Service Manual: Tigercat H250B Harvester

SERVICE MANUAL
Tigercat H250B Harvester

ISSUE 1.2, MARCH, 2009
TABLE OF CONTENTS
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
OIL COOLER, RADIATOR AND FAN ............................................................................. 10
TRACK DRIVE ................................................................................................................ 11
BOOM FUNCTIONS ....................................................................................................... 12
SWING ............................................................................................................................ 15
ATTACHMENT ................................................................................................................ 17
H250B-SM00
Tigercat
H250B Available Literature ®
Operator's Manual ....................................... Part No. 31774A
Service Manual (This Manual) .................... Part No. 31775A
Parts Catalog ............................................... Part No. 31776A P.O. Box 544
Paris, Ontario
Canada N3L 3T6
Tel: (519) 442-1000
Fax: (519) 442-1855
Tigercat H250B Harvester Introduction
ii
Tigercat H250B
Harvester Introduction
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 H250B Harvester.
Serial Number 250H0101 and up.
The operator's manual will assist the operator with the techniques of proper and safe operation of the
H250B Harvester. 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.
H250B-016
iii
Tigercat H250B Harvester 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
SECTION 1 - SAFETY
MARCH, 2009
CONTENTS - SECTION 1
BATTERY DISCONNECT SWITCH ........................................................... 1.6, 1.8

COOLING SYSTEM ........................................................................................... 1.8
EXHAUST FUMES ............................................................................................ 1.9
FIRE PREVENTION ........................................................................................ 1.15
DRY CHEMICAL CLEANUP PROCEDURES ................................................ 1.19
FIRE PREVENTION GUIDELINES .............................................................. 1.15
WHAT TO DO AFTER A MACHINE FIRE HAS OCCURRED ........................ 1.18
WHAT TO DO TO PREPARE FOR A MACHINE FIRE ................................... 1.16
WHAT TO DO WHEN A MACHINE FIRE OCCURS ....................................... 1.17
FIRST AID ......................................................................................................... 1.4
FLUID INJECTION INJURY ............................................................................. 1.10
FLUID LEAKS .................................................................................................... 1.8
GREASE INJECTION INJURY ........................................................................ 1.11
LIGHTNING SAFETY AWARENESS
LIGHTNING SAFETY ................................................................ 1.12, 1.13, 1.14
WHAT IS A LIGHTNING STRIKE ................................................................. 1.12
LOOSE CLOTHING HAZARD ............................................................................ 1.9
PROTECTIVE CLOTHING ................................................................................. 1.3
SAFETY PRECAUTIONS, OPERATING ........................................................... 1.5
SAFETY PRECAUTIONS, SERVICING ............................................................. 1.7
SAFETY SYMBOLS .......................................................................................... 1.2
SIGNAL WORDS ............................................................................................... 1.2
Tigercat H250B Harvester Safety
SAFETY SYMBOLS
This safety alert symbol means ATTENTION!

BECOME ALERT! YOUR SAFETY IS INVOLVED!
The safety alert symbol identifies important safety
messages on machines, safety signs, in manuals,
or elsewhere. When you see this symbol, be alert
to the possibility of personal injury or death.
Follow the instructions in the safety message.
Understanding Signal Words
DANGER
DANGER indicates an imminently hazardous

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

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

situation which, if not avoided, may result in minor
or moderate injury.
1.2
These safety rules highlight both general and specific
GENERAL measures that the operator should be familiar with
SAFETY PRECAUTIONS and adhere to. More specific measures are illustrated
with pictograms which may also be attached to the
Remember that safety is a prime responsibility of all. machine in locations pertinent to their respective
message. Keep safety labels in good condition.
To minimize the risks and promote safety at all
Repair or replace damaged labels.
times, this section of the operator’s manual details a
number of safety rules which should always be
followed and obeyed. KEEP CLEAR
Study all the safety messages in this manual and on
When approaching an operating machine on foot,
the labels on the machine carefully.
stay at least 500 feet (150M) away from the machine
Also read and follow the safety section of the and all related attachments until the operator
attachment operator's manual. recognizes your presence. Make sure that all
Follow all instructions from safety inspector and equipment is shut down with attachment resting
supervisors. securely on stable ground before advancing to the
machine.
Always avoid the discharge path of all saws.
Operators of this equipment must be fully trained by Wear a suitable hearing protective device such as
a qualified person in safety and operating procedures. earmuffs or earplugs to protect against noise.
The operator must be fully aware of the capabilities Prolonged exposure to loud noise can cause
and limitations of the equipment and must at no time impairment or loss of hearing.
exceed them. The machine is to be used only for its
intended purpose. Learn the most efficient operating
techniques.
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
Use recommended protective clothing and safety or leaving the cab.
devices such as gloves, safety boots, safety hat, When mounting or dismounting the machine always
goggles, and ear protection when necessary. use the 3 point technique - Use one hand with 2 feet
Fellow workers and other bystanders around the or 2 hands with one foot.
machine must also be provided with the appropriate
safety devices mentioned above.
1.3
When moving the machine, ensure that adequate
GENERAL SAFETY PRECAUTIONS clearance is available on both sides and above the
continued machine or any of its attachments. Extra clearance
may be required particularly where the ground is
uneven.
Approach with extreme caution, any area where
overhanging electrical powerlines are present.
Serious injury or death by electrocution can result if
the machine or any of its attachments are not kept a
safe distance from these lines.
Maintain a minimum distance of 10 ft. (3m) between
the machine or boom and any power line carrying up
to 50,000 volts or less.
Avoid mounting or dismounting the machine in areas
with slippery surfaces. Powerlines carrying more than 50,000 volts require
a minimum safety distance of 10 ft. (3m) plus 1/2
If this is not possible clean up or cover slippery
inch (10mm) for each addition 1,000 volts above the
surfaces with a non-slip material.
50,000 volt level. If State/Provincial, local or job site
Machines should be completely cleaned of debris at regulations require even greater safety distances
least daily, particularly around the engine exhaust than stated above, adhere strictly to these regulations
components. Hydraulic oil leaks, excess grease, for your own protection.
fuel and oil accumulation (including spillage) should
When the machine is transported, make sure that it
be eliminated immediately. Machine should be
is adequately secured to the transporting vehicle.
washed completely at every major service.
Comply with instructions in this manual and also
your company’s regulations for the operation of this
machine.
Read, understand and follow all general safety
precautions specified by attachment and saw
manufacturers.
Access to a cell phone or radio to call for assistance
in an emergency is advised. Be aware that signal
Keep a first aid kit in an easily accessible location on strength for cell phones and radios changes with
the vehicle at all times. terrain and location.
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 WARNING
provided and approved with seating for the operator
Engine exhaust, some of its constituents, and
only.
certain vehicle components contain or emit
Do not allow anyone to operate the machine who chemicals known to the State of California to
may not be physically fit or who may be under the cause cancer and birth defects or other
influence of alcohol or drugs. reproductive harm.
Inspect the machine daily for signs of damage,
unusual wear, fluid leaks, or faulty operation. Repair
or replace malfunctioning parts and systems WARNING
immediately. Battery posts, terminals and related accessories
Do not operate the machine with any defective or contain lead and lead compounds. Wash
inoperable components. hands after handling.
Do not operate the machine with any of the exhaust
system, safety covers, or other devices removed.
1.4
Prior to commencing work, check all equipment
OPERATING controls to ensure that the machine responds
SAFETY PRECAUTIONS correctly.
Ensure that the windshield guard is installed and
properly secured.
Keep the cab door closed when operating the machine

Shut off engine when refuelling - DO NOT refuel the to prevent accidental entry of branches and debris
engine while smoking or when near open flame or into the cab.
sparks.
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 Always rest the attachment on solid ground or trailer
properly and secured. when not operating, regardless if the engine is
running or shut off.
When the engine is running, DO NOT allow anyone
in areas of the machine where they may be injured or
crushed by moving components.
Maintain a safe operating distance between the
machine and other personnel. Never swing the boom
with or without trees, over the heads of bystanders.
Make sure that all of the controls are positioned as Use only prearranged and approved signalling
specified in the starting instructions in the operator's practices.
manual.
Operate the machine only from a seated position in
Check that no other personnel have moved into a the operator’s seat.
hazardous area before starting the machine.
Sound the machine horn before starting the machine.
WARNING
For engine starting and stopping procedures refer

to STARTING ENGINE and STOPPING ENGINE
in SECTION 2 of the THIS MANUAL. For correct
engine speeds, refer to THROTTLE CONTROL in
SECTION 2 of the THIS MANUAL.
Never use a liquid starting aid to start an engine
with a pre-heat device.
1.5
Before transporting the machine:
OPERATING SAFETY PRECAUTIONS
continued • Secure the attachment to the trailer.
Do not allow other people either in the cab or • Shut down the engine and turn the master
anywhere else on the machine. disconnect switch off.
• Check to ensure that all doors, panels and access
covers are installed and properly secured.
WARNING
Always lower the boom to the ground and
shut down the engine before leaving the cab.
Before leaving operator's cab, lower the attachment

onto solid ground or the trailer.
WARNING
When leaving the operator's cab for an extended
period shut the engine off. Safe mounting of this machine onto a trailer
or truck is the responsibility of the owner.
Never work alone. Regularly inform other crew
members of your intentions, location and length of
time to perform duties. DANGER
A falling or swinging load or boom can cause
serious injury or death. Do not operate the
machine 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.
250BTH-
Turn the battery disconnect switch off if the vehicle

is to be idle for an extended period of time
(Example - overnight).
IMPORTANT
24 VOLT
ELECTRICAL SYSTEM
1.6
SAFETY INTERLOCK SWITCH ON LEFT ARMREST:
SERVICING The left arm rest is equipped with a safety
SAFETY PRECAUTIONS interlock switch (1) to prevent the machine from
being operated while the armrest is in the raised
position (pilot system is shut off).
NOTE: The engine can be started but the
machine functions cannot be operated with the
left arm rest up.
ARMREST
•
L.H. ARM REST IN
DOWN POSITION AND
Conduct maintenance inspections at least as LIMIT SWITCH ON
frequently as recommended in section 3 of the
operator's manual. 1
When servicing or repairing equipment, shut the LIMIT SWITCH

ACTUATING LEVER
engine down. Turn Master Disconnect switch OFF. ON SEAT BASE
Install a “DO NOT START ENGINE” sign on the

••
operator’s cab door when making repairs to the
machine. •
247-25 PILOT SYSTEM SHUT OFF
To operate:
With the engine running and the left arm rest
DOWN, push the pilot reset switch.
Before performing maintenance or repair work on any Once the safety interlock system has been
equipment, consult the manufacturer’s instruction activated, the safety of both the operator and
manual and follow recommended procedures. all persons outside the cab becomes the
responsibility of the operator.
The radiator and the engine cooling system should
be inspected daily and cleaned as necessary to The left arm rest safety interlock switch (pilot
maintain moderate engine temperatures. system shut off limit switch) and the pilot
reset switch are a safety feature and their
function must not be defeated in any way.
WARNING
WARNING, HOT FLUIDS AND HOT MACHINE

SURFACES CAN CAUSE SERIOUS BURNS!
• Before servicing the machine, allow the

engine cooling system, fuel system,
exhaust system, hydraulic system and
machine surfaces to cool down.
• Use a thermometer to check surface and
system temperatures to ensure it is safe to
begin service work.
• DO NOT begin service work until the
surface or system temperature has cooled
down to below 100°F (38°C)!
1.7
SERVICING SAFETY PRECAUTIONS

continued WARNING
Diesel fuel or hydraulic fluid under pressure
Prior to welding on any part of the machine, it
can penetrate the skin and cause serious
should be cleaned and a fire extinguisher should
personal injury, blindness, or death. If any
be made available at the welding location. Care
fluid is injected into the skin, it must be
must be taken in attaching the welding machine
surgically removed within a few hours by a
grounding clamp so current does not pass
doctor familiar with treating this type of injury.
through bearings, especially the swing bearing.
240B-003
Never use your bare hand to check for fluid leaks.

