MOTOR (SWING MOTOR SPEED)

CW ROTATION

SERIAL NUMBER 250T0111 TO 250T0115 NOTE: Constant loosening and tightening of the locknut (sealnut) on the adjusting screws will eventually cause the seal in the nut to break down and leak. Because of this it is best to keep the adjusting procedure brief.

• •

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

From inside the cab close and latch cab door.

4.

Lower the LH. arm rest and press the PILOT RESET switch to activate the pilot system.

T250-02

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

7. Repeat step (6) with foot pedal in 'FULL RIGHT' position.

•

VIEWED FROM BELOW

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

5. Turn anti-stall switch OFF and the swing brake ON.

SPOOL TRAVEL STOP • 19MM WRENCH • 6MM ALLEN KEY

FLOW ADJUSTING SCREW FOR PORT 'B' (TYPICAL)

MAIN CONTROL VALVE (S/N 250T0111 TO 250T0115) 5. To adjust swing speed;

2. Start engine and place throttle control in FULL. 3.

CONTROL VALVE MANIFOLD HIGH PRESSURE LIMITING CONTROL

•

SUMMARY: SERIAL NUMBER 250T0111 TO 250T0115 1. Position machine on level ground.

2. Ensure hydraulic oil is at operating temperature.

3. Connect gauge to "LS" port.

4. Start engine, FULL rpm.

PILOT END CAP

•

5. Turn anti-stall switch OFF. 6. Turn swing brake ON

MAKE UP VALVE

•

Set swing motor crossline reliefs:7. Set SWING LEFT crossline relief.

8. Set SWING RIGHT crossline relief.

MAIN VALVE BODY

9. Set swing speed (spool travel stops)

• 90919-1

MAIN VALVE SPOOL TRAVEL STOP 15.5

Tigercat T250 Loader

250T-21

Swing

SWING DRIVE CIRCUIT SERIAL NUMBER 250T0111 TO 250T0115 15.6

Tigercat T250 Loader

250T-22

Swing

SWING DRIVE CIRCUIT SERIAL NUMBER 250T0131 AND UP 15.7

Tigercat T250 Loader

Swing

SWING DRIVE COMPONENTS

FOOT PEDAL CONTROL VALVE

SERIAL NUMBER 250T0131 AND UP SWING PUMP On these later machines the swing pump manufacturer may vary but they are all axial-piston variable displacement pumps controlled by a pressure compensator.

MAIN PUMP

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

For a detailed description of the foot pedal control valve refer to SECTION 5 in THIS MANUAL. PILOT MANIFOLD 'PB' TO STABILIZER PILOT MANIFOLD

•• BELL HOUSING

• •• •

SWING BRAKE

•

•

PILOT RELIEF VALVE

•

PRESSURE COMPENSATOR

•

• SWING PUMP (LINDE SHOWN)

PILOT SHUT OFF VALVE

RETURN OIL FROM STABILIZER PILOT MANIFOLD 230B-04

•

GAUGE TEST PORT

PILOT MANIFOLD ASSEMBLY

One solenoid operated pilot valve (position 7) on the pilot manifold controls the flow of pilot oil to operate the swing brake function.

250-07

250-13

SWING PUMP S/N 250T0131 AND UP

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

SWING PUMP SCHEMATIC

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

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

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

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

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

15.8

Tigercat T250 Loader

Swing

SWING CONTROL VALVE SERIAL NUMBER 250T0131 AND UP

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

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

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

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

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

OUTLET SECTION

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

SWING 'CCW' PORT RELIEF (TURN FULLY IN)

•

•

SWING

•

•

INLET SECTION

AT041ZIL

•

RELIEF VALVE PORT 'A'

MAIN RELIEF (4000 PSI)

GAUGE TEST PORT

RELIEF VALVE PORT 'B'

SEAL GROOVES

A

B SPOOL CENTERING SPRINGS

•

• • •

•

•

•

• • • PILOT END CAP

AT041YIL

•

•

• •

• SPOOL TANK PASSAGE

PARALLEL PASSAGE

LOAD CHECK VALVE

THRU' NEUTRAL PASSAGE

WORK PORT BRIDGE

TANK PASSAGE

SWING CONTROL VALVE SERIAL NUMBER 250T0131 AND UP 15.9

PILOT END CAP

Tigercat T250 Loader

Swing

SWING MOTOR SERIAL NUMBER 250T0131 AND UP

SWING CIRCUIT DESCRIPTION

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

The swing circuit is supplied with hydraulic oil by a variable displacement piston pump. The swing valve receives oil at the inlet section and directs it through the three open center spool sections, to the outlet section. From there it is directed back to tank via the oil cooler, a check valve to the return manifold and four dual element filters. A 50 psi. relief valve is installed in the oil cooler line to bypass the oil around the oil cooler, usually on cold start ups when the oil is cold and thicker.

CROSS LINE RELIEF VALVES

•

SERIAL NUMBER 250T0131 AND UP

PRESSURE PORTS

••

ORIFICE CONNECTOR PORT 'U'

••

• • •• •

CASE DRAIN LINE

••

•

SWING BRAKE

TEE'D TO FOOT PEDAL PILOT LINES

SWING MOTOR

250-13

SWING BRAKE

ORIFICE FROM BRAKE RELEASE PILOT

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

•

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

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

Internal leakage in the swing motor is returned to tank via the case drain port on the motor, through the in-tank strainer.

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

• • •

• 2 - STAGE CROSS LINE RELIEF VALVES

SYSTEM PRESSURE LINES

PRESSURE LINES FROM CONTROL VALVE

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

15.10

Tigercat T250 Loader

Swing

PRESSURE SETTINGS SET SWING RELIEFS ON "SWING" VALVE SERIAL NUMBER 250T0131 AND UP Swing main relief valve setting .............. 4000 psi C/Clockwise port relief setting ...... Turned fully IN Clockwise port relief setting ......... Turned fully IN Motor crossline relief valves (low setting) ......................................... Non adjustable 2000 psi Pump compensator setting .................... 3600 psi Pump standby setting .................... Turned fully IN

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

CAUTION Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

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

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

1. Park machine on level ground, lower grapple to the ground and stop engine.

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

Continued on page 12

15.11

Tigercat T250 Loader COMPENSATOR ADJUSTING SCREW

Swing STANDBY ADJUSTING SCREW

STANDBY ADJUSTING SCREW

•

COMPENSATOR ADJUSTING SCREW

••

PRESSURE COMPENSATOR

• 217-21

•• •

PUMP PRESSURE COMPENSATOR (LINDE) MAIN PUMP

••

SWING PUMP

• BELL HOUSING

••

SWING PUMP (PARKER)

250-12

• ••

COMPENSATOR ADJUSTING SCREW

PRESSURE COMPENSATOR

••

SWING PUMP

• •

STANDBY ADJUSTING SCREW

PRESSURE COMPENSATOR 250-07

SWING PUMP (LINDE)

Continued from page 11

•

3. On the swing pump compensator valve: •

•

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

Tighten the jamnut.

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

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

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

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

7. Place swing brake in ON position.

SWING PUMP 250-11

SWING PUMP (KAWASAKI)

8. Start the engine** and put throttle control to the IDLE position. **CAUTION: Before starting engine, ensure relief valve is unscrewed as stated in step 5, otherwise damage could occur to the piston pump.

9.

From inside the cab close and latch the cab door.

10. Lower the LH. arm rest and press the PILOT RESET switch to activate the pilot system.

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

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

15.12

Tigercat T250 Loader

Swing

13. Set throttle to FULL rpm.

SWING DRIVE GEARBOX

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

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

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

16. The adjusting screw on the STANDBY valve must remain screwed fully IN. 17. Stop engine. Remove pressure gauge and wipe up any excess oil from test port area.

ALTERNATE BRAKE RELEASE PORT 'Z' (PLUGGED)

SUMMARY:

STEEL DISC FLUSHING PORT 'T'

FRICTION DISC

CONNECTOR/ ORIFICE 0.062" DIA

FLUSHING PORT 'U'

SERIAL NUMBER 250T0131 AND UP 1. Position machine on level ground.

•

2. Ensure hydraulic oil is at operating temperature.

• •

•

•

3. Turn compensator adjusting screw fully in.

BRAKE RELEASE PORT 'Y'

4. Ensure STANDBY adjusting screw is fully in.

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

6. Turn main relief on swing valve out.

7. Connect gauge to "swing" valve.

8. Place swing brake ON. 9. Start engine, IDLE position.

10. Set SWING MAIN relief.

11. Place throttle in FULL position.

12. Set Pump COMPENSATOR. 13. Stop engine.

• •

BK005-8

CROSS SECTION OF SWING BRAKE

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

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

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

WARNING Never drive machine with swing brake ON, If grapple makes contact with an imoveable object, forces could damage swing drive gearbox

15.13

Tigercat T250 Loader SWING BEARING WEAR LIMITS It is important that the swing bearing be periodically inspected for wear. Any significant wear will be noticeable by observing too much "tilting" of the upper frame relative to the lower frame. A small amount of designed-in clearance in the bearing is normal and is present in a new machine.

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

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

Swing The following procedure will verify the amount of wear in the ball race: 1. Position machine with boom fully extended as in position 1.

2. Set indicator to zero.

3. Lower boom as in position 2.

4. Note tilt reading on indicator.

5. Return machine to position 1.

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

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

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

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

A

24

6

POSITION 1

INDICATOR

250T-34 250T-35

DETAIL A 15.14

POSITION 2

Tigercat T250 Loader

SECTION 17 - GRAPPLE NOVEMBER 2003

CONTENTS - SECTION 17 SERIAL NUMBER 250T0111 TO 250T0115 CIRCUIT DESCRIPTION ......................................................................... 17.4 CIRCUIT DIAGRAM ................................................................................. 17.5 CONTROL VALVE, AUXILIARY ............................................................... 17.2 PRESSURE SETTINGS ........................................................................... 17.6 SUMMARY, PRESSURE SETTINGS ....................................................... 17.7 SERIAL NUMBER 250T0131 AND UP CIRCUIT DESCRIPTION ......................................................................... 17.8 CIRCUIT DIAGRAM ................................................................................. 17.9 CONTROL VALVES, MAIN AND AUXILIARY .......................................... 17.2 CYLINDER CYCLE TIMES, ADJUST, OIL FLOW ................................. 17.10 PRESSURE SETTINGS ............................................................. 17.10, 17.11 SUMMARY, PRESSURE SETTINGS ..................................................... 17.12 BOOM CONNECTIONS .............................................................................. 17.4 CONTROL VALVE, JOYSTICK ................................................................... 17.2 GRAPPLE SYSTEM COMPONENTS ......................................................... 17.2 PUMPS ........................................................................................................ 17.2

Tigercat T250 Loader

Grapple

GRAPPLE SYSTEM COMPONENTS

"MAIN" PUMP, GRAPPLE OPEN-CLOSE

MAIN PUMP

•

•

BELL HOUSING

BELL HOUSING

••

•• ••

•• ••

PRESSURE COMPENSATOR

••

PRESSURE COMPENSATOR

AUXILIARY PUMP, GRAPPLE ROTATE & OPEN-CLOSE

"SWING" PUMP, GRAPPLE ROTATE (LINDE SHOWN)

250-07 250-07

GRAPPLE PUMPS S/N 250T0131 AND UP

GRAPPLE PUMP S/N 250T0111 TO 250T0115

PUMP(S) SERIAL NUMBER 250T0111 TO 250T0115

GRAPPLE CONTROL VALVE SERIAL NUMBER 250T0111 TO 250T0115

Supply oil for the grapple OPEN-CLOSE circuit and the grapple ROTATE circuit is provided by the AUXILIARY PUMP which is a pressure compensated axial-piston variable displacement pump controlled by a pressure compensator.

The grapple open/close and rotate functions are controlled by two of the three spool sections in the "auxiliary" valve. This control valve is located in the upper frame below the floor plates inside the valve compartment.

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

For a detailed description of the "auxiliary" control valve, refer to SWING CONTROL VALVE S/N 250T0131 AND UP in SECTION 15 of THIS MANUAL.

PUMP(S) SERIAL NUMBER 250T0131 AND UP Supply oil for the grapple ROTATE circuit is provided by the "SWING" PUMP which is a pressure compensated axial-piston variable displacement pump controlled by a pressure compensator, refer to SWING PUMP in SECTION 15 of THIS SERVICE MANUAL for a detailed description.

Supply oil for the grapple OPEN-CLOSE circuit is provided by the "MAIN" PUMP, refer to MAIN PUMP in SECTION 4 of THIS MANUAL for a detailed description.

JOYSTICK CONTROL VALVE The grapple open/close and grapple rotate functions are controlled by the LH. & RH. joysticks which when moved to the LEFT or RIGHT send a proportional pilot signal to the grapple control valve(s)* to open/close or rotate the grapple.

GRAPPLE CONTROL VALVES SERIAL NUMBER 250T0131 AND UP The grapple rotate function is controlled by one of three spool sections in the "swing" valve and the grapple open-close functions are controlled by one of six (optional 7) spool sections in the "main" valve. The control valves are located in the upper frame below the floor plates inside the valve compartment.

For a detailed description of the "swing" control valve, refer to SWING CONTROL VALVE S/N 250T0131 AND UP in SECTION 15 of THIS MANUAL. For a detailed description of the "main" control valve, refer to SECTION 4 in THIS MANUAL.