Turn the battery disconnect switch off and
disconnect the battery negative terminal. Also, Fluid leaks under pressure may not be visible.
disconnect the engine ground connection from the When searching for leaks, wear work gloves and
frame. use a wrench or piece of wood to move hydraulic
hoses. Do not grab hold of hydraulic hoses. Wear
safety goggles for eye protection.
•
••
••
••
DISCONNECT THE DISCONNECT THE Explosive release of fluids from the pressurized
TWO MULTI-PIN TWO MULTI-PIN
PLUGS FROM THE PLUGS FROM THE cooling system can cause serious burns.
ENGINE CPU ANTI-STALL
CONTROLLER
250B-
Shut off engine. Only remove engine radiator filler
250B-
cap when cool enough to touch with bare hands.
Disconnect the engine CPU (Central Processing
Unit) by unplugging the two multi-pin connectors Slowly loosen cap to first stop to relieve pressure
from the left side of the engine. Also disconnect before removing completely.
the two multi pin connectors on the anti-stall Do not change any pressure or relief setting unless
controller. authorized instruction has been obtained.
Refer also to the attachment operator's manual for Use the proper tool for the job. Repair or replace
welding procedures and precautions. worn or damaged tools including lifting equipment
immediately.
IMPORTANT
24 VOLT
ELECTRICAL SYSTEM
1.8

continued
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 Before draining any fluids, know the proper way to
your head. Remove rings and other jewellery to dispose of them.
prevent electrical shorts and entanglement in moving
parts.
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 attachment or boom,
ensure they are firmly supported.
If the engine is running inside a building, ensure that

sufficient ventilation is available to prevent a build-
up of toxic exhaust fumes. Run the engine only
when it is necessary for testing or adjustments.
Work in a ventilated area. If it is necessary to run an
engine in an enclosed area, use an exhaust pipe
extension to remove toxic exhaust fumes.
If you don't have an exhaust pipe extension, either
work outside, or open the shop doors.
1.9
SERVICING SAFETY PRECAUTIONS WARNING

continued
Diesel fuel or hydraulic fluid under pressure
FLUID INJECTION INJURY
can penetrate the skin and could result in
Hydraulic and diesel fuel systems on forestry death or serious injury. If any fluid is injected
machines operate at very high pressures, often under the skin, a medical doctor familiar with
207 bar (3000 psi) and above. If a loose the treatment of this type of injury must
connection or a defect in a hose should occur, a surgically remove it within a few hours.
fine, high velocity stream of fluid will result. Even
In the event of any suspected fluid injection
for systems pressurized to as little as 7 bar (100
injury
psi), this fluid stream can penetrate human skin
as if it were a hypodermic needle. • Report the injury to your supervisor
immediately.
• Seek professional medical attention
immediately.
As always the best defence against suffering the
effects of fluid injection is to prevent the accident
from occurring in the first place.
When searching for possible fluid leaks
• Never search for leaks with your bare hands.
Initially, an accidental fluid injection beneath the Always wear thick protective gloves.
skin may only produce a slight stinging sensation. • Be sure to wear safety goggles for eye
There is a danger that you will tend to ignore this, protection.
thinking that it will get better with time. Most often,
• Keep all body parts well away from the area
it does not! Within a very short time the wound
being investigated for leaks.
may begin to throb painfully, indicating that tissue
damage has already begun. • Use the end of a long piece of wood to move
hoses or other obstacles.
Similarly fluid injected directly into a blood vessel
can spread rapidly through your circulatory
system. The human body has little ability to purge
injected fluid.
Diesel fuel or hydraulic fluid under pressure can
penetrate the skin and could result in death or
serious injury. If any fluid is injected under the
skin, a medical doctor familiar with the treatment • Place the end of a long piece of wood in the
of this type of injury must surgically remove it suspected path of any fluid stream. Never
within a few hours. use any part of your body.
Time becomes critical as tissue damage • Recognize that the source of the leak and
progresses rapidly. The longer you delay getting the fluid streaming from it may be very small
professional medical attention, the more damage and not easily visible. You may only be able
can occur. to see the fluid that accumulates as a result
of the fluid stream.
Although fluid injection accidents are rare, the
resulting injury has on occasion required the When performing any service work
amputation of a finger, a hand or in some cases • Stop the engine and relieve all diesel fuel or
the entire limb. The longer the delay in getting hydraulic pressure before disconnecting any
professional medical aid, the further up the limb lines or otherwise working on the system.
the tissue damage can spread. An injury of this • Never grab any hydraulic or diesel fuel
type can become very serious or even fatal if not connectors or hoses when they are
dealt with promptly and properly. subjected to pressure.
• Always ensure that hoses are rated for the
pressures to which they will be subjected.
• Never use any hoses that you suspect could
be defective.
1.10

continued
GREASE INJECTION INJURY WHEN
USING PNEUMATIC GREASE GUNS
Pneumatic grease guns can deliver grease at
pressures from 17 - 400 Bar (246 - 5801 psi). It
takes less than 7 Bar (100 psi) to inject a
substance through human skin.
ALWAYS get professional medical treatment
immediately after any type of injection injury.
Provide the physician with information on the type
of grease, the pressure setting of the gun, and
similar details.
The amount of fluid injected, type of fluid (or
material), pressure at which it was injected, and
the elapsed time between injection and surgery all
influence the chances of successful treatment for
this type of serious injury.
Prior to using a high pressure pneumatic grease
gun perform the following:
• All operators of high pressure pneumatic
grease guns MUST be trained in the hazards
of its operations and the treatment for such
injuries.
• DO NOT OPERATE a high pressure
pneumatic grease gun unless you have been
trained in the proper operation and are
aware of all safety precautions of such a
tool.
• Wear protective clothing such as gloves,
safety hat and safety glasses.
• Inspect all parts of the grease gun for wear
and tear and replace all worn or damaged
parts.
• Ensure that protective shrouds are installed
on all grease gun nozzles as safety devices.
• Remove dirt and grease from grease fittings
prior to greasing.
• Replace any defective grease fittings on
equipment with new fittings immediately.
• When badly positioned fittings are identified,
replace them with angled or swivel fittings for
easier access.
1.11
LIGHTNING SAFETY AWARENESS LIGHTNING SAFETY
WHAT IS A LIGHTNING STRIKE? In spite of the popular myth that being struck by
lightning is an unlikely event, the facts show that
Lightning is a discharge of the electricity produced
lightning strikes occur frequently. As a result
by a thunderstorm. As the thunderstorm develops,
loggers are at high risk because their work is
many small particles of ice within the storm
outdoors and close to known strike points such as
clouds bump together. These collisions create a
tall trees and heavy equipment.
positive charge at the top of a cloud and a
negative charge at the bottom. As this continues a Loggers can increase their chances of avoiding a
second positive charge builds up on the ground lightning strike by following a few simple safety
beneath the cloud, concentrated around high practices.
objects such as hills, trees, buildings, equipment
1. Designate a member of your crew to
and even people.
When the difference between the electrical charge
• Monitor daily weather forecasts
in the cloud and on the ground becomes great • Observe local weather conditions
enough to overcome the resistance of the
insulating air between them, an electrical current • Alert all other members of the crew when
flows instantly. This is a lightning strike. a possible lightning threat develops.
The electrical potential in a lightning strike can be 2. Don’t start or continue any work that cannot
as much as 100 million volts. Lightning strikes can be stopped immediately, when a storm
occur over very large distances, even as much as moves nearby.
60 km (37 miles). Lightning travels both in front of 3. Anticipate a high-risk situation and take
and behind a thunderstorm and so strikes happen action early by moving to a low-risk location.
even when rain has not started or has stopped. Do not hesitate. If there is lightning, you are
Lightning can hit in the same place, many times in danger.
and often spreads out over 18 m (60 feet) within
the soil around the strike point. 4. Obey the rule - If you see lightning, Flee. If
you hear thunder, Clear.
Thunder always accompanies lightning. When
lightning occurs, the air through which it travels is 5. Do not follow the now obsolete guideline to
instantaneously heated to a temperature more take shelter when the time between seeing
than 28,000°C (50,000°F). The air expands rapidly lightning and hearing thunder is 30 seconds
due to this heating, then quickly contracts as it or less. This does not provide sufficient time
cools. It is this contracting shock wave that we to ensure safety. Always follow step 4.
hear as thunder. 6. Remain in your safe location for 30 minutes
In many areas of the world, lightning strikes are after the last sight of lightning or the last
second only to flooding as the greatest cause of sound of thunder.
storm related deaths and injuries. Although only The safest location during lightning activity is
10% of lightning strike victims are killed, virtually inside a fully enclosed, substantially constructed
all from cardiac or respiratory arrest, over 70% of building, a house, office, school, shopping area,
those that survive suffer severe, life-long injury etc. These are the safest because of the electrical
and disability. The symptoms of a lightning strike wiring and plumbing that they contain. Should
include memory loss, fatigue, chronic pain, lightning strike, the electrical current will travel
dizziness, sleeping difficulty and the inability to through the wiring or plumbing into the ground.
complete several tasks at one time. When such a building is nearby, always seek
shelter there first.
1.12
LIGHTNING SAFETY CONT'D WHAT TO DO IF YOU ARE OUTSIDE AND SEE
Unfortunately loggers do not often work close to LIGHTNING OR HEAR THUNDER.
buildings and therefore other alternatives need to If you can, get inside.
be considered.
1. Run to the nearest building, motor vehicle or
Sheds, weather shelters, hunting blinds, tents and fully enclosed ROPS equipment cab
other partially open or small structures are not immediately. Being anywhere outside is not
safe against lightning strikes as they lack the safe.
electrically grounded components of larger
buildings. They are intended for sun or rain 2. If inside a building:
protection only. Do not seek shelter from lightning • Don’t watch the lightning storm from open
strikes inside these structures. windows or doorways. Stay in inner
The second safest location during lightning rooms.
activity is inside a fully enclosed car, van, truck or • Stay well away from corded telephones,
bus with a metal roof and metal sides. The electrical appliances, lighting fixtures,
electrical energy of a lightning strike to these radio microphones, electrical sockets and
vehicles is carried to ground by the conducting plumbing pipes and fixtures.
outer metal surfaces. This is called the skin effect.
3. If inside a motor vehicle or fully enclosed
Do not seek safety from lightning strikes in ROPS equipment cab:
vehicles with fiberglass or plastic body shells or in
convertible top vehicles. None of these are safe, • Under no circumstances whatsoever step
as they do not offer skin effect lightning outside of the vehicle or off the equipment
protection. to move to another shelter. Very
dangerous electrical pathways to ground
Heavy forestry equipment such as a skidder, may go through you.
loader, feller buncher, forwarder, etc. with a fully
enclosed rollover protective structure (ROPS) cab • Shut down all operation, turn off the
take advantage of the skin effect and are engine, close all doors and raise all
therefore safe in electrical storms. windows.
However machines with a rollover canopy only are • Sit squarely in the seat with your hands in
not safe against lightning strikes as they are open your lap and your feet flat on the floor mat.
to electrically conductive rainwater and do not • Do not touch any metallic objects
benefit from the skin effect. Operators of this referenced to the outside of the vehicle.
equipment must abandon their machines and get Do not touch any door and window
to a safer location before lightning strikes. handles, control levers, foot pedals,
Note that the rubber tires on motor vehicles and steering wheels, cab interior walls and any
heavy equipment do not increase safety from other inside to outside metal objects.
lightning strikes. Lightning has already travelled a • Do not touch any radio or telephone
great distance through the air to strike the vehicle. connected to an outside antenna.
In comparison a few inches of rubber in a tire
offers absolutely no additional insulation.
1.13
LIGHTNING SAFETY CONT'D What to do if you feel your skin tingling, your
If you are caught outside and have no where hair stands on end, light metal objects vibrate
else to go. or you hear a crackling sound.
1. Avoid wide-open areas where you project 1. Lightning is probably about to strike. You only
above the surrounding landscape. have a few seconds to act.
2. Seek shelter in a low place, such as a ditch, 2. Put your feet together. Crouch down like in a
ravine, valley, canyon or cave. baseball catcher’s position. Hold your head
down. Cover your ears to protect them
3. Get away from open water such as ponds or
against the noise of the thunder.
streams.
3. Do not lie flat on the ground. By touching as
4. Do not take shelter under any isolated tall
little of the ground as possible, the lightning
trees or small groups of trees.
may not move across the ground to you.
5. Seek shelter amongst the dense, thick
What to do if a co-worker has been struck by
growth of the shortest trees.
lightning.
6. Avoid entering any small enclosures or
1. The victim does not carry any electrical
shelters.
charge. There is no danger to anyone
7. Do not seek shelter under any motor vehicle helping this person. You can touch him or her
or heavy equipment. immediately.
8. Keep clear of any materials that can conduct 2. Call your local emergency response
electricity such as wire fences and gates, telephone number immediately.
metal pipes, poles, rails and tools.
3. If the victim has no pulse, their heart has
9. Stay at least 15m (50 feet) away from metal stopped or they have stopped breathing,
objects such as a fuel tank, a vehicle or start cardiopulmonary resuscitation (CPR) or
machinery without a cab, motorcycle, ATV, mouth –to-mouth resuscitation immediately.
etc. Use a portable defibrillator if one is available.
10. Stay at least 5m (16 feet) apart from any 4. Be careful about staying in the storm to take
other members of a group so that lightning care of the victim. You can get hit by lightning
won’t travel between you. too. If you can, move the victim to a building
as soon as possible.
11. Do not use the telephone except for
emergencies. To further increase your awareness about
lightning safety, see the following web sites.
National Weather Service Lightning Safety
http://www.lightningsafety.noaa.gov
National Lightning Safety Institute
http://www.lightningsafety.com
1.14
4. Clean out all accumulated forest debris
(twigs, pine needles, branches, bark, leaves,
FIRE PREVENTION saw dust, small wood chips) and any other
combustible materials from inside the
machine belly pans or lower machine
structures as well as from areas in proximity
to the engine, fuel and hydraulic oil systems
no less frequently than at the completion of
each work shift.
5. Inspect the machine regularly for any
signs of diesel fuel or hydraulic system
When working in a forest environment, it is leakage. Check for worn or eroded fuel or
impossible to prevent combustible debris from hydraulic lines before starting up any
collecting in tight corners of the machine. This equipment.
debris, in itself, may cause a fire; however, when 6. Clean up any grease, diesel fuel,
mixed with fuel, oil or grease in a hot or confined hydraulic and lubricating oil accumulation
place, the danger of fire is greatly increased. and spillage immediately.
The following fire prevention guidelines should be
7. Steam clean the engine, transmission,
used to supplement the operator’s fire prevention
brake, fuel and hydraulic tank compartments
efforts. In no case should the guidelines be used,
of all equipment at least once a month or
or assumed, as replacements for diligent operator
more frequently when working in logging
efforts at preventing fires.
conditions where large amounts of
The following guidelines will help to keep your
combustible forest debris are present.
equipment up and running efficiently and keep the
risk of fire to a minimum. 8. Use only nonflammable solutions for
1. Maintain a CHARGED fire extinguisher on cleaning the machine and components.
the machine at all times and KNOW HOW TO 9. Inspect the exhaust system daily for any
USE IT. signs of leakage. Check for worn, cracked,
2. Remove debris and blow out dust regularly broken or damaged pipes or muffler. Also
from the air intake doors, engine radiator and check for missing or damaged bolts or
charge air cooler, hydraulic oil cooler, diesel clamps. Should any exhaust leaks or
fuel cooler and air conditioning condenser defective parts be found, repairs must be
core to prevent overheating of the engine and made immediately. Engine exhaust leaks can
hydraulics and to maintain efficient operation cause fires. Do not operate the machine
of the machine. Refer to CLEANING A/C until the exhaust leak is repaired.
CONDENSER, OIL COOLER AND
10. During daily operation of the machine, the
RADIATOR in SECTION 2 of the
occurrence of exhaust leaks are usually
OPERATOR’S MANUAL.
accompanied by a change or increase in
3. Blow off all forest debris and fine organic engine exhaust noise levels. These
material accumulated near hot engine audible warnings cannot be ignored.
exhaust components (turbocharger and Should any exhaust leaks occur during
exhaust manifold as well as exhaust pipes and operation, the machine must be shut down
muffler) at the completion of each work shift or immediately and not put back to work until
more frequently when working in logging the necessary repairs have been completed.
conditions where large amounts of
combustible forest debris are present. Visual 11. Park the machine at least 50 feet away
inspection after blow off to ensure thorough from other equipment at the end of each
cleanliness is vital. Engine exhaust systems shift.
provide numerous small pockets where saw 12. Never leave the machine parked with
dust, small wood chips and other flammable boom, arch or blade suspended off the
forest debris can gather. Even small ground. Should their supporting hydraulic
accumulations close to hot exhaust hoses burn through during a fire, pressurized
components can ignite and smolder. If hydraulic oil may be injected into the fire and
dislodged this smoldering debris can fall into the boom, arch or blade will fall rapidly to the
other areas of the machine and thereby ground.
spread a fire.
1.15
17. AFTER transporting (trucking) a machine
FIRE PREVENTION from one job site to the next, open all doors
continued and access panels and blow off any debris
that may have repositioned itself onto the
13. Turn the battery disconnect switch to engine and exhaust parts due to wind
OFF at shut down to de-energize all turbulence caused by the journey.
electrical circuits. 18. Before starting repair work, such as
14. Remain with the machine for at least 45 welding, the surrounding area should be
minutes at the end of operations while the cleaned and a fire extinguisher should be
machine cools. close by.
19. Store rags and other combustible
materials in a safe, fireproof location.
20. Do not use the machine on top of or to push
piles of burning timber. A machine fire will
most probably result.
EQUIPMENT FIRES ADVERSELY EFFECT YOUR