*See the following GRAPPLE CONTROL VALVES. For a detailed description of the joystick control valve refer to SECTION 5 in THIS MANUAL. 17.2

Tigercat T250 Loader

Grapple

OUTLET SECTION

GRAPPLE 'OPEN' PORT RELIEF 3500 PSI

• GRAPPLE OPEN/CLOSE

•

OUTLET SECTION

GRAPPLE ROTATE 'CCW' PORT RELIEF 1750 PSI (TIGERCAT)

GRAPPLE 'CLOSE' PORT RELIEF 3500 PSI

•

•

•

GRAPPLE ROTATE

SLASHER

INLET SECTION

•

•

GRAPPLE ROTATE 'CCW' PORT RELIEF 1750 PSI (TIGERCAT)

SWING

•

•

AT041ZIL

GAUGE TEST PORT

•

SLASHER

GRAPPLE ROTATE

•

GRAPPLE ROTATE 'CW' PORT RELIEF 1750 PSI (TIGERCAT)

•

MAIN RELIEF (3300 PSI)

INLET AT041ZIL SECTION GAUGE TEST PORT

GRAPPLE ROTATE 'CW' PORT RELIEF 1750 PSI (TIGERCAT)

• MAIN RELIEF (4000 PSI)

•

"SWING" CONTROL VALVE FOR GRAPPLE ROTATE FUNCTION SERIAL NUMBER 250T0131 AND UP

"AUXILIARY" CONTROL VALVE FOR GRAPPLE FUNCTIONS SERIAL NUMBER 250T0111 TO 250T0115

RELIEF VALVE PORT 'B'

SEAL GROOVES RELIEF VALVE PORT 'A'

A

B

SPOOL CENTERING SPRINGS

•

• • •

•

•

•

• •

•

• PILOT END CAP

•

• •

• SPOOL TANK PASSAGE

LOAD CHECK VALVE

PARALLEL PASSAGE

THRU' NEUTRAL PASSAGE

WORK PORT BRIDGE

TANK PASSAGE

PILOT END CAP

AUXLIARY OR SWING CONTROL VALVE, CROSS SECTION

AT041YIL

S/N 250T0131 AND UP GRAPPLE 'OPEN' PORT RELIEF 3500 PSI

• •

• GRAPPLE SPOOL SECTION

FLOW ADJUSTING SCREW FOR PORT 'A' (TYPICAL)

B

A

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

250T-03

VIEWED FROM BELOW S/N 250T0131 AND UP GRAPPLE 'CLOSE' PORT RELIEF 3500 PSI

•

HIGH PRESSURE LIMITING CONTROL

•• CONTROL VALVE MANIFOLD

"MAIN"/GRAPPLE OPEN-CLOSE CONTROL VALVE SERIAL NUMBER 250T0131 AND UP 17.3

Tigercat T250 Loader

Grapple CIRCUIT DESCRIPTION SERIAL NUMBER 250T0111 TO 250T0115

277-8

GRAPPLE CONNECTIONS

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.

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

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

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

Moving R.H. joystick in the cab will direct pilot oil to the ends of the grapple rotate spool section in the "auxiliary" valve to shift the spool and direct hydraulic oil from the pump to the grapple rotate motor to rotate the grapple either 'CW' or 'CCW'.

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

17.4

Tigercat T250 Loader

250T-24

Grapple

GRAPPLE CIRCUIT SERIAL NUMBER 250T0111 TO 250T0115 17.5

Tigercat T250 Loader

Grapple

CAUTION

STANDBY ADJUSTING SCREW SCREWED FULLY IN, DO NOT ADJUST

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

• ••

CAUTION Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

COMPENSATOR ADJUSTING SCREW

T250-D16

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

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

PRESSURE SETTINGS SET GRAPPLE OPEN-CLOSE AND GRAPPLE ROTATE RELIEF VALVES ON "AUXILIARY" VALVE

AUXILIARY/SWING PUMP (LINDE) PRESSURE COMPENSATOR VALVE

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

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

OUTLET SECTION

GRAPPLE 'OPEN' PORT RELIEF 3500 PSI

• GRAPPLE OPEN/CLOSE

•

SERIAL NUMBER 250T0111 TO 250T0115 Main relief setting .................................... 3300 psi Grapple open port relief setting ............. 3500 psi Grapple close port relief setting ............ 3500 psi Grapple rotate CW port relief setting ... *1750 psi Grapple rotate CCW port relief setting . *1750 psi Pump compensator setting .................... 2900 psi Pump standby setting .................... Turned fully IN

* Set Tigercat grapple to 1750 psi. Set Hultdins grapple to 2900 psi.

3. On the auxiliary pump compensator valve: •

•

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

Tighten the jamnut.

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

•

SLASHER GRAPPLE ROTATE

• GRAPPLE ROTATE 'CCW' PORT RELIEF 1750 PSI (TIGERCAT)

INLET SECTION

GAUGE TEST PORT

•

• •

AT041ZIL

GRAPPLE ROTATE MAIN RELIEF 'CW' PORT RELIEF 1750 PSI (3300 PSI) (TIGERCAT)

•

"AUXILIARY" CONTROL VALVE FOR GRAPPLE FUNCTIONS SERIAL NUMBER 250T0111 TO 250T0115

1. Park machine on level ground.

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

GRAPPLE 'CLOSE' PORT RELIEF 3500 PSI

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

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

8. From inside the cab close and latch the cab door.

9. Lower the LH. arm rest and press the PILOT RESET switch to activate the pilot system.

17.6

Tigercat T250 Loader

Grapple Reset auxiliary pump compensator:-

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

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

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

22. Set throttle to FULL rpm.

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

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

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

SUMMARY:

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

SERIAL NUMBER 250T0111 TO 250T0115

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

2. Ensure that hydraulic oil is at operating temperature.

SET GRAPPLE ROTATE PORT RELIEF VALVES: 14. Position and secure grapple to prevent from turning in either direction.

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

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

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

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

Reset main relief valve:19. Loosen locknut on "auxiliary" main relief and unscrew adjusting screw 3 full turns.

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

Grapple open-close and grapple rotate on "auxiliary" valve:1. Position machine on level ground.

3. Turn compensator adjusting screw fully in.

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

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

6. Connect gauge to "auxiliary" valve.

7. Start engine, idle throttle.

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

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

10. Position grapple to prevent from turning.

11. Set GRAPPLE ROTATE 'CW' port relief on "auxiliary" valve.

12. Set GRAPPLE ROTATE 'CCW' port relief on "auxiliary" valve.

13. Reset main relief.

14. Set engine throttle control to full position.

15. Set pump compensator.

16. Stop engine

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

17.7

Tigercat T250 Loader CIRCUIT DESCRIPTION SERIAL NUMBER 250T0131 AND UP The grapple OPEN-CLOSE circuit is supplied with hydraulic oil by the main pump. The grapple OPEN-CLOSE control valve mounted on the Linde "main" valve manifold receives oil at the two 'P' ports and directs it through the manifold to the six spool sections. When no function is being operated the main pump will de-stroke and provide a stand by pressure of 500 psi and zero flow.

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

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

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

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

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

17.8

Tigercat T250 Loader

250T-23

Grapple

GRAPPLE CIRCUIT SERIAL NUMBER 250T0131 AND UP 17.9

Tigercat T250 Loader

Grapple

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

CAUTION Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

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

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

PRESSURE SETTINGS

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

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

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

11. While holding the L.H. joystick in the CLOSE position, check gauge pressure reading. If less than set value, turn relief valve adjusting screw in until set value is obtained on gauge.

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

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

ADJUST OIL FLOW TO CYLINDERS (CYLINDER CYCLE TIMES)

SET GRAPPLE OPEN-CLOSE RELIEF VALVES ON LINDE "MAIN" VALVE MANIFOLD SERIAL NUMBER 2500141 AND UP

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

Grapple open-close port relief settings ....... 3500 psi 1. Park machine on level ground.

3. Loosen locknuts on both port relief valve adjusting screws on the grapple open-close spool section of the valve and turn adjusting screws out until spring pressure is relieved then turn adjusting screws one full turn in.

GRAPPLE OPENCLOSE SPOOL SECTION

•

OPEN

••

B

CLOSE

5. Start engine and place throttle control in full.

••

6. From inside the cab close and latch the cab door.

8. Turn anti-stall switch off.

••

A

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

7. Lower the LH. arm rest and press the PILOT RESET switch to activate the pilot system.

FLOW ADJUSTING SCREW FOR PORT 'A' (TYPICAL)

GRAPPLE 'OPEN' PORT RELIEF

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

• FLOW ADJUSTING GRAPPLE 'CLOSE' SCREW FOR PORT PORT RELIEF 'B' (TYPICAL) T250-03

VIEWED FROM BELOW

OIL FLOW ADJUSTMENT S/N 250T0131 AND UP

1.

Hydraulic oil must be at operating temperature.

2.

Start engine and place engine throttle control in FULL position.

3. From inside the cab close and latch the cab door.

17.10

Tigercat T250 Loader 4. Lower the LH. arm rest and press the PILOT RESET switch to activate the pilot system.

5. Turn anti-stall switch off.

6.

Fully retract cylinders (grapple open).

7.

Place L.H. joystick lever in 'FULL GRAPPLE CLOSE' position and fully ** extend cylinder.

Record cycle time from stop to stop.

8.

Place L.H. joystick lever in 'FULL GRAPPLE OPEN' position and fully ** retract cylinder.

Record cycle time from stop to stop. ** When extending or retracting the cylinders to record the time, it is better to stop the cylinder just before it gets to the end of it's stroke rather than let it bottom out and impose unnecessary loads on the cylinder parts and boom structures.

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

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

Grapple PRESSURE SETTINGS SET GRAPPLE ROTATE RELIEF VALVES ON "SWING" VALVE SERIAL NUMBER 2500141 AND UP Main relief setting ................................. 4000 psi Grapple rotate port relief settings ..... *1750 psi Pump compensator setting ................. 3600 psi Pump standby setting ................. Turned fully IN

* Set Tigercat grapple to 1750 psi. Set Hultdins grapple to 2900 psi.

NOTE: Ensure that the MAIN relief valve on the swing valve and the PUMP COMPENSATOR valve are set correctly before setting the grapple rotate port relief valves. Refer to PRESSURE SETTINGS in SECTION 15 of THIS MANUAL for this procedure.

1. Park machine on level ground.

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

3. Position and secure grapple to prevent rotation in either direction.

OUTLET SECTION

GRAPPLE ROTATE 'CCW' PORT RELIEF 1750 PSI (TIGERCAT)

GRAPPLE ROTATE 'CW' PORT RELIEF 1750 PSI (TIGERCAT)

•

•

GRAPPLE ROTATE

•

SLASHER

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

SWING

•

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

INLET AT041ZIL SECTION GAUGE TEST PORT

• MAIN RELIEF (4000 PSI)

•

"SWING" CONTROL VALVE FOR GRAPPLE ROTATE FUNCTION SERIAL NUMBER 250T0131 AND UP

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

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

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

7. From inside the cab close and latch the cab door.

Continued on page 12

17.11

Tigercat T250 Loader

Grapple

Continued from page 11

5. Connect gauge to "swing" valve.

8. Lower the LH. arm rest and press the PILOT RESET switch to activate the pilot system.

6. Place engine throttle control at full rpm.

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

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

7. Set GRAPPLE ROTATE CW port relief on "swing" valve.

8. Set GRAPPLE ROTATE CCW port relief on "swing" valve.

9. Release grapple.

10. Stop engine.

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

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

13. Release grapple from it's secured position.

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

SUMMARY: SERIAL NUMBER 250T0131 AND UP Grapple open-close on Linde "main" valve:1. Position machine on level ground.

2. Ensure that hydraulic oil is at operating temperature.

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

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

5. Start engine, full rpm.

6. Turn anti-stall swich off.

7. Set GRAPPLE OPEN port relief on "main" valve.

8. Set GRAPPLE CLOSE port relief on "main" valve.

9. Set cylinder cycle times (oil flow adjusting screws).

10. Stop engine.

Grapple rotate on "swing" valve:1. Position machine on level ground.

2. Ensure that hydraulic oil is at operating temperature.

3. Secure grapple to prevent from rotating.

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

17.12

Tigercat T250 Loader

SECTION 18 - *DELIMBER*/SLASHER NOVEMBER 2003

* NOTE: The DELIMBER function on the T250 Loader is an OPTIONAL installation.