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

• Prevent the fire from happening in the first
place by ensuring that all machine systems
are frequently inspected and always well
maintained.
• Ensure that any hand held fire extinguishers
are charged and in working order. Fire
extinguishers require routine care. Follow the
manufacturer’s instructions for inspection and
maintenance shown on the label of the fire
extinguisher and in the extinguisher
manufacturer's manual.
• Ensure that any pressurized water systems
on the machine (if applicable) are charged
and in working order. Refer to
PRESSURIZED WATER SYSTEM
MAINTENANCE in SECTION 3 of the
OPERATOR’S MANUAL.
• Ensure that you have the proper fire
extinguishers on site. Most fires involving
mobile forestry equipment will be Class A or
15. Remove all keys, lock equipment and fuel B.
cap at the end of operations to reduce the Dry chemical extinguishers should be rated
risk of vandalism. ABC and pressurized water extinguishers
16. Be cautious when smoking. An open should be rated A.
flame, a lighted cigarette, etc., should not be Class A fires involve ordinary combustibles
permitted around any vehicle, especially such as wood, cloth, paper, rubber and many
during fuelling operations or when the fuel plastics, Class B fires occur with flammable
system is open to the atmosphere or when liquids such as diesel fuel, oil and grease and
servicing batteries. Class C fires apply to energized electrical
equipment.
1.16
WHAT TO DO WHEN A MACHINE FIRE OCCURS
FIRE PREVENTION
continued • If operating the machine when a fire occurs:
1. Lower all working attachments to the ground.
• Ensure that the nozzle of any hand held
2. Shut the engine off.
extinguisher and pressurized water system
available on the machine and at the work site 3. Activate the fire suppression system**.
fits within the access holes in the doors of
4. Radio or call for help. Be certain to report a
the machine.
fire immediately.
• Ensure that your fire detection system* is in
working order. Refer to FIRE DETECTION 5. Exit the machine taking fire extinguisher and
SYSTEM in SECTION 2 of the pressurized water system hose (if applicable)
OPERATOR’S MANUAL. with you.
• Ensure that your fire suppression system** is 6. At all times ensure your own personal safety
charged and in working order. Refer to FIRE and the safety of anyone that may be in the
SUPPRESSION SYSTEM in SECTION 2 of area. Approach any fire with extreme
the OPERATOR’S MANUAL. caution. All fires can be very dangerous and
• Ensure that you are familiar with the life threatening.
recommended procedures for fire contained 7. Only if you can safely do so, turn OFF the
in the emergency action plan of your battery disconnect switch.
company.
• Ensure that you follow all national, state / • Before deciding to fight the fire, be certain that:
provincial and local regulations dealing with 1. The fire is small and not rapidly spreading.
fire fighting in effect in your specific
2. There is always a clear, safe escape route to
geographic region. Regulations will vary from
your back.
region to region but most will usually require
that: 3. You have received training in the use of the
1. Workers assigned to fire fighting duties available fire extinguishing systems and are
must be physically capable of performing confident that you can operate them
them safely and effectively. effectively.
2. Workers designated to use fire fighting • Be aware that engine coolant , diesel fuel or
equipment as part of an emergency action hydraulic hoses could fail during a fire. If this
plan must receive full and proper training happens, hot coolant, fuel or oil could possibly
from a qualified instructor. be ignited by the fire.
3. Whenever portable fire extinguishers are
• If in any doubt about whether or not to fight the
provided for use in the workplace, training
fire – DON’T. Instead stand well clear of the fire
must be provided to familiarize workers
and wait for help to arrive.
with the general principles of fire
extinguisher use and the hazards involved • If possible a dry chemical fire extinguisher or
with fire fighting. fire suppression system** should be used first
4. Training must be provided upon initial to fight a machine fire. Then immediately
employment and at least annually afterwards use the pressurized water hose
thereafter. supplied with the machine (if applicable) or a
• Ensure that after you have received the pressurized water extinguisher (if available). A
training as outlined above, that you know fire suppressed by dry chemical may re-ignite
how to use the fire extinguisher, the from the heat retained by any debris in the
pressurized water system (if applicable) and area. The water will cool the area, reducing the
the fire suppression system** on your chances of re-ignition.
machine. There is not enough time available
to read instructions during a fire emergency.
• Ensure that all information necessary for you
to immediately contact all sources of help
(local fire department, etc) in the event of a
fire emergency is recorded and readily
available at all times.
1.17
WHAT TO DO AFTER A MACHINE FIRE HAS
FIRE PREVENTION OCCURRED
continued
• Before returning the machine to work.
• Use the PASS method. This is the most 1. Ensure that the cause of the fire is
effective use of a fire extinguisher. determined and all appropriate repairs are
completed.
• Pull the pin at the top of the extinguisher
that keeps the handle from being pressed. 2. Ensure that the fire detection system* or
Break the plastic seal as the pin is pulled.
the fire suppression system** is properly
• Aim the nozzle at the base of the fire. Do serviced and in working order (if
not aim the nozzle at the flames. In order applicable).
to put out the fire, you must extinguish the
fuel, not the flames. Hose nozzles are 3. Ensure that all extinguishers used in
often clipped to the extinguisher body. fighting the fire are replaced or recharged.
Release the hose before taking aim. • Notify your equipment dealer and / or
• Squeeze the handle to release the Tigercat Industries Inc. by completing an
pressurized extinguishing agent. The incident report, Tigercat form number 5101.
handle can be released at any time to stop
the discharge.
*NOTE: Fire detection systems are offered by
Tigercat as an optional installation on some Tigercat
• Sweep from side to side at the base of the product lines. Please disregard any references made to
fire until the fire is completely out or the fire detection systems if not installed on your machine.
fire extinguisher is empty
**NOTE: Dry chemical fire suppression systems are
offered by Tigercat as an optional installation on some
Tigercat product lines. Please disregard any references
made to fire suppression systems if not installed on
your machine.
TYPICAL FIRE EXTINGUISHER

20229A ACCESS HOLE
• Place the nozzle of the fire extinguisher into
the appropriate fire extinguisher access hole
and discharge the extinguisher.
• Only if you can safely do so, open the
access panels to the machine in the area of
the fire.
• Failing all attempts to access the machine
compartment, discharge the extinguisher
through the mesh or any available openings
on the machine.
• Ensure that the machine and all components
have cooled down sufficiently after a fire so
that re-ignition does not occur.
• Remain with the machine until help arrives.
1.18
DRY CHEMICAL CLEANUP PROCEDURES 3. In areas exposed to heat during the fire, the
dry chemical powder will melt forming a
Both ABC dry chemical fire extinguishers and fire
coating that cakes or crusts on all surfaces.
suppression systems discharge a chemical
powder to extinguish the fire. The chemical To break down the caked dry chemical, spray
makeup and the small particle size of the powder or wash these areas with a 50/50 mixture of
as well as the force of the discharge all contribute hot water and isopropyl alcohol. Allow this
to the fire fighting capability. These same mixture to stand in place for several minutes.
characteristics also permit the powder to
The caked dry chemical when exposed to
penetrate into and fully cover all components in
moisture is also mildly acidic. Therefore when
the vicinity of the discharge.
the break down procedure has been
The following are recommendations for the completed, follow this immediately with the
cleanup and neutralizing of areas exposed to dry neutralizing procedure as described in step 2.
chemical powder.
Workers performing this work should wear
protective clothing, safety goggles and a fine
particle dust mask to minimize their personal
exposure to the dry chemical powder.
Ensure that all electrical systems have been
completely de-energized prior to any cleanup.
1. In areas of the machine that remained cool
and dry during the fire, the dry chemical will
stay in powder form.
Be certain to clean these areas immediately
to prevent any settled residual powder from
coming into contact with moisture whether
through direct contact or humidity in the air.
Remove the powder residue by blowing off
with air, sweeping, dusting or vacuuming
using a HEPA filter capable of trapping the
small dry chemical particles. Then wipe all
surfaces with a damp cloth.
2. In areas exposed to moisture, the dry
chemical powder will combine with water to
form a paste that is mildly acidic. Note that
all surfaces covered by this dry chemical
paste including electrical contacts are
vulnerable to corrosive attack.
To neutralize the acidic paste on large
surfaces, spray or wash these areas with a
mixture of 3 parts hot water to 1 part baking
soda. Allow this mixture to stand for several
minutes before rinsing with warm water.
Wash the area with a mild soap and water
solution. Rinse thoroughly with water. Blow-
dry to remove all residual water.
Cleaning of electrical contacts should be
done using an electrical contact cleaner that
has no flash or fire point and is non-corrosive
and non-conductive such as CRC Contact
Cleaner 2000.
1.19
1.20
SECTION 3 - LUBRICATION & MAINTENANCE
CONTENTS - SECTION 3 MARCH, 2009
AIR CLEANER
FILTER RESTRICTION INDICATOR ......................................................... 3.16
IMPORTANT STEPS TO FOLLOW ........................................................... 3.15
IMPROPER SERVICING .......................................................................... 3.15
MAINTENANCE ........................................................................................ 3.15
UNLOADER VALVE .................................................................................. 3.16
AIR CONDITIONING ..................................................................................... 3.17
APPROVED HYDRAULIC OILS .................................................................... 3.12
CASE DRAIN STRAINER ............................................................................. 3.14
ELECTRICAL SCHEMATIC
SHEET 1 ................................................................................................... 3.27
SHEET 2 ................................................................................................... 3.28
SHEET 3 ................................................................................................... 3.29
SHEET 4 ................................................................................................... 3.30
EMERGENCY EXITS, CHECK MONTHLY ..................................................... 3.6
FILTER RESTRICTION INDICATOR ............................................................ 3.16
FIRE PREVENTION ....................................................................................... 3.6
GENERAL ............................................................................................... 3.5, 3.7
HYDRAULIC PRESSURIZATION SYSTEM ..................................... 3.13, 3.18
HYDRAULIC OIL RETURN FILTERS ............................................................ 3.13
HYDRAULIC OILS ........................................................................................ 3.12
LUBRICATION AND SERVICE POINTS ....................................................... 3.10
NEW MACHINE MAINTENANCE ................................................................... 3.2
FIRST 50-100 HOUR INSPECTION AND SERVICE REPORT .................... 3.2
INITIAL PRE-DELIVERY INSPECTION ...................................................... 3.2
TIGHTENING POINTS ................................................................................ 3.2
OIL LOST FROM LEAKAGE .......................................................................... 3.5
OIL SAMPLE COLLECTION PROCEDURES ................................................. 3.4
OIL SAMPLING PROGRAM ........................................................................... 3.3
PAG OIL ....................................................................................................... 3.17
PILOT PRESSURE FILTER ......................................................................... 3.14
PRESSURE SETTINGS ..................................................................... 3.22, 3.23
PRESSURIZATION HYDRAULIC SYSTEM ........................................ 3.13, 3.18
PREVENTIVE MAINTENANCE SCHEDULE .................................................. 3.2
REFRIGERANT ............................................................................................ 3.17
SCHEDULED MAINTENANCE
EVERY 8 HOURS: ...................................................................................... 3.8
EVERY 125 HOURS ................................................................................... 3.8
EVERY 250 HOURS ................................................................................... 3.8
EVERY 500 HOURS: .................................................................................. 3.9
EVERY 1000 HOURS .................................................................................. 3.9
EVERY 2000 HOURS .................................................................................. 3.9
TORQUE, FLUID CONNECTIONS ...................................................... 3.24, 3.26
TORQUE SETTINGS, RECOMMENDED ...................................................... 3.20
TORQUE SPECIFICATIONS - GENERAL .................................................... 3.20
UNLOADER VALVE ...................................................................................... 3.16
VACUUM PUMP ........................................................................................... 3.19
Tigercat H250B Harvester Lubrication and Maintenance
PREVENTIVE MAINTENANCE SCHEDULE
NEW MACHINE MAINTENANCE
*INITIAL PRE-DELIVERY INSPECTION:-

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

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

THIS REPORT MUST BE COMPLETED AND RETURNED TO
Tigercat Industries Inc. WARRANTY DEPARTMENT.
Tightening points:~
WARNING Check torque on swing bearing
retaining bolts
Engine mounting bolts
Main pump mounting bolts
WARNING, HOT FLUIDS AND HOT MACHINE Swing pump mounting bolts
SURFACES CAN CAUSE SERIOUS BURNS! Swing gearbox mounting bolts
Swing motor mounting bolts
• Before servicing the machine, allow the
engine cooling system, fuel system, exhaust Cab securing bolts
system, hydraulic system and machine Boom pin nuts
surfaces to cool down.
Track shoe bolts
• Use a thermometer to check surface and Track roller retaining bolts
system temperatures to ensure it is safe to
Track sprocket retaining bolts
begin service work.
Track drive gearbox mounting bolts
• DO NOT begin service work until the
surface or system temperature has cooled Track drive motor mounting bolts
down to below 100°F (38°C)! All hydraulic connections
Hose clamps
Pin retainers
IMPORTANT
Any other loose nut, bolt or fitting
Before driving machine ensure that the track
tension (sag) is set correctly.
Track sag may be set less than specified for Refer to diesel engine service manual and
shipping purposes. attachment manual for additional required
maintenance at this scheduled time period.
NOTE: Use of filters other than genuine Tigercat

replacement filters is not recommended.
3.2
TIGERCAT OIL SAMPLING PROGRAM

Effective for all 2008 model year 200 series log loaders sold in U.S.A. and Canada, oil sampling must be
performed during the warranty period as per the schedule below. Warranty coverage of Powertrain
components, specifically main pump, pilot pump (if applicable), swing pump (if applicable), rotary manifold,
swing motor, swing gearbox and swing bearing, main control valves, track motors and final drive
gearboxes (if applicable) is contingent on performance of regular oil sampling at the owner’s expense
during the warranty period.
200 Series
Location First Sample Follow-up Samples
Hydraulic Oil 100 hrs Every 1000 hrs or 6 Months
Swing Drive Gearbox 100 hrs Every Oil Change (500 hours or 3 Months)
Track Drive Gearboxes 100 hrs Every 1000 hrs or 6 Months
(if applicable)
FIRST SAMPLE
There will be no charge for the first oil samples required to be taken during the 100-Hour Inspection
Service that will be scheduled and performed by your Tigercat dealer. Refer to NEW MACHINE
MAINTENANCE in THIS SECTION.
FOLLOW-UP SAMPLES
All follow-up samples must be taken as indicated in the chart above and will be the responsibility of the
machine owner.
Copies of all oil analysis results must be forwarded to the Tigercat Warranty Department for
continued warranty coverage. If samples are taken using the Tigercat Oil Analysis Program, a copy of
all results will automatically be sent to Tigercat.
Tigercat Oil Analysis Kits are available from your Tigercat dealer parts department. If required,
arrangements can also be made with your Tigercat dealer to supply and perform all of the required follow-
up oil samples.
Refer also to OIL SAMPLE COLLECTION PROCEDURES in THIS SECTION for sample valve and drain
plug locations.
TIGERCAT OIL ANALYSIS KITS

Each kit includes a Pre-paid Sample Bottle and Sample Information Form. Pre-printed mailing labels are
also included to ensure all samples are quickly returned directly to the lab for immediate analysis and
results within 24 hours of receipt.
The same type of sample bottle can be used for all types of oil testing including:
Hydraulic Circuits, Final Drives, Axles, Gearboxes, Engines, etc.
To ensure accurate and meaningful results are obtained, each kit also includes detailed instructions on
how properly collect, prepare and ship the oil samples.
Contact your Tigercat Dealer Parts Department to order Kits.
3.3
TIGERCAT OIL SAMPLING PROGRAM

OIL SAMPLE COLLECTION PROCEDURES
Fill out the Sample Information Form (SIF)
completely and accurately. When taking multiple oil
samples, fill out all of the required SIF forms in OIL SAMPLING
CONNECTOR
their entirety, prior to taking any oil samples. Then,
immediately package each completed SIF form •
together with the matching oil sample in the black
outer shipping container as each individual sample
is taken. This will reduce the possibility of mixing
up or incorrectly identifying the SIF forms and oil
samples. Incorrectly identified samples could result
in a false warning alarm.
The accuracy of the lab analysis results is very
dependent on the quality of the oil sample taken. 250B-012 HYDRAULIC OIL RETURN MANIFOLD
Collection of clean oil samples that are Hydraulic Oil Samples:
representative of the main body of oil are essential • Hydraulic oil samples should be taken from the
if meaningful lab results are to be obtained. circulating oil flow at operating temperature,
Erroneous readings may result if proper collection, with no functions actuated, using sample
handling, packaging and shipping practices are not valves that are permanently located on the
followed prior to the sample being tested by the machine whenever possible.
lab. To be able to accurately compare and trend the • To obtain a representative oil sample, sample
lab results over time, all follow-up samples should valves must be purged before the actual oil
be consistently taken from the same location using sample is taken. Drain a minimum of 3 or 4
the same techniques as all previous samples. ounces of oil into a separate container and
discard this oil using approved recycling
• Ensure that all sample valves and drain plugs methods.
are clean and free of debris. • Replace the dust cover on the sample valve
• Remove the sample bottle cap only when immediately after taking the oil sample and
ready to take the sample. Keep the cap clean – sealing the sample bottle.
do not put it in your pocket or let it get
contaminated in any way. Gearbox Samples:
• Do not allow any airborne dirt, etc. to enter the • These samples can be taken during the oil
sample bottle. change process.
• Avoid contamination of the sample – replace • To obtain a representative oil sample, ensure
the sample bottle cap immediately after filling the oil is warm and has not settled very long
the bottle to approximately ¾ full. All samples (within 30 minutes of shutdown).
taken should be immediately forwarded to the • Place the required drain container under the
lab for processing. machine to capture the used oil to be
Contact your Tigercat dealer to purchase additional discarded using approved recycling methods.
or replacement hydraulic sample valves or drain • Remove the drain plug and allow
plugs. approximately 50% of the oil to drain, then
In cases where oil samples must be pumped or place the sample bottle in the stream of
otherwise drawn out of a reservoir or housing, a draining oil to obtain a representative sample.
hand operated oil suction pump is also available
from your Tigercat dealer.
3.4
GENERAL
CAUTION
All handles, steps and platforms must be kept free of grease, oil, fuel mud, snow ice
and forest debris to prevent risk of personal injury
Clean around filler caps before checking or During daily operation of the machine, the
adding fluids. occurrence of exhaust leaks are usually
Clean around hydraulic fittings before breaking accompanied by a change or increase in
connection. Plug or cap immediately. engine exhaust noise levels. These audible
warnings cannot be ignored. Should any
Clean up spills as soon as possible. exhaust leaks occur during operation, the
Always use clean oil and containers. machine must be shut down immediately and
Drain dirty oil while still warm. not put back to work until the necessary
repairs have been completed.
Do not exceed recommended fluid levels.
Always have a fire extinguisher at hand.
Service all hydraulic filters after the failure of a
pump, motor, cylinder or valve. Failures of this For safety, always lower boom assembly to the
nature could contaminate the entire hydraulic ground when leaving cab, leaving machine
system. unattended or during service.
Top up diesel fuel at each shift to reduce
contamination by condensation.
Clean up oil spills in engine enclosure
immediately.
Before welding on machine be sure the
negative battery terminal is disconnected and
the anti-stall controller and all multi pin
connectors from the engine are unplugged.
Also see attachment operator's manual for
welding precautions.
When welding, secure ground connection as
close to working position as possible to
prevent arcing across machined surfaces or
through bearings.
Clean away all branches, bark and chips.
Clean up all traces of oil to avoid fires.
Inspect the EXHAUST SYSTEM DAILY for
any signs of LEAKAGE. Check for worn,
cracked, broken, or damaged pipes or muffler.
Also check for missing or damaged bolts or
clamps. Should any exhaust leaks or defective
parts be found, repairs must be made
immediately. Engine exhaust leaks can cause
fires, DO NOT OPERATE the machine until
the exhaust leak is repaired.
*OIL LOST FROM LEAKAGE

LOST 0IL (LITERS) LOST 0IL (GALLONS)
PER PER PER PER PER PER
LEAKAGE RATE DAY MONTH YEAR DAY MONTH YEAR
ONE DROP IN 10 SECONDS 0.424 12.72 152.0 0.112 3.36 40.0
ONE DROP IN 5 SECONDS 0.852 25.6 306.6 0.225 6.75 81.0
ONE DROP PER SECOND 4.26 127.76 1533.1 1.125 33.75 405.0
THREE DROP PER SECOND 14.2 425.86 5110.31 3.75 112.5 1350.0
DROPS BREAK INTO STREAM 90.83 2725.5 32706.0 24.00 720.0 8640.0
3.5
GENERAL
CHECK EMERGENCY EXIT, MONTHLY:~ FIRE PREVENTION
An alternate exit route is provided: the right side Maintaining your machine properly will greatly
window can be used as an emergency exit. This extend its life and reduce your operating costs.
exit is only to be used if the side door cannot be
Fire can result in a machine loss which can be
opened.
financially devastating.
CAUTION
AFTER transporting (trucking) a machine
from one job sight to the next, open all doors
and access panels and blow off any debris
that could have re-positioned itself onto the
234T-031
SLIDING WINDOW HANDLE engine and exhaust parts due to wind
Open the right side window by lifting the latch turbulence caused by the journey.
handle and slide the window open.
1. Pine needles and bark when allowed to
accumulate, form a fuel source that when
1 ignited is extremely difficult to extinguish. A
thorough program of regular cleaning and
1 •• washing will reduce the possibility of a fire
starting. In the event a fire does start, the
•• INSIDE CAB regular cleaning program will improve the
chances of successfully extinguishing a fire.
2. Pay close attention to wiring and plumbing
routings during maintenance, ensure that ALL
wiring harnesses or hydraulic hoses are
properly restrained and clamped to prevent
damage from chaffing.
3. If equipped, read the fire suppression system
manual and have the system serviced
regularly by qualified personnel.
234T-046 R.H. WINDOW SCREEN
4. In case of fire lower the boom system to the
On machines equipped with window screens, there
ground and shut off the engine before
are two hand knobs (1), one on the inside and one
discharging the fire suppression system.
on the outside that can be removed to open the
window screen. Only one hand knob has to be Also refer to FIRE PREVENTION in SECTION 1 of
removed to open the window screen as follows: THIS MANUAL for additional information.
From inside the cab:
Open the cab window and turn the inside hand
knob (1) counterclockwise to remove the hand
knob and open the window screen. Push the
window screen out to open it. Exit the cab if you
can safely do so.
From outside the cab:
The window screen can also be opened from the
outside by unscrewing the hand knob on the
outside (1) and remove it. When the hand knob is
removed the screen can be swung open.
It is therefore essential that this exit be inspected
monthly to ensure it is operational.
3.6
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
EVERY 8 HOURS:~
• Check engine coolant level Clean:~
• Oil cooler, engine radiator and a/c condensor
• Check engine oil level
• Remove potentially damaging limbs or sticks
• Drain fuel/water separator and all debris
• Check hydraulic oil level
Check:~
• Check swing gearbox oil level • For leakage around hydraulic components and
Fill reservoir to halfway mark flexible hoses
• Check air cleaner unloader valve. • For loose nuts, bolts and fittings
• Check air intake filter restriction indicator. • Condition and tension of fan belts.
Replace primary filter if indicator is in red zone.
• All engine air intake system components
Replace secondary (safety) filter every third (including charge air cooler) rubber elbows,
primary filter change to guarantee maximum connector hoses, tubes and clamps for
performance and reliability. damage, hardening, wear, cracks, leaks, loose
Lubricate:~ clamps or loose hanger bracket hardware and
• Swing pinion; repair or replace immediately.
1-fitting - 10 shots while swinging • Conduct an overall visual inspection.
• Swing bearing; • Refer to diesel engine service manual and
1-fitting - 10 shots while swinging attachment manual for additional required
• ‡ Boom joints; maintenance at this scheduled time period.
4-fittings - purge
• ‡ Cylinders; boom, stick & tilt;
4-fittings total - purge
‡ Lubricating cylinder pins and boom joints:-
1. Ensure machine is on level ground.
2. Fully extend booms and lay attachment
on ground.
3. Slightly force tip of stick boom onto
support but do not lift machine.
4. While in this position lubricate all cylinder
retaining pins and boom joints.
NOTE: This procedure will allow grease
to flow to the normally "loaded" side of
the pin and bearing surfaces.
3.7
EVERY 125 HOURS:~ EVERY 250 HOURS:~
• Perform 8 hour maintenance • Perform 8 hour maintenance
And in addition check:~ • Perform 125 hour maintenance
• Return filters restriction indicator with engine
And in addition:~
running at high idle and oil flow.
• Clean and thoroughly inspect all surfaces of
• Track drive gearbox oil level with both level the main and stick booms for cracks. All cracks
plugs in line with the horizontal plane and must be properly repaired in their early stages.
above center. Note that in most cases cracks will continue to
• Fluid level in batteries unless maintenance grow in size and often lead to major structural
free. damage. Failure to regularly inspect for
cracks and immediately repair the boom
• Engine rpm.
system will void the structural warranty.
• All hydraulic pressures. Contact your Tigercat dealer for specific
• Hydraulic pumps and motor securing bolts. procedures required to correctly repair any
• Torque tightening points as per new machine cracks found.
maintenance.
Visually check for damage to:~
• Main and stick booms and cylinders.
• Tracks, track frames and carbody.
• Swing bearing area.
• Attachment.
Make repairs immediately.
Visually inspect for:~
• Frayed electrical wiring and hydraulic hoses.
• Wear in any other components.
• Charge Air Cooler for damage, wear, cracks,
or leaks and repair immediately.
Clean/replace:~
• Air conditioner re-circulation filter.
• Cab fresh air filter.
• Refer to diesel engine service manual and
attachment manual for additional required
3.8
EVERY 500 HOURS:~ EVERY 1000 HOURS:~
And in addition replace:~ • Perform 500 hour maintenance
• Air intake safety element • Replace oil in track drive gearboxes. Fill track
• Replace engine oil and filter. drive gearbox with both level plugs in line with
• Replace engine fuel filter. the horizontal plane and above center.
• Replace engine fuel/water separator. And in addition check:~