CONTENTS - SECTION 18 CIRCUIT DESCRIPTION ............................................................................. 18.6 CONTROL VALVES ADJUST OIL FLOW, "MAIN" LINDE VALVE .......................................... 18.17 DELIMBER OPEN/CLOSE ("MAIN LINDE VALVE") ................................. 18.4 DELIMBER OPEN/DUMP VALVE ............................................................. 18.5 DIVERTER VALVE, SAWS ....................................................................... 18.5 PILOT MANIFOLD .................................................................................... 18.2 TOP/SLASHER SAW CUT ("AUXILIARY" OR "SWING" VALVE) ............ 18.2 TOP/SLASHER SAW CUT ("MAIN" LINDE VALVE) ................................. 18.4 TOP/SLASHER SAW RETRACT ("AUXILIARY" OR "SWING") ............... 18.2 DELIMBER/SLASHER CONNECTIONS ...................................................... 18.6 FUSE AND RELAY PANEL FOR DELIMBER OPTION ............................. 18.10 PILOT MANIFOLD ....................................................................................... 18.2 PRESSURE SETTINGS ............................................................................ 18.14 PRESSURE SETTINGS, SUMMARY ........................................................ 18.17 PUMPS ........................................................................................................ 18.2 RELAY AND FUSE PANEL FOR DELIMBER OPTION ............................. 18.10 SAW SPEED ADJUSTMENT, OIL FLOW ................................................. 18.17 SCHEMATIC DIAGRAMS DELIMBER OPEN/DUMP VALVE ............................................................. 18.5 DELIMBER/SLASHER CIRCUIT AT REST ............................................ 18.11 DELIMBER/SLASHER SAWS DIVERTER VALVE .................................. 18.5 SYSTEM CIRCUIT S/N 250T0111 T0 250T0115...................................... 18.8 SYSTEM CIRCUIT S/N 250T0131 AND UP ............................................. 18.9 TROUBLESHOOTING DELIMBER RELAY CIRCUIT ............................... 18.10

Tigercat T250 Loader

Delimber/Slasher

DELIMBER/SLASHER CIRCUIT COMPONENTS

DELIMBER OPEN

MAIN PUMP, DELIMBER AND SLASHER

•

• •

BELL HOUSING

PILOT RELIEF VALVE

•

•

•

•

••

PILOT SHUT OFF VALVE

•

••

RETURN OIL TO TANK

PRESSURE COMPENSATOR

•

GAUGE TEST PORT

PILOT MANIFOLD ASSEMBLY PILOT MANIFOLD

230B-04

••

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

AUXILIARY PUMP, (LINDE SHOWN) SLASHER CUT AND RETRACT 250-07

SLASHER CUT TOP/SLASHER SAWS RETRACT

'PB' PLUGGED

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

DELIMBER/SLASHER PUMPS

PUMPS

SLASHER SAW CUT AND SAWS RETRACT CONTROL VALVE (AUXILIARY VALVE RENAMED SWING VALVE ON LATER MACHINES)

Supply oil for the slasher CUT and RETRACT circuit is provided by the AUXILIARY PUMP which is an axial-piston variable displacement pump controlled by a pressure compensator.

For a more detailed description of this pump, refer to SWING PUMP in SECTION 15 of THIS MANUAL. Supply oil for the delimber OPEN, slasher CUT and TOP SAW CUT circuit is provided by the MAIN PUMP. For a more detailed description of this pump, refer to MAIN PUMP in SECTION 4 of THIS MANUAL.

The slasher saw cutting function and the retraction of both the slasher saw and the top saw are controlled by one of three spool sections in the "auxiliary" control valve. A spool section on the "main" valve also supplies a proportion of the oil required for the SLASHER CUT function.

For a detailed description of the slasher control valve, "slasher/auxiliary (swing)" control valve, refer to SWING CONTROL VALVE S/N 2500141 AND UP in SECTION 15 of THIS MANUAL.

18.2

Tigercat T250 Loader

Delimber/Slasher

OUTLET SECTION

• SLASHER SAW 'RETRACT' PORT RELIEF 1500 PSI

SLASHER 'CUT' PORT RELIEF 2500 PSI

•

SLASHER

•

•

•

INLET SECTION AT041ZIL

MAIN RELIEF (4000 PSI)

•

RELIEF VALVE PORT 'A'

GAUGE TEST PORT

SEAL GROOVES

A

RELIEF VALVE PORT 'B'

B

SPOOL CENTERING SPRINGS

•

• • •

•

•

•

• • • PILOT END CAP

AT041YIL

•

•

• •

• SPOOL TANK PASSAGE

PARALLEL PASSAGE

LOAD CHECK VALVE

THRU' NEUTRAL PASSAGE

WORK PORT BRIDGE

'AUXILIARY'/ 'SWING' CONTROL VALVE, SLASHER SECTION

18.3

TANK PASSAGE

PILOT END CAP

Tigercat T250 Loader

Delimber/Slasher DELIMBER 'OPEN' PORT RELIEF 2500 PSI

FLOW ADJUSTING SCREW FOR PORT 'A'

• •• B

A

•• •

••

CONTROL VALVE MANIFOLD T250-02

VIEWED FROM BELOW

SLASHER 'CUT' PORT RELIEF 2700 PSI

•

FLOW ADJUSTING SCREW FOR PORT 'B'

HIGH PRESSURE LIMITING CONTROL

MAIN CONTROL VALVE, DELIMBER/SLASHER/TOP SAW S/N 250T0111 TO 250T0115 SLASHER 'CUT' PORT RELIEF 2700 PSI

FLOW ADJUSTING SCREW FOR PORT 'A'

• • B

A

• •• CONTROL VALVE MANIFOLD T250-03

•

VIEWED FROM BELOW

DELIMBER 'OPEN' PORT RELIEF 2500 PSI

• HIGH PRESSURE LIMITING CONTROL

FLOW ADJUSTING SCREW FOR PORT 'B'

MAIN CONTROL VALVE, DELIMBER/SLASHER/TOP SAW S/N 250T0131 AND UP

DELIMBER, SLASHER AND TOP SAW CONTROL VALVE (MAIN VALVE) The delimber arms OPEN/CLOSE functions, the top saw CUT and the slasher CUT functions are controlled by one of the six spool sections on the Linde "main" control valve manifold.

For a detailed description of the Linde "main" control valve, refer to SECTION 4 of THIS MANUAL.

18.4

Tigercat T250 Loader

Delimber/Slasher

DELIMBER OPEN/DUMP VALVE

DIVERTER VALVE, SAWS The delimber valve is a pilot operated three way directional valve consisting of an aluminum body and a screw-in poppet type pilot operated valve cartridge.

The delimber open/dump valve is a solenoid operated three way directional valve consisting of an aluminum valve body, a screw-in poppet type solenoid operated valve cartridge and a screw-in check valve cartridge.

"D" TO DELIMBER ARMS CYLINDER BASE END, VIA ROTARY MANIFOLD

PORT '3', SUPPLY OIL FROM 'MAIN' VALVE AND 'SWING' VALVE SLASHER CUT PORTS

DELIMBER VALVE

SOLENOID VALVE CARTRIDGE

••

••

• •

• CHECK VALVE PORT '4', SLASHER CUT

"V" SUPPLY FROM DELIMBER VALVE (SWING VALVE) "T" TANK LINE TO STICK VALVE OUTLET SECTION 240B-D25

T250-04

•

PORT '1', PILOT SUPPLY

••

•• ••

PORT '2', TOP SAW CUT

DELIMBER/SLASHER SAWS DIVERTER VALVE

••

DELIMBER OPEN/DUMP VALVE

DELIMBER/SLASHER SAWS DIVERTER VALVE SCHEMATIC In the neutral position with the no pilot pressure at port '1', port '3' (INPUT) is connected to port '2' to operate the top saw. With pilot pressure applied to port '1', (delimber open function), port '3' (INPUT) is connected to port '4' to operate the slasher saw.