• Hyd. Oil return filters † • Fuel intake strainer
• Hyd. Oil pilot pressure filter †

• Oil in swing gearbox EVERY 2000 HOURS:~
Fill reservoir to halfway mark • Perform 8 hour maintenance
Lubricate:~ • Perform 125 hour maintenance
• Door and cover hinges • Perform 250 hour maintenance
8 fittings - 1 shot
• Perform 500 hour maintenance
Check:~ • Perform 1000 hour maintenance
• Torque on swing bearing and swing gearbox
retaining bolts And in addition:~
• Drain and refill hydraulic oil tank with
• Torque on track drive gearboxes and motor
recommended hydraulic oil. See APPROVED
mounting bolts
HYDRAULIC OILS
• Track rollers and idlers for oil leakage. These • Replace all air intake rubber components such
components are filled with oil and considered as elbows and connectors - High temperatures
maintenance free. If oil leakage is detected in this area can cause the rubber to harden.
repair of component(s) will be necessary. See AIR INTAKE MAINTENANCE in THIS
• Refer to diesel engine service manual and SECTION.
attachment manual for additional required
† NOTE: Use of filters other than genuine Tigercat

replacement filters is not recommended.
3.9
LUBRICATION AND SERVICE POINTS
3.10
3.11
APPROVED HYDRAULIC OILS

Use only one of the following oils to fill or replenish the hydraulic system.
3.12
RETURN 5. Wearing face protection (in case of an oil
MANIFOLD squirt), unscrew the old filter. Dispose of old
filter and any oil properly.
• 6. The new Tigercat filter is supplied with two
gaskets enclosed, examine the filter head
closely to determine which gasket should be
used and follow the instructions to ensure
proper installation.
FILTER
HEAD
•
1-WATER •• •
ABSORBING
RETURN FILTER GASKET
(COLOUR BLUE)
•
•• • • FILTER
ELEMENT
3-HYDRAULIC SQUARE SECTION GASKET INSTALLATION

RETURN FILTERS FILTR_SEALS 2
HYDRAULIC RETURN FILTERS Square Section Gasket

250B-014
HYDRAULIC OIL RETURN FILTERS Remove used gasket and clean groove in
head.
The majority of return oil entering the hydraulic tank
Apply clean oil to new gasket surfaces.
passes through 4 spin-on hydraulic oil filters. One of
the filters is a water absorbing filter (color blue) Install new gasket into groove in filter head.
which is in place to assist with the removal of Screw on new filter until gasket makes contact.
unwanted moisture from the hydraulic oil (the filters Tighten filter an additional 3/4 turn.
are rated 10 micron abs).
DO NOT use bottom nut for filter installation or
Each filter head has a bypass valve with a 25 psi damage/leakage may result. Bottom nut is to
cracking pressure so that oil can bypass the filters if assist in filter removal only.
they become restricted. The "in" side of the filter FILTER
heads are connected to a return manifold. A filter HEAD
restriction indicator and an oil sampling connector •
are mounted onto the manifold. To check the •
condition of the filter elements; With the hydraulic oil GASKET
at normal operating temperature, place engine
throttle control to FULL and with no machine • FILTER
ELEMENT
functions operating, the filter restriction indicator
should be in the GREEN zone. If the pointer is in the
FILTR_SEALS 2 'O' RING GASKET INSTALLATION
RED zone replace all four filter elements.
'O' Ring Gasket
CAUTION Remove used gasket and clean gasket seat in
head.
The hydraulic tank is pressurized by air.
Before servicing the hydraulic system, open Apply clean oil to new gasket surfaces.
the hydraulic tank air vent shut-off valve to Install new gasket on inside lip of filter.
release air pressure on the hydraulic fluid. Screw on new filter until gasket makes contact.
Changing the filters: Tighten filter until top edge makes metal to
metal contact with filter head.
1. Ensure Loader is on level ground with stabilizers (approximately 1 1/2 additional turns after
down. Lower grapple to ground and stop engine. gasket contact)
2. Open the hydraulic tank air vent shut-off valve
DO NOT use bottom nut for filter installation or
and vent the pressure from the hydraulic tank.
damage/leakage may result. Bottom nut is to
See SERVICING HYDRAULIC
assist in filter removal only.
PRESSURIZATION SYSTEM in this section.
3. Wipe clean the area around the filter and head. 7. Start the engine and check for leaks.
4. Place rags below to catch the spillage of oil.
3.13
LOCATED LOWER
LEFT SIDE OF
ENGINE
COMPARTMENT
•• PILOT
FILTER
ELEMENT
250B-016 HYDRAULIC PILOT FILTER

PILOT PRESSURE FILTER
This single full flow filter, is mounted in the output
line between the pilot pump and the pilot manifold.
For service and replacement intervals see 250B-017 CASE DRAIN STRAINER
SERVICE AND LUBRICATION CHART in THIS
Changing the filter or strainer:
SECTION.
1. Ensure Loader is on level ground with
CASE DRAIN STRAINER
stabilizers down. Lower grapple to ground and
The case drain strainer is used to filter all case drain stop engine.
oil from the pumps and motors before it returns to
2. Wipe clean the area around the filter and head.
the reservoir. For service and replacement intervals
see SERVICE AND LUBRICATION CHART in THIS 3. Place rags below to catch the spillage of oil.
SECTION. 4. Wearing face protection (in case of an oil
The strainer element requires no regular squirt), unscrew the old filter. Dispose of old
maintenance over the life of the machine. This filter and any oil properly.
element requires maintenance only in the case of 5. Check the seating area for the gasket on the
damage or contamination due to a hydraulic pump filter head and wipe it clean.
or motor failure.
6. The new filter has an attached gasket, apply
IMPORTANT:
hydraulic oil to the gasket surface.
The strainer element is NOT a filter element.
Always use the correct replacement element. Use 7. Screw on the new filter until the gasket makes
of an incorrect (filter type) element will result in contact with the seat in the filter head.
pump damage. 8. Turn filter an additional 1/2 turn by hand to
SWING PUMP CHARGE PRESSURE FILTER tighten.
The swing pump charge pressure filter is a full flow DO NOT use bottom nut for filter installation or
filter mounted on a filter head with built-in bypass. damage/leakage may result. Bottom nut is to
The filter is located in the output side of the charge assist in filter removal only.
pump. For service and replacement intervals see
SERVICE AND LUBRICATION CHART in THIS 9. Start the engine and check for leaks.
SECTION.
IMPORTANT
Contaminated hydraulic fluid can lead to premature failure of hydraulic components and costly
repairs. Filters must be replaced at the recommended time intervals, Refer to SCHEDULED
MAINTENANCE in THIS SECTION.
Use of hydraulic oil filters other than the Tigercat brand could lead to severe wear and rapid failure
of hydraulic system components.
Filters that are an integral part of the engine (fuel and lubricating oil) should be serviced and replaced
according to the engine manufacturer's operation and maintenance manual.
3.14
In addition to the LUBRICATION AND
MAINTENANCE SCHEDULE, the following
instructions should also be noted. INDICATOR
AIR CLEANER MAINTENANCE

The most common and most damaging air intake
••
servicing problems are:
OVER SERVICING
Filter elements increase in dust cleaning efficiency AIR
CLEANER
as dust builds up on the media. Looks can be UNLOADER
deceiving. A filter that is dirty is actually more
efficient than one that is clean. A filter with dust
VALVE
250B-023
• AIR CLEANER
build up on the media reaches nearly 100% dust AIR CLEANER
cleaning efficiency. Only when a filter is so
clogged with dirt that air restriction goes beyond The air cleaner on this machine uses 2 filter
the engine manufacturer’s guidelines, should be elements, a primary element and a safety element.
replaced. To ensure maximum engine protection, it is
IMPROPER SERVICING important that the elements be serviced correctly
and at proper servicing intervals.
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
SAFETY
replaced at every third primary element change. 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.
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
•• PRIMARY
ELEMENT
may be causing leakage.
6. Inspect the new filter for damage. AIR CLEANER .PLT AIR FILTER ELEMENTS
7. Insert the new filter properly. Apply pressure to
the outer rim of the filter, not the flexible center.
8. Check connection and ducts for air tight fit.
Ensure that all clamps, bolts and connections
are tight. Leaks here send dust directly to the
engine.
3.15
INDICATOR
INDICATOR
• ••
AIR
CLEANER
UNLOADER
250B-023 FILTER RESTRICTION INDICATOR VALVE
250B-023
• AIR CLEANER
FILTER RESTRICTION INDICATOR
AIR CLEANER UNLOADER VALVE
A filter restriction indicator is located in the engine
enclosure to the left of the frame access panel. This rubber valve on the tube of the air cleaner
The indicator is remote mounted and is connected housing should be checked at the beginning of
to the outlet side of the air filter with a 1/4" every shift. (8 hours) If this valve is missing,
diameter hose. Replace the primary air filter when damaged or has become hard, it will cause the air
the indicator shows RED. This indicator provides a cleaner to become ineffective. The unloader valve
continuous reading whether the engine is running should be replaced every 1000 hours.
or is shut down. After replacing the filter, reset the Remove the unloader valve from the tube of the air
indicator by pressing the reset button. cleaner housing.
NOTE: Replace the safety element every third Check and clean the valve. A good valve should be
primary filter change. soft and flexible. If it is plugged, then check the
filter elements, they may need replacing. Re-attach
the valve to the tube.
The valve should suck closed at engine warm-up
speed.
When operating in high dust conditions this valve
should be checked and squeezed every 2 hours to
release dust buildup.
INTAKE TUBING AND JOINTS
Check all air intake system components, rubber
elbows, connector hoses, tubes and clamps for
damage, hardening, wear, cracks, leaks, loose
clamps or loose hanger bracket hardware and
250B-028 AIR CLEANER
repair or replace immediately.
Replace all air intake rubber components such as
elbows and connectors every 2000 hours - High
temperatures in this area can cause the rubber to
harden.
3.16
CHECKING AIR CONDITIONING SYSTEM
CAUTION
IMPORTANT: It is recommended that during cold
weather when the A/C system is not in use, that it If using compressed air for cleaning, use at
be run for a period of 5 minutes every two weeks 30 psi. or less.
to circulate oil to all components of the system. • Always use personal protective equipment
to guard against flying debris.
PAG OIL
R134a REFRIGERANT
(polyalkylene glycol) HINGE OUT A/C
CONDENSER
2 LBS. 15 OZ. 2 OZ.
AIR CHARGE
COOLER
Any service work must be performed by
authorized A/C technicians. The system should
be charged with 2 lbs. 12 oz. of R134a refrigerant. • ••
At least 2 oz. of PAG (polyalkylene glycol) oil RADIATOR
should be present in the system and must be used

on 'O' rings and fittings during assembly.
•
OIL COOLER
••
A/C COMPRESSOR
250B-009 CHECK A/C CONDENSER CORE
Use the following checklist to maintain system
between service intervals. The compressor and
• charge valves are located on the left side of the
engine and accessible through the engine
compartment door. The receiver dryer is located in
the lower engine compartment beside the front left
engine mount and accessible from either
underneath the engine compartment or through
the engine compartment door.
Perform the following checks on system:
a. Check and adjust compressor drive belt
250B-023 tension. Do not over tighten.
A/C COMPRESSOR
b. Check fresh air filter and re-circulating air filter.
Clean or replace as required.
c. Check to see that compressor clutch will
engage.
d. Check blower operation and air vents.
e. Check the condenser core for dirt and debris.
3.17
SERVICING HYDRAULIC RELIEF
PRESSURIZATION SYSTEM
TOP RIGHT
SIDE OF
• VALVE
Refer also to HYDRAULIC PRESSURIZATION RESERVOIR