250T-27

250-27

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

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

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

18.5

The purpose of the valve in the circuit is to divert hydraulic oil to operate either the TOP SAW CUT function with the DELIMBER ARMS CLOSED or the SLASHER CUT function while the DELIMBER ARMS are OPEN.

Tigercat T250 Loader

Delimber/Slasher

DELIMBER/SLASHER CONNECTIONS Hydraulic connections for the delimber and the slasher are located in a compartment box at the front of the lower frame. Access to the connections is made by removing the cover plate.

LOWER FRAME

HYDRAULIC CONNECTIONS BOX

COVER PLATE

••

•

•

DELIMBER/SLASHER HYDRAULIC CONNECTIONS All five connections consist of two No.16 JIC connectors for the slasher cut and top saw cut functions, two No. 12 JIC connectors for the delimber open and both saws retract functions and a 16 JIC connector for the tank return line function.

DELIMBER/TOP SAW/SLASHER CIRCUIT DESCRIPTION Refer to appropriate CIRCUIT DIAGRAM The delimber/slasher circuit is supplied with hydraulic oil by both the "main" and "auxiliary" (renamed "swing" on later machines) pumps. One spool section in the "main" control valve and one spool section in the "auxiliary" valve hydraulically control all of the delimber or slasher functions.

The "main" control valve receives oil at the two 'P' ports on the back of the "main" control valve manifold and directs it through the manifold to the six spool sections. When no function is being operated the pump will de-stroke and provide a stand by pressure of 500 psi and zero flow.

T250-05

SHUT-OFF VALVES (TYPICAL)

DELIMBER VALVE

DELIMBER OPEN

SAWS RETRACT

TOP SAW CUT

••

•• • ••

••

••

••

SLASHER CUT

DELIMBER/SLASHER TANK HYDRAULIC CONNECTIONS, T250-04 COVER REMOVED All fittings are capped when not in use with special steel JIC caps to prevent leakage, in addition to the caps, shut-off valves are installed in the lines and should be in the CLOSED position when not operating a delimber or slasher.

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

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

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

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

Adjustable spool travel stops on each pilot end cap of the spool section can be adjusted to limit spool travel and control the flow of oil to the delimber arms cylinders and both the slasher and top saw motors and bar cylinders. Controlling the flow of oil to the cylinders also controls the speed.

The "auxiliary/"swing" valve receives oil at the inlet section, from there it is directed through the three open center spool sections, to the outlet section.

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

•• •• DELIMB ARMS OPEN

•• •• DELIMB ARMS CLOSE

LH JOYSTICK

TOP/SLASHER SAW(S) RETRACT TOP/SLASHER SAW(S) CUT

RH JOYSTICK Two push button switches on each of the two joystick handles and two relays (numbers 7 and 8) electrically control the delimber and slasher functions:380-1

380-2

Open delimber arms; Push BOTTOM LEFT L.H. Joystick switch, Current flows through wires GRN D1 to energize the DELIMBER OPEN SOLENOID valve on the pilot manifold and allow pilot oil to shift the spool in the delimber spool section of the "main" valve and direct system oil to the delimber open/dump valve 'V' port.

18.6

Tigercat T250 Loader

Delimber/Slasher

Current also flows through wire GRN D1, diode module (6) and wire GRN SPP to energize the DELIMBER OPEN RELAY (8) and allow current to energize the DELIMBER OPEN/DUMP VALVE SOLENOID. This will allow system oil at 'V' port to pass through the DELIMBER OPEN/DUMP VALVE to the ROTARY MANIFOLD and on to the base end of the DELIMBER ARM CYLINDERS to open the arms.

Jumper wire GRN SPP carries current from the contacts of DELIMBER CLOSE RELAY (7) and wire TAN 88 to "latch" RELAY (8) so that the joystick switch may be released to the spring return center position while the delimber arms remain in the OPEN position. The diode in diode module #6 in wire GRN D1 prevents the current from travelling back to the joystick switch and also the DELIMBER OPEN SOLENOID valve on the pilot manifold, which was de-energized when the joystick switch was released.

Close delimber arms; Push BOTTOM RIGHT L.H. Joystick switch, Current flows through wire GRN 86 and energizes DELIMBER CLOSE RELAY (7).

In this condition current is removed from wire TAN 88 to de-energize DELIMBER OPEN RELAY (8) coil and also de-energize DELIMBER OPEN/DUMP VALVE solenoid.

Oil from the base end of the DELIMBER ARMS CYLINDER is returned to tank via the DELIMBER OPEN/DUMP VALVE 'T' port, this is due to oil entering the rod end of the cylinders from the DELIMBER ACCUMULATOR to close the arms.

Pilot oil flows through the TOP/SLASHER SAW CUT solenoid pilot valve on the pilot manifold to shift the spool in the TOP/SLASHER SAW CUT spool sections of both the "main" valve and the "swing"/"auxiliary" valve to allow an increased volume of system oil to flow to the ROTARY MANIFOLD. The increased volume of system oil is combined at the lower output part of the ROTARY MANIFOLD into a single supply line and directed via the DELIMBER DIVERTER VALVE to the SLASHER SAW MOTOR and the rod end of the SLASHER SAW CYLINDER to run the saw motor and cut with the saw bar.

Due to the DELIMBER OPEN switch having been pressed, the spool in the DELIMBER DIVERTER VALVE will have been shifted to re-direct system oil from the DELIMBER SAW functions to the SLASHER SAW functions.

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

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

Cut with delimber top saw; Push BOTTOM LEFT R.H. joystick switch, Current flows through wires GRN 87 and GRN 39 and energizes TOP/SLASHER SAW CUT solenoid valve on pilot manifold.

Pilot oil flows through the TOP/SLASHER SAW CUT solenoid pilot valve to shift the spool in the TOP/ SLASHER SAW CUT spool sections of both the "main" valve and the "swing"/auxiliary" valve to allow system oil to flow through the ROTARY MANIFOLD to the TOP SAW MOTOR and the rod end of the TOP SAW CYLINDER to run the saw motor and cut with the saw bar.

Cut with slasher saw; Push BOTTOM LEFT L.H. Joystick switch, Push BOTTOM LEFT R.H. joystick switch, Current flows from LH joystick switch through wire GRN D1, diode module (6) and wire GRN SPP to energize the DELIMBER OPEN RELAY (8) and allow current to energize the DELIMBER OPEN/ DUMP VALVE solenoid. Current also flows from R.H. joystick switch through wires GRN 87 and GRN 39 and energizes TOP/SLASHER SAW CUT solenoid valve on pilot manifold.