SYSTEM 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 PRESSURE
GAUGE
FRONT OF
ENGINE
COMPARTMENT
5. Slowly turn the relief valve OUT until the

pressure gauge reading drops to 10 psi.
Tighten the relief valve locking nut.
AIR VENT SHUT-OFF
FILTER VALVE AIR COMPRESSOR/
VACUUM PUMP
••
• ••
HYDRAULIC RESERVOIR
250B-004 VENT AND SHUT-OFF VALVE • PRESSURE/
VACUUM
GAUGE
1. Open the air vent shut-off valve to vent air from COMPRESSOR/
the tank. VACUUM
SOLENOID
VALVE
• TOP RIGHT
SIDE OF
RESERVOIR
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
250B-003 HYDRAULIC RESERVOIR
rubber nipple off as indicated on the gauge.
The gauge should now read 0 psi.
6. Watch the tank pressure gauge for several
3. Close air vent shut-off valve and turn relief minutes for any indications of a loss in system
valve adjustment fully IN. pressure.
4. Hold down the charge tank button on the 7. If tank pressure falls check all fittings and
instrument panel, or use the hand fill pump to connections for leaks. NPT connectors must be
pressurize the hydraulic tank. fastened using pipe sealant to prevent leakage.
If using the hand fill pump, remove hose clamp A properly installed system should be capable
from end of suction hose, remove hose from of maintaining constant pressure over night.
stored position and operate hand pump until a NOTE: The tank pressure can decrease without
gauge reading of 11-12 psi is obtained. Close substantial leaks due to the contraction of air
oil fill shut-off valve, place hose in stored within the hydraulic tank. This may occur when
position and secure with the hose clamp. the air and oil temperature within the tank
decreases.
3.18
VACUUM PUMP AIR COMPRESSOR/
VACUUM PUMP
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
•• PRESSURE/
VACUUM
GAUGE
for hydraulic reservoir pressurization also acts as COMPRESSOR/
a vacuum pump for this purpose. VACUUM
SOLENOID
VALVE
•• TOP RIGHT
SIDE OF
RESERVOIR
SERVICE NOTE:
Before doing any work on the hydraulic system
follow the steps below:
REMOVE KEY FROM 250B-003 HYDRAULIC RESERVOIR
KEY SWITCH
VACUUM
TANK
SWITCH
•
••
250B-027 REMOVE KEY 250BT-002 VACUUM TANK SWITCH

1. Turn the start key to the OFF position and 3. Turn the vacuum pump switch ON.
remove the key. NOTE: The key switch must
be in the OFF position to provide electrical NOTE:
power to the vacuum pump circuit and The vacuum pump will start and stop as
maintain a constant vacuum. required to maintain a constant vacuum.
FRONT OF 4. Perform all required work on the hydraulic

ENGINE system.
COMPARTMENT
5. Turn the vacuum pump switch OFF.
6. Relieve the vacuum in the hydraulic tank by
AIR VENT
OPENING and CLOSING the air vent shut-off
SHUT-OFF
FILTER VALVE valve.
•• IMPORTANT
•• It is recommended that the start key be
removed while servicing the hydraulic
system.
HYDRAULIC RESERVOIR
250B-004 VENT AND SHUT-OFF VALVE Do not attempt to START the machine or
turn key to the RUN position. The vacuum
2. Relieve any pressure in the hydraulic tank by pump only operates when the key switch
OPENING and CLOSING the air vent shut-off is in the OFF position.
valve.
After using pump to perform service work
on pumps or motors, charge tank and
purge all air out of the pump and motor
case before start-up.
Do not leave machine unattended or
overnight with vacuum pump on.
3.19
TORQUE CHART
LOCATION THREAD TORQUE (LUBRICATED)
DIAMETER lbf-ft Nm
Cylinders
Piston nut, main boom cylinder 2 1/2"-12 UNF (GC) 1640 2222
Piston nut, stick cylinder 2 1/2"-12 UNF (GC) 1640 2222
Piston nut, heel cylinder 2"-12 UNF (GC) 1500 2035
Piston nut, grapple cylinder 1 3/4"-12 UNF (GC) 1750 2355
Gland, grapple cylinder 4 1/2" I/D CYLINDER 450 607
Keeper plate bolts, heel cylinder 3/4"-10 UNC (G8) 275-325 370-440
Keeper plate bolts, Main boom cylinder 7/8"-14 UNF (G8) 300-325 405-440
Keeper plate bolts, Stick boom cylinder 3/4"-16 UNF (G8) 240-270 323-363
Boom joint and cylinder pin retaining bolts 3/4"-10 UNC (G8) 282-310 393-420
Main and Stick boom pin retaining nut 2"-12 UNF (G8) 400 540
Heel to Stick boom pin retaining nut 1 3/4"-12 UNF (G8) 400 540
Cab securing bolts 7/8"-9 UNC (G8) 400-450 540-610
Swing bearing bolts 7/8"-9 UNC (G8) 400-450 540-610

Swing gearbox mounting bolts M20-2.5 (10.9) 400 540
Swing motor mounting bolts M18-2.5 (12.9) 200 275
Engine mounting
Bolts, bracket/mount to chassis 7/8"-9 UNC (G8) 400-450 540-610
Bolts, bracket to engine M12-1.75 (10.9) 75 100
Engine cooling fan mounting bolts M10-1.5 (12.9) 25 30
Pump drive
Drive plate to flywheel 3/8"-16 UNC (G8) 40 54
Bell housing to engine M10-1.5 (10.5) 45 60
Undercarriage
Track shoe bolts 3/4 UNF T/T* T/T*
Idler bolts M16-2 (10.9) 175 235
Roller mounting bolts 7/8"-9 UNC (G8) 450 610
Sprocket bolts M20-2.5 (10.9) 380 515
Gearbox mounting bolts 3/4"-10UNC (G8) 310 417
Drive motor mounting bolts M12-1.75 (10.9) 80 110
*T/T represents Torque-Turn, this is a method of torquing the track shoe bolts. Refer to SECTION 11 in
the Tigercat SERVICE MANUAL for a complete description on this method of applying torque.
Torque values pertaining to the engine and attachment are provided in the appropriate manuals.
3.20
GENERAL TORQUE SPECIFICATIONS
The torque values listed below are for general use only.
IMPERIAL DO NOT use these values if a different torque value or
tightening procedure is shown for a specific application.
GRADE 8 BOLTS GRADE 5 BOLTS

IMPERIAL BOLT TORQUE SPECIFICATIONS
GRADE 8 BOLTS GRADE 5 BOLTS
COARSE DRY LUBRICATED COARSE DRY LUBRICATED
THREAD lbf-ft Nm lbf-ft Nm THREAD lbf-ft Nm lbf-ft Nm
1/4" - 20 11 - 12 15 - 16 8 - 10 11 - 13 1/4" - 20 7- 8 10 - 11 8 - 10 11 - 13
5/16" - 18 26 - 30 35 - 40 20 - 28 27 - 38 5/16" - 18 14 - 18 19 - 24 10 - 15 13 - 20
3/8" - 16 44 -48 60 - 65 33 - 36 45 - 49 3/8" - 16 31 - 34 42 - 46 23 - 25 31 - 34
7/16" - 14 70 - 77 95 - 104 52 - 57 71 - 77 7/16" - 14 49 - 54 66 - 73 37 - 41 50 - 55
1/2" - 13 106 - 117 144 - 158 80 - 88 109 - 119 1/2" - 13 75 - 83 102 - 112 57 - 63 77 - 85
9/16" - 12 153 - 168 208 - 228 115 - 127 156 - 172 9/16" - 12 109 - 120 148 - 162 82 - 90 111 - 122
5/8" - 11 212 - 233 288 - 316 159 - 175 216 - 237 5/8" - 11 150 - 165 204 - 223 113 - 124 152 - 168
3/4" - 10 376 - 414 510 - 561 282 - 310 393 - 420 3/4" - 10 266 - 293 360 - 397 200 - 220 271 - 298
7/8" - 9 606 - 667 822 - 904 455 - 501 617 - 679 7/8" - 9 394 - 433 535 - 586 296 - 326 402 - 441
1" - 8 909 - 1000 1233 - 1355 682 - 750 925 - 1016 1" - 8 591 - 649 802 - 879 443 - 489 601 - 663
1 1/8" - 7 1288 - 1417 1746 - 1921 966 - 1062 1310 - 1441 1 1/8" - 7 794 - 873 1077 - 1183 596 - 656 808 - 889
1 1/4" - 7 1817 - 1999 2464 - 2710 1360 - 1496 1844 - 2027 1 1/4" - 7 1120 - 1232 1519 - 1670 840 - 924 1139 - 1252
FINE DRY LUBRICATED FINE DRY LUBRICATED
THREAD lbf-ft Nm lbf-ft Nm THREAD lbf-ft Nm lbf-ft Nm
1/4" - 28 13 - 14 18 - 19 10 - 13 14 - 17 1/4" - 28 9 - 10 12 - 13 9 - 10 12 - 13
5/16" - 24 23 - 28 31 - 38 18 - 25 25 - 33 5/16" - 24 17 - 22 23 - 29 16 - 20 21 - 27
3/8" - 24 49 - 54 67 - 73 37 - 41 50 - 55 3/8" - 24 35 - 39 48 - 53 26 - 29 35 - 39
7/16" - 20 78 - 86 106 - 116 58 - 64 79 - 86 7/16" - 20 55 - 61 75 - 83 41 - 45 56 - 61
1/2" - 20 120 - 132 163 - 179 90 - 99 122 - 134 1/2" - 20 85 - 94 116 - 127 64 - 70 87 - 95
9/16" - 18 171 - 188 232 - 255 128 - 141 174 - 191 9/16" - 18 121 - 133 164 - 180 91 - 100 124 - 135
5/8" - 18 240 - 264 326 - 358 180 - 198 244 - 268 5/8" - 18 170 - 187 231 - 253 128 - 141 174 - 191
3/4" - 16 420 - 462 570 - 626 315 - 347 427 - 470 3/4" - 16 297 - 327 403 - 443 223 - 245 303 - 332
7/8" - 14 668 - 735 906 - 996 501 - 550 679 - 745 7/8" - 14 434 - 477 589 - 646 326 - 359 442 - 486
1" - 14 995 - 1096 1359 - 1486 746 - 821 1012 - 1113 1" - 14 646 - 711 876 - 965 484 - 534 657 - 724
1 1/8" - 12 1445 - 1590 1960 - 2155 1083 - 1191 1469 - 1613 1 1/8" - 12 891 - 980 1208 - 1328 668 - 735 906 - 996
1 1/4" - 12 2012 - 2213 2728 - 2997 1509 - 1660 2046 - 2250 1 1/4" - 12 1240 - 1364 1682 - 1849 931 - 1024 1262 - 1387
METRIC
METRIC BOLT TORQUE SPECIFICATIONS