18.7

Tigercat T250 Loader

250T-26

Delimber/Slasher

DELIMBER/TOP SAW/SLASHER CIRCUIT SERIAL NUMBER 250T0111 T0 250T0115 18.8

Tigercat T250 Loader

250T-25

Delimber/Slasher

DELIMBER/SLASHER CIRCUIT SERIAL NUMBER 250T0131 AND UP 18.9

Tigercat T250 Loader

Delimber/Slasher

FUSE AND RELAY PANEL FOR DELIMBER OPTION

T250-D17BW

1

DIODE MODULE 1

DIODE MODULE 2

DIODE MODULE 3

RELAY 1

RELAY 2

RELAY 3

RELAY 4 2

LOW ENG. OIL PRESS.

PILOT LOCK-OUT

A/CHEATER

LOW HYD. OIL

3 4 5

DIODE MODULE 4

DIODE MODULE 5

DIODE MODULE 6

RELAY 5

RELAY 30

RELAY 31

RELAY 32

WORK LIGHTS

CHARGE TANK

CHARGE TANK

VACUUM TANK

6

RELAY 7

RELAY 8

DELIMBER CLOSE

DELIMBER OPEN

7

GAUGES 5A SAFETY 15A ANTI-STALL 2A JOYSTICKS 15A BK-UP ALRM 15A WIPER/WASH 15A FUEL 10A

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

21552B R0.AI

• •• DELIMB ARMS OPEN

• •• DELIMB ARMS CLOSE

TOP/SLASHER SAW(S) RETRACT TOP/SLASHER SAW(S) CUT

380-2 LH JOYSTICK RH JOYSTICK TROUBLESHOOTING DELIMBER RELAY CIRCUIT If an electrical problem is suspected, the operation of the joystick switches and the delimber relays can be verified with the following procedure.

380-1

DANGER Ensure that all personnel are clear of the delimber and slasher during this trouble shooting procedure. Delimber arms will OPEN and CLOSE and the top saw and slasher saw(s) WILL OPERATE during this procedure

1. With the OPEN delimber arms switch pressed, voltage should be present at wires GRN D1 and GRN SPP, (See fig.1) if so, go to step 2. If voltage is NOT present in wire GRN D1, press the ARMS CLOSE switch and check wire GRN 86, (See fig.2) If voltage IS present at wire GRN 86, there may be a problem with the bottom left joystick switch or in wire GRN D1 from the joystick switch to the instrument panel. If voltage is NOT present in wire GRN 86, check for voltage at wire RED 15 in the instrument panel. If voltage is NOT present at wire RED 15, check 15 amp fuse; if voltage IS present at wire RED 15, check bottom right joystick switch and wiring to switches.

2. With the OPEN delimber arms switch RELEASED, voltage should still remain present at wire GRN SPP but NOT at wire GRN D1, (See fig.3). If this is the case go to step 3. If voltage IS present at wire GRN D1, check diode module no. 1. If voltage is NOT present at wire GRN SPP, check relays 7 & 8.

18.10

Tigercat T250 Loader

Delimber/Slasher

DELIMBER/SLASHER CIRCUIT AT REST 250T-28

3. With the CLOSE delimber arms switch pressed, voltage should be present at wire GRN 86 and voltage at wire GRN SPP will drop to zero, (See fig.2). If voltage on wire GRN SPP does not drop to zero, check relay 7 for operation. With the CLOSE delimber arms switch RELEASED, voltage will drop to zero on wire GRN 86 and will remain at zero on wire GRN SPP. If this does not happen suspect the bottom right joystick switch.

4. With the CUT saw switch pressed, voltage should be present at wires GRN 87/YEL J2/ GRN 39. (See fig. 4) If voltage is NOT present in these wires, suspect the bottom left joystick switch.

5. When the RETRACT saw switch is pressed, voltage should be present in wire GRN 40.

(See fig. 5) If voltage is NOT present in wire GRN 40, suspect the bottom right joystick switch.

18.11

Tigercat T250 Loader

Delimber/Slasher

FIG. 1 OPEN DELIMBER ARMS 250T-29

FIG. 2 CLOSE DELIMBER ARMS 250T-30

18.12

Tigercat T250 Loader

Delimber/Slasher

FIG. 3 DELIMBER ARMS OPEN WITH BOTTOM LEFT SWITCH RELEASED 250T-31

FIG. 4 CUT WITH TOP OR SLASHER SAW 250T-33

18.13

Tigercat T250 Loader

Delimber/Slasher

FIG. 5 RETRACT DELIMBER TOP SAW AND SLASHER SAW 250T-33

PRESSURE SETTINGS SET TOP SAW CUT, SLASHER CUT AND DELIMBER

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

CAUTION Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

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

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

NOTE: The procedure to set the relief valves for the TOP SAW and SLASHER SAW involve setting both the "auxiliary*" valve, "swing*" on later machines and the "main" valve at the same time. This is due to the SLASHER CUT function receiving oil simultaneously from the two valves.

PORT RELIEF SETTINGS ON "MAIN" VALVE Top/slasher saw cut port relief setting . 2700 psi Delimber open port relief setting .......... 2500 psi PORT RELIEF SETTINGS ON AUXILIARY* OR SWING* VALVE

S/N 250T0111 to 250T0115 Main relief setting (auxiliary valve) .... § 3300 psi S/N 250T0131 and UP Main relief setting (swing valve) ........ § 4000 psi Slasher saw cut port relief setting ........ 2500 psi Saw retract port relief setting ............... 1500 psi § Refer to SWING section of THIS MANUAL to set the "AUXILIARY"/"SWING" MAIN RELIEF VALVE. Ensure that these values are correct before proceeding.

18.14

Tigercat T250 Loader

Delimber/Slasher

NOTE: "Main" and "auxiliary*" valves are being set at same time.

SLASHER & TOP SAW CUT/ DELIMBER OPEN SPOOL SECTION

1. Park machine on level ground.

2. Turn off all three shut-off valves (four on earlier machines) at the delimber/slasher hydraulic connections box on the lower frame.

4. Loosen the locknut on port relief valve adjusting screws for the SLASHER/TOP SAW CUT spool section of the "auxiliary*" valve and turn the SAW RETRACT adjusting screw out until spring pressure is relieved then turn adjusting screw one full turn in. Turn the SLASHER CUT adjusting screw all the way in, tighten locknut. NOTE: This is a temporary setting.