CLASS 4.8 CLASS 8.8 OR 9.9 CLASS 10.9 CLASS 12.9
SIZE LUBRICATED DRY LUBRICATED DRY LUBRICATED DRY LUBRICATED DRY
Nm lbf-ft Nm lbf-ft Nm lbf-ft Nm lbf-ft Nm lbf-ft Nm lbf-ft Nm lbf-ft Nm lbf-ft
M6 4.8 3.5 6.0 4.5 9.0 6.5 11.0 8.5 13.0 9.5 17.0 12.0 15.0 11.5 19.0 14.5
M8 12.0 8.5 15.0 11.0 22.0 16.0 28.0 20.0 32.0 24.0 40.0 30.0 37.0 28.0 47.0 35.0
M10 23.0 17.0 29.0 21.0 43.0 32.0 55.0 40.0 63.0 47.0 80.0 60.0 75.0 55.0 95.0 70.0
M12 40.0 29.0 50.0 37.0 75.0 55.0 95.0 70.0 110.0 80.0 140.0 105.0 130.0 95.0 165.0 120.0
M14 63.0 47.0 80.0 60.0 120.0 88.0 150.0 110.0 175.0 130.0 225.0 165.0 205.0 150.0 260.0 190.0
M16 100.0 73.0 125.0 92.0 190.0 140.0 240.0 175.0 275.0 200.0 350.0 225.0 320.0 240.0 400.0 300.0
M18 135.0 100.0 175.0 125.0 260.0 195.0 330.0 250.0 375.0 275.0 475.0 350.0 440.0 325.0 560.0 410.0
M20 190.0 140.0 240.0 180.0 375.0 275.0 475.0 350.0 530.0 400.0 675.0 500.0 625.0 460.0 800.0 580.0
M22 260.0 190.0 330.0 250.0 510.0 375.0 650.0 475.0 725.0 540.0 925.0 675.0 850.0 625.0 1,075.0 800.0
M24 330.0 250.0 425.0 310.0 650.0 475.0 825.0 600.0 925.0 675.0 1,150.0 850.0 1,075.0 800.0 1,350.0 1,000.0
M27 490.0 360.0 625.0 450.0 950.0 700.0 1,200.0 875.0 1,350.0 1,000.0 1,700.0 1,250.0 1,600.0 1,150.0 2,000.0 1,500.0
M30 675.0 490.0 850.0 625.0 1,300.0 950.0 1,650.0 1,200.0 1,850.0 1,350.0 2,300.0 1,700.0 2,150.0 1,600.0 2,700.0 2,000.0
M33 900.0 675.0 1,150.0 850.0 1,750.0 1,300.0 2,200.0 1,650.0 2,500.0 1,850.0 3,150.0 2,350.0 2,900.0 2,150.0 3,700.0 2,750.0
M36 1,150.0 850.0 1,450.0 1,075.0 2,250.0 1,650.0 2,850.0 2,100.0 3,200.0 2,350.0 4,050.0 3,000.0 3,750.0 2,750.0 4,750.0 3,500.0
TORQUECHARTGENERAL.XLS
3.21
PRESSURE SETTINGS
Engine RPM ....................................................................... 1875 rpm @ Full throttle (no load)
............................................................................................. 900 rpm @ Idle (no load)
Pilot System
Main Relief ....................................... 34.5 Bar (500 psi) + 1/2 turn in @ Full throttle
Main Valve High Pressure Limiting Control
MAIN PUMP P.O.R. (‘PX’ port) ........................... 310 Bar (4500 psi) @ Full throttle
Margin Pressure (‘PX’ - ‘PL’) ................................. 26 Bar (375 psi) @ Full throttle
Main Valve Port reliefs
Hoist DOWN ...................................................... Spool out 4.5 turns 8 Seconds
Hoist UP ................................................................ Spool out 8 turns 8.5 Seconds
R.H. Track Forward ........................................................ See Note 6
R.H. Track Reverse ........................................................ See Note 6
Feed Reducer A **Rotate CW ......................... 110.3 Bar (1600 psi) 34 L/m 30 rpm
Feed Reducer B **Rotate CCW ...................... 110.3 Bar (1600 psi) 34 L/m 30 rpm
L.H. Track Forward ......................................................... See Note 6
L.H. Track Reverse ........................................................ See Note 6
Stick IN ............................................................. Spool out 5.25 turns 6 Seconds
Stick OUT .............................................................. Spool out 7 turns 6.75 Seconds
Feed Reducer A - **Pump 2 Return ........................... *0 Bar (*0 psi) Spool out 0.5 turns
Feed Reducer B - **Pump 2 Pressure ............. *283 Bar (*4100 psi) Spool out 8 turns
Spare Section - No Adjustment Required .................................... NA
Feed Reducer A - Pump 1 Return .............................. *0 Bar (*0 psi) Spool out 0.5 turns
Feed Reducer B - **Pump 1 Pressure ............. *262 Bar (*3800 psi) Set Saw Speed 9500 rpm
Drive Brake Release Pressure ............................ 34.5 Bar (500 psi)
Drive Begin Of Regulation (See Note 7) ............ 214 Bar (3100 psi)
Note: Pressures set at Full Throttle unless otherwise specified.
* Set pressure with gauge on 'PL' port
** Dependent on Head
Cab Tilt
Cab Tilt Main Relief ............................................. 207 Bar (3000 psi)
Cab Tilt Counterbalance Valves ....................... 241.3 Bar (3500 psi)
Swing Pump
Swing Pump Charge Pressure ................................ 24 Bar (350 psi)
Pump POR ...................................... 310 Bar (4500 psi) + 1/2 turn in
HIGH PRESSURE RELIEF Swing CCW ......***352 Bar (***5100 psi)
HIGH PRESSURE RELIEF Swing CW..........***352 Bar (***5100 psi)
***Swing machine slowly 5 times in each direction before setting pressures. Do not hold pressure over
relief more than 8 seconds at a time. Wait 5 seconds to avoid overheating.
ALL PRESSURES MUST BE SET WITH HYDRAULIC OIL AT OPERATING TEMPERATURE.

NOTE: The above values are for reference purposes only,
SEE SERVICE MANUAL FOR SETTING PROCEDURE.
3.22
PRESSURE SETTINGS
NOTES:
1. SYSTEM TO BE AT OPERATING TEMPERATURE WHEN SETTING PRESSURES.
2. ALL PRESSURES MEASURED IN PSI. ALL SPEEDS MEASURED IN SECONDS.
3. F - DENOTES PRESSURES SET AT FULL ENGINE RPM.
I - DENOTES PRESSURES SET AT ENGINE IDLE.
4. PORT RELIEFS CANNOT BE ADJUSTED. EACH PORT RELIEF HAS A SPECIFIC SETTING
AND SHOULD NOT BE INTERCHANGED WITH OTHER PORT RELIEFS.
5. SET MARGIN PRESSURE WITH PILOT SYSTEM ACTIVATED (DO NOT USE ANY
FUNCTIONS). THIS IS THE BOTTOM (LARGE) ADJUSTMENT ON THE MAIN PUMP.
6. TRACK SPEEDS SET TO 12 RPM LOW (10 RPM LOW FOR SHOVEL LOGGER
UNDERCARRIAGE OPTION) AND 28 RPM HIGH BY MAKING ADJUSTMENTS IN THE
FOLLOWING ORDER:
A) SET MOTOR MAXIMUM DISPLACEMENT TO 105cc.
B) SET LOW FORWARD (VALVE FLOW SETTING).
C) SET HIGH FORWARD (MOTOR MINIMUM DISPLACEMENT).
D) SET HIGH REVERSE (VALVE FLOW SETTING).
7. TRACK DRIVE BEGIN OF REGULATION VALVES TO BE SET AT ENGINE IDLE USING THE
FOLLOWING PROCEDURE:
A) DISCONNECT AND PLUG BOTH MOTOR BRAKE RELEASE LINES.
B) LOWER MAIN PUMP P.O.R. TO 3100 PSI. AT IDLE.
C) OPERATE TRACK IN HIGH SPEED (TRACK SHOULD NOT MOVE).
D) ADJUST BEGIN OF REGULATION VALVE ON EACH MOTOR TO GIVE PRESSURE
BEWTEEN 800 AND 1000 PSI AT MOTOR TEST PORT.
E) RESET MAIN PUMP P.O.R. AT FULL ENGINE RPM AND RECONNECT BRAKE LINES.
8. TILT CAB NOTES:
A) TURN COUNTERBALANCE VALVES OUT FULLY, THEN IN 1 TURN.
B) TILT VALVE IS FACTORY PRESET.
37884B.AI R0 MAIN AND PILOT VALVE CIRCUIT DESCRIPTION AND DESIGNATIONS

3.23
Par
arkker Assemb
Assemblly Tor que
orque
The 4-Bolt Split Flange consists of four main The four-bolt port is simply a circular opening (flow
components: passage) surrounded by four tapped holes in a certain
• A body (flange head) pattern for acceptance of the flange clamping bolts. The
• An O-ring flat surface of the port compresses the O-ring
• One “captive” or two “split” flange clamps contained in the groove in the flange head when the
• Four bolts and washer clamp bolts are torqued. In some instances, the groove
is in the port and not in the flange head. The bolts,
through the clamp halves, clamp down the flange head
on to the flat surface of the port compressing and
WASHERS trapping the O-ring in the groove and leaving no gap for
it to extrude under pressure. The hydraulic pressure is
•• BOLTS
thus sealed by the compressed O-ring as long as the
•• FLANGE bolts are tightened enough to maintain solid metal to
CLAMP metal contact between the flange head at the outside
• diameter of the O-ring and the top of the port.
Flange Port Assembly
FLANGE
HEAD The steps to properly assemble the flange port
clamping bolts are:
O-RING
•• TAPPED
1. Make sure sealing surfaces are free of burrs, nicks,
scratches or any foreign particles.
• HOLES
2. Lubricate the O-ring.
• 3. Position flange and clamp halves.
4. Place lock washers on bolts and insert through
clamp halves.
5. Hand tighten bolts.
FLANGE.TIFF 6. Torque bolts in diagonal sequence (see Fig. T9) in
small increments to the appropriate torque level
Fig. T8 - 4 Bolt Split Flange Components listed in Table T6 or Table T7 on this page.
FLANGE2.TIFF
Fig. T9 - Flange Bolt Tightening Sequence
Dash Flange Inch Bolt Torque Metric Bolt Torque DASH FLANGE INCH BOLT TORQUE METRIC BOLT TORQUE
SIZE SIZE (J518) FT LBS (ISO 6162) N-M
Size Size (J518) ft. lbs. (ISO 6162) N-m
8 1/2 5/16-18 17 +/- 2 M8 25
8 1/2 5/16-18 17 +/- 2 M8 25 12 3/4 3/8-16 30 +/- 4.5 M10 49
12 3/4 3/8-16 25 +/- 3.5 M10 49 16 1 7/16-14 46 +/- 4.5 M12 85
16 1 3/8-16 31 +/- 4.5 M10 49 20 1 1/4 1/2-13 69 +/- 6 M14* 135
20 1-1/4 7/16-14 41 +/- 5 M12* 85 24 1 1/2 5/8-11 125 +/- 8 M16 210
24 1-1/2 1/2-13 52 +/- 6 M12 85 32 2 3/4-10 208 +/- 20 M20 425
32 2 1/2-13 60 +/- 6 M12* 135 SO
40 2-1/2 1/2-13 85 +/- 9 M12 95 * Does not meet ISO 6162 specification.
48 3 5/8-11 144 +/- 15 M16 220 Table T7 - Code 62 Flange Recommended Bolt Torque
56 3-1/2 5/8-11 125 +/- 8 M16 220
64 4 5/8-11 125 +/- 8 M16 220
80 5 5/8-11 125 +/- 8 M16 220
* Does not meet ISO 6162 specification.
Table T6 - Code 61 Flange Recommended Bolt Torque
3.24
Par
arkker Assemb
Assemblly Tor que
orque
JIC 37 Degree Flare NPTF
Tube Connection Swivel or Hose Tube Connection Swivel or Hose
SAE Dash Size Thread Size FFWR Connection FFWR SAE Dash Size Thread Size TFFT Connection TFFT
-2 5/16-24 NA NA -2 1/8-27 2-3 2-3
-3 3/8-24 NA NA -3 NA NA NA
-4 7/16-20 2 2 -4 1/4-18 2-3 2-3
-5 1/2-20 2 2 -5 NA NA NA
-6 9/16-18 1 1/2 1 1/4 -6 3/8-18 2-3 2-3
-8 3/4-16 1 1/2 1 -8 1/2-14 2-3 2-3
-10 7/8-14 1 1/2 1 -10 7/8-14 NA NA
-12 1 1/16-12 1 1/4 1 -12 3/4-14 2-3 2-3
-14 1 3/16-12 1 1 -14 NA NA NA
-16 1 5/16-12 1 1 -16 1-11 1/2 1.5-2.5 1.5-2.5
-20 1 5/8-12 1 1 -20 1 1/4-11 1/2 1.5-2.5 1.5-2.5
-24 1 7/8-12 1 1 -24 1 1/2-11 1/2 1.5-2.5 1.5-2.5
-32 2 1/2-12 1 1 -32 2-11 1/2 1.5-2.5 1.5-2.5
-40 3-12 1 1 -40 NA NA NA
F.F.W.R : Flats From Wrench Resistance T.F.F.T. : Turns from finger tight
All values are for Steel, Stainless Steel and Brass All pipe values are for Steel, Stainless Steel and Brass
O'ring Face Seal / Seal-Lok BSPT

Tube Connection Swivel or Hose Tube Connection Swivel or Hose
SAE Dash Size Thread Size FFWR Connection FFWR SAE Dash Size Thread Size TFFT Connection TFFT
-2 NA NA NA -2 1/8-28 2-3 2-3
-3 NA NA NA -3 NA NA NA
-4 9/16-18 1/4 TO 1/2 1/2 TO 3/4 -4 1/4-19 2-3 2-3
-6 11/16-16 1/4 TO 1/2 1/2 TO 3/4 -6 3/8-19 2-3 2-3
-8 13/16-16 1/4 TO 1/2 1/2 TO 3/4 -8 1/2-14 2-3 2-3
-10 1-14 1/4 TO 1/2 1/2 TO 3/4 -10 NA NA NA
-12 1 3/16-12 1/4 TO 1/2 1/3 TO 1/2 -12 3/4-14 2-3 2-3
-16 1 7/16-12 1/4 TO 1/2 1/3 TO 1/2 -16 1-11 1.5-2.5 1.5-2.5
-20 1 11/16-12 1/4 TO 1/2 1/3 TO 1/2 -20 1 1/4-11 1.5-2.5 1.5-2.5
-24 2-12 1/4 TO 1/2 1/3 TO 1/2 -24 1 1/2-11 1.5-2.5 1.5-2.5
-32 NA NA NA -32 2-11 1.5-2.5 1.5-2.5
F.F.W.R : Flats From Wrench Resistance T.F.F.T. : Turns from finger tight
All values are for Steel, Stainless Steel and Brass All pipe values are for Steel, Stainless Steel and Brass
SAE J1926 Straight Thread Port Assembly Torques

ASSEMBLY TORQUE (+10 % - 0)
Non-Adjustable Adjustable Plugs
SAE
Thread Hollow Hex Hex Head
Dash Triple-Lok Ferulok
Size Seal-Lok Seal-Lok Triple-Lok Ferulok
Size Pipe Fittings HP5ON-S P5ON-S
ft. lbs ft. lbs ft. lbs ft. lbs ft. lbs ft. lbs
N-m N-m N-m N-m N-m N-m
(in. lbs) (in. lbs) (in. lbs) (in. lbs) (in. lbs) (in. lbs)
2 5/16-24 (310) 20 (85) 10 (310) 20 (60) 7 (30) 3.5 (85) 10
3 3/8-24 (310) 20 (155) 18 (310) 20 (100) 11 (55) 6 (155) 18
4 7/16-20 (310) 20 (260) 29 (310) 20 (180) 20 (120) 13.5 (260) 29
5 1/2-20 (360) 40 (280) 32 (360) 40 (250) 28 (170) 19 (280) 32
6 9/16-18 (420) 46 (350) 40 (420) 46 (350) 40 (410) 46 (350) 40
8 3/4-16 60 80 (620) 70 60 80 (620) 70 60 80 (620) 70
10 7/8-14 100 135 85 115 100 135 85 115 100 135 85 115
12 1 1/16-12 135 185 135 183 135 185 135 183 135 185 135 183
14 1 3/16-12 175 235 175 237 175 235 175 237 175 235 175 237
16 1 5/16-12 200 270 200 271 200 270 200 271 200 270 200 271
20 1 5/8-12 250 340 250 339 250 340 250 339 250 340 250 339
24 1 7/8-12 305 415 305 414 305 415 305 414 305 415 305 414
32 2 1/2-12 375 510 375 509 375 510 375 509 375 510 375 509
3.25
EATON Aeroquip Assemb
Assemblly Tor que
orque
Recommended Eaton recommends that a The values listed are for
Parallel Torque wrench be used to steel connections. Contact
Connection assure proper fitting Eaton Aeroquip for torques values for
Assembly torque assembly of these other materials
connections.
Straight Thread O-Ring Straight Thread O-Ring

Boss Low Pressure with Boss High Pressure
37º (SAEJ514) with ORS (J1453)
Jam Nut or Jam Nut or Jam Nut or Jam Nut or
Thread Straight Straight Thread Straight Straight
Dash Size Fitting Torque Fitting Torque Dash Size Fitting Torque Fitting Torque
Size (inches) lb.-ft. Newton Meters Size (inches) lb.-ft. Newton Meters
-03 3/8-24 8-9 12-13 -03 3/8-24 8-10 11-16
-04 7/16-20 13-15 18-20 -04 7/16-20 14-16 20-22
-05 1/2-20 14-15 19-21 -05 1/2-20 18-20 24-27
-06 9/16-18 23-24 32-33 -06 9/16-18 24-26 33-35
-08 3/4-16 40-43 55-57 -08 3/4-16 50-60 68-78
-10 7/8-14 43-48 59-64 -10 7/8-14 72-80 98-110
-12 1 1/16-12 68-75 93-101 -12 1 1/16-12 125-135 170-183
-14 1 3/16-12 83-90 113-122 -14 1 3/16-12 160-180 215-245
-16 1 5/16-12 112-123 152-166 -16 1 5/16-12 200-220 270-300
-20 1 5/8-12 146-161 198-218 -20 1 5/8-12 210-280 285-380
-24 1 7/8-12 154-170 209-230 -24 1 7/8-12 270-360 370-490
-32 2 1/2-12 218-240 296-325
ORS SAE 37º (JIC)

Swivel Swivel
Swivel Swivel Thread Nut Nut
Thread Nut Nut Dash Size Torque Torque
Dash Size Torque Torque Size (inches) lb.-ft. Newton Meters
Size (inches) lb.-ft. Newton Meters -04 7/16-20 11-12 15-16
-04 9/16-18 10-12 14-16 -05 1/2-20 15-16 20-22
-06 11/16-20 18-20 24-27 -06 9/16-18 18-20 24-28
-08 13/16-16 32-35 43-47 -08 3/4-16 38-42 52-58
-10 1-14 46-50 62-68 -10 7/8-14 57-62 77-85
-12 1 3/16-12 65-70 88-95 -12 1 1/16-12 79-87 108-119
-16 1 7/16-12 92-100 125-136 -16 1 5/16-12 108-113 148-154
-20 1 11/16-12 125-140 170-190 -20 1 5/8-12 127-133 173-182
-24 2-12 150-165 204-224 -24 1 7/8-12 158-167 216-227
-32 2 1/2-12 245-258 334-352
Metric BSPP
Thread Size Straight Adapter or Locknut Torque Nominal
mm lb.-ft. Newton Meters Thread Size Straight Adapter or Locknut Torque
M10x1 13-15 18-20 inches** lb.-ft. Newton Meters
M12x1.5 15-19 20-25 G1/8-28 13-15 18-20
M14x1.5 19-23 25-30 G1/4-19 19-23 25-30
M16x1.5 33-40 45-55 G3/8-19 33-40 45-55
M18x1.5 37-44 50-60 G1/2-14 55-70 75-95
M20x1.5 52-66 70-90 G3/4-14 103-118 140-160
M22x1.5 55-70 75-95 G1-11 162-184 220-250
M26x1.5 81-96 110-130 G1 1/4-11 170-192 230-260
M27x2 96-111 130-150 G1 1/2-11 258-347 350-470
M33x2 162-184 220-250 ** "G" denotes parallel threads, other than ISO 6149
M42x2 170-192 230-260 (Port connection only)
M48x2 258-347 350-470
Eaton Aeroquip Fluid Conveyance Products A-HOOV-MC001-E January 2005
3.26
ELECTRICAL SCHEMATIC SHEET 1
T250B-006
3.27
T250B-007
3.28
T250B-008
3.29
T250B-009
3.30
MAIN AND PILOT VALVE CIRCUIT DESCRIPTION AND DESIGNATIONS
37884B.AI R0
COMMON CONVERSIONS
To Convert Into Multiply By To Convert Into Multiply By
Bar PSI 14.5 Cu. in. cc 16.39
cc Cu. in. 0.06102 °F °C (°F - 32) /1.8
°C °F (°C x 9/5) + 32 Gallons Liters 3.785
Kg lbs. 2.205 HP KW 0.7457
KW HP 1.341 Inches mm 25.4
Liters Gallons 0.2642 lbs. Kg 0.4535
mm Inches 0.03937 lb.-ft. Nm 1.356
Nm lb.-ft. 0.7375 PSI Bar 0.06896
N lbs. 0.22481 In. of HG PSI . 4912
In. of H2O PSI . 03613
lbs. N 4.4482
3.31
Weights of Commercial Wood
Species kg/m3 lb/ft3 Species kg/m3 lb/ft3
Alder, Red 737 46 Maple, Big Leaf 753 47

Ash, White 769 48 Maple, Black 865 54
Aspen, Quaking 689 43 Maple, Red 801 50
Bald Cypress 817 51 Maple, Silver 721 45
Basswood, American 673 42 Maple, Sugar 897 56
Beech, American 865 54 Oak, Black 1009 63
Birch, Paper 801 50 Oak, Chestnut 977 61
Birch, Yellow 929 58 Oak, Red 1009 63
Cedar, Alaska 577 36 Oak, Red, Swamp 1073 67
Cedar, Incense 721 45 Oak, Swamp Chestnut 1041 65
Cedar, Northern White 449 28 Oak, White 993 62
Cedar, Port-Orford 897 36 Oak, White, Swamp 1105 69
Cedar, Western Red 433 57 Pine, Jack 801 50
Cherry, Black 721 45 Pine, Loblolly 993 62
Cottonwood, Eastern 785 49 Pine, Lodgepole 625 39
Douglas Fir, Coast 881 55 Pine, Long Leaf 993 62
Douglas Fir, Inland North 577 36 Pine, Norway, Red 673 42
Elm, American 865 54 Pine, Short Leaf 993 62
Fir, Alpine 449 28 Pine, Slash 993 62
Fir, Balsam 721 45 Pine, Sugar 817 51
Fir, Nobel 481 30 Pine, Western Yellow 721 45
Fir, Red 769 48 Pine, White-Western 561 35
Fir, Silver 577 36 Pine, White-Eastern 577 36
Fir, White 753 47 Poplar, Yellow 609 38
Gum, Black 721 45 Redwood 801 50
Gum, Blue 1121 70 Spruce, Black 513 32
Gum, Red 801 50 Spruce, Engleman 625 39
Gum, Tupelo 897 56 Spruce, Red 545 34
Hemlock, Eastern 801 50 Spruce, Sitka 529 33
Hemlock, Western 657 41 Spruce, White 545 34
Hickory, Pecan 993 62 Sweetgum 801 50
Hickory, True 1009 63 Sycamore, American 833 52
Larch, Western 769 48 Tamarack 753 47
Locust, Black 929 58 Walnut, Black 929 58
Magnolia, Cucumber 785 49 Willow, Black 801 50
Note: The values shown here are green weights.

3.32
SECTION 4 - HYDRAULIC SYSTEM

MARCH, 2009
CIRCUIT DIAGRAM
LOAD SENSING SYSTEM ....................................................................... 4.12
DIFFUSERS/STRAINERS
CLEANING ................................................................................................. 4.5
HYDRAULIC OIL RESERVOIR
DESCRIPTION ........................................................................................... 4.2
RESERVOIR ............................................................................................... 4.3
HYDRAULIC PUMPS
GENERAL DESCRIPTION ......................................................................... 4.6
MAIN PUMP ............................................................................................... 4.6
MAIN PUMP CONTROLLER ................................................................ 4.18
HYDRAULIC SYSTEM OPERATION
AUXILIARY OR SWING SYSTEM .............................................................. 4.2
MAIN CIRCUIT DESCRIPTION ................................................................ 4.11
FLOW ON DEMAND AND LOAD COMPENSATION ............................ 4.12
MAIN HYDRAULIC CIRCUIT .................................................................... 4.11
MAIN HYDRAULIC SYSTEM ...................................................................... 4.2
MARGIN PRESSURE ................................................................................. 4.7
PILOT CIRCUIT .......................................................................................... 4.2
LOAD SENSING
BASIC DESCRIPTION
CLOSED CENTRE SYSTEM ................................................................ 4.10
OPEN CENTRE SYSTEM ...................................................................... 4.9
BASIC PRINCIPALS ................................................................................... 4.8
MARGIN PRESSURE ................................................................................. 4.7
OPERATING TIPS .................................................................................... 4.11
SET MARGIN PRESSURE ....................................................................... 4.18
MAIN PUMP POR VALVE SETTING ........................................................... 4.20
MAIN VALVE DESCRIPTION ................................ 4.13, 4.14, 4.15, 4.16, 4.17
MARGIN PRESSURE SETTING .................................................................. 4.18
POR VALVE SETTING ................................................................................. 4.20
PRESSURE SETTINGS ..................................................................... 4.22, 4.23
STRAINERS/DIFFUSERS
CLEANING ................................................................................................. 4.5
Tigercat H250B Harvester Hydraulic system
HYDRAULIC SYSTEM OPERATION manifold provides hydraulic connection to the
undercarriage and permits continuous 360
The hydraulic system has two separate circuits; degree swing.
1. Variable-displacement swing drive closed 3. PILOT CIRCUIT
loop hydraulic circuit with internal charge
pump. The pilot circuit is supplied with oil from the
main pump via the main control valve. The
2. Variable-displacement main hydraulic circuit pilot system is turned on and off by the pilot
for the track drive/boom hoist and stick/head shut off valve located on the pilot manifold
rotate/pump 1 and pump 2 functions. which is controlled by the armrest switch and
The pilot circuit is supplied oil by the main the pilot reset button. Refer to PILOT
pump via the main hydraulic valve. SYSTEM description in SECTION 5 of this
manual.
1. MAIN HYDRAULIC SYSTEM
This a closed centre system utilizing a
HYDRAULIC OIL RESERVOIR
variable-displacement axial-piston pump with
Also refer to SECTION 2 of the OPERATOR'S
load sensing and horsepower limiting control.
MANUAL for additional service information.
The load sensing system ensures that the
pump will deliver only the amount of oil that is Located at the left rear corner of the machine, the
required by an individual function or hydraulic reservoir (or tank) has a capacity of
combination of functions. 250L (66 U.S. gallons).
This feature improves fuel economy and cuts Hydraulic oil is drawn from the tank by the pumps
back on heat generation because power is through the suction hose and tube at the base of
not wasted on excess pump flow that is not the tank. The bulk of the oil returning to the tank is
being used. Refer to LOAD SENSING directed to the return manifold and the four return
HYDRAULIC SYSTEM in THIS SECTION. filters and from there to the return tubes in the
hydraulic tank. There is a bypass valve built into
The horsepower limiting control is one which
each filter head preset at 1.7 Bar (25 psi) which
ensures that the engine will not lug down
will open in the event the elements become
below the full load rpm by reducing the output
restricted. A strainer/diffuser is attached to the end
from the main hydraulic pump. Refer to
of each of the two return tubes. The reusable
ENGINE ANTI-STALL description in
return strainers with a 250 micron particle
SECTION 9 of this manual.
retention, screen oil prior to re-entering the tank.
The main control valves are pressure and
Case drain oil from the main pump, swing pump,
flow compensated to provide load
swing motor, and pilot return lines go through a
independent operation for all functions.
spin-on strainer and returns to the reservoir.
2. SWING SYSTEM The strainer element requires no regular
maintenance over the life of the machine. This
This closed loop circuit uses a variable-
element requires maintenance only in the case of
displacement piston pump which delivers oil
damage or contamination due to a hydraulic