SLASHER SAW RETRACT PORT RELIEF 1500 PSI

OUTLET SECTION

•

SLASHER

OPEN

B

•• SLASHER & TOP SAWS CUT PORT RELIEF 2700 PSI

CUT

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

•

VIEWED FROM BELOW

"MAIN" LINDE VALVE FOR DELIMBER AND SLASHER FUNCTIONS S/N 250T0111 TO 250T0115

T250-02

SLASHER & TOP SAWS CUT PORT RELIEF 2700 PSI

FLOW ADJUSTING SCREW FOR PORT 'A' (TYPICAL)

••

GRAPPLE ROTATE

•

•• ••

A

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

SLASHER & TOP SAWS CUT PORT RELIEF 2500 PSI

FLOW ADJUSTING SCREW FOR PORT 'A' (TYPICAL)

DELIMBER 'OPEN' PORT RELIEF 2500 PSI

CUT

•

B

SWING

• INLET AT041ZIL SECTION GAUGE TEST PORT

• •

•

A

MAIN RELIEF (3300 PSI) S/N 250T0111 T0 250T0115 (4000 PSI) S/N 250T0131 AND UP

"AUXILIARY" OR "SWING" CONTROL VALVE FOR SLASHER FUNCTIONS 5. Loosen the locknut on the SLASHER & TOP SAW CUT port relief valve adjusting screw on the "main" valve and turn the adjusting screw out until spring pressure is relieved then turn adjusting screw one full turn in.

6. Loosen the locknut on the DELIMBER OPEN port relief valve adjusting screw on the "main" valve and turn the adjusting screw out until spring pressure is relieved then turn adjusting screw one full turn in.

SLASHER & TOP SAW CUT/ DELIMBER OPEN SPOOL SECTION

OPEN

• •• DELIMBER 'OPEN' PORT RELIEF 2500 PSI

FLOW ADJUSTING SCREW FOR PORT 'B' (TYPICAL)

"MAIN" LINDE VALVE FOR DELIMBER AND SLASHER FUNCTIONS T250-03 S/N 250T0131 AND UP 7. Connect a 0 - 5000 psi.. pressure gauge to the "auxiliary*" control valve test port on the inlet section of the valve.

*NOTE VALVE DESCRIPTION: This valve is labelled "auxiliary" valve on S/N 250T0111 TO 250T0115 and "swing" valve on S/N 250T0131 AND UP. 18.15

Tigercat T250 Loader L.S. GAUGE TEST CONN.

•

Delimber/Slasher 15. While holding the R.H. joystick TOP/SLASHER SAW CUT switch pressed, check gauge pressure reading at "auxiliary*" valve test connection, turn SLASHER CUT port relief valve adjusting screw out until set value (2500 psi) is obtained on gauge.

HIGH PRESSURE LIMITING CONTROL (HPLC)

LINDE MAIN VALVE MANIFOLD

•

••

16. Tighten locknut on adjusting screw taking care not to turn the adjusting screw. SLASHER CUT port relief on "auxiliary*" valve is now set.

• 'P' GAUGE TEST CONN.

8.

LOAD SENSING RELIEF VALVE (P2)

•

103-17A

GAUGE TEST PORTS

17. While holding the R.H. joystick SAW RETRACT switch pressed, check gauge pressure reading at "auxiliary*" valve test connection. If less than set value (1500 psi), turn SAW RETRACT port relief valve adjusting screw in until set value is obtained on gauge.

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

Connect a 0 - 5000 psi.. pressure gauge to the 'L.S.' test port on the back of the "main" valve.

19. While holding the L.H. joystick DELIMBER OPEN switch pressed, check gauge pressure reading at "main" valve 'L.S.' test connection. If less than set value (2500 psi), turn DELIMBER port relief valve adjusting screw in until set value is obtained on gauge.

9. From inside the cab close and latch the cab door.

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

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

11. Lower the LH. arm rest and press the PILOT RESET switch to activate the pilot system.

12. Turn anti-stall switch OFF.

21. Remove pressure gauges and wipe up any excess oil from test port area.

•• • DELIMB ARMS OPEN

•• • DELIMB ARMS CLOSE

TOP/SLASHER SAW(S) RETRACT TOP/SLASHER SAW(S) CUT

380-1 380-2 LH JOYSTICK RH JOYSTICK 13. While holding the R.H. joystick TOP/SLASHER SAW CUT switch pressed, check gauge pressure reading at "main" valve 'L.S.' test connection. If less than set value, turn TOP/ SLASHER SAW CUT port relief valve adjusting screw in until set value (2700 psi) is obtained on gauge.

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

14. Tighten locknut on adjusting screw taking care not to turn the adjusting screw. TOP/SLASHER SAW CUT port relief on "main" valve is now set.

18.16

Tigercat T250 Loader

Delimber/Slasher

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

SPOOL TRAVEL STOP AND LOCKNUT • 19mm WRENCH • 6mm ALLEN KEY

• • •

PORT RELIEF VALVE

••

•

ADJUSTING SCREW • 5mm ALLEN KEY

LOCKNUT • 17mm WRENCH

FLOW ADJUSTING SCREW FOR PORT 'A' (TYPICAL)

•

PILOT END CAP

CUT

B

MAIN VALVE BODY

•

A 90744-3

OPEN

MAIN VALVE PORT RELIEF VALVE

SUMMARY: Set top saw cut, slasher cut and delimber open reliefs on "main" valve and slasher cut and saws retract on "auxiliary" valve:-

• VIEWED FROM BELOW

T250-03

1. Park machine.

FLOW ADJUSTING SCREW FOR PORT 'B' (TYPICAL)

2. Turn off the three accessory shut-off valves.

3. Ensure hydraulic oil is at operating temperature.

"MAIN" LINDE VALVE TYPICAL OIL FLOW ADJUSTMENT

4. Turn SAW RETRACT port relief on "auxiliary" valve out.

To adjust speed; (Refer to fig. 250T-03) Loosen locknut on spool travel stop adjusting screw and turn adjusting screw IN (clockwise) until end of adjusting screw lightly touches end of spool. Do not screw adjusting screw beyond point of contact with spool or spool will begin to move. Back out adjusting screw X turns* and tighten locknut on adjusting screw. Repeat this procedure on opposite end of spool section. *Refer to CYCLE TIMES, FACTORY SETTINGS in SECTION 3 of THIS MANUAL.

5. Turn SLASHER CUT port relief on "auxiliary" valve fully in.

6. Turn SLASHER CUT and TOP SAW CUT port reliefs on "main" valve out.

7. Turn DELIMBER OPEN port relief on "main" valve out.

8. Connect gauges to "main" and "auxiliary" valves.

9. Start engine, FULL rpm.

10. Activate pilot system.

11. Turn anti-stall switch OFF. 12. Set SLASHER CUT port relief on "main" valve.

13. Set SLASHER CUT port relief on "auxiliary" valve.

14. Set SAW RETRACT port relief on "auxiliary" valve.

15. Set DELIMBER OPEN port relief on "main" valve.

16. Remove all gauges.

18.17

Tigercat T250 Loader

Delimber/Slasher

18.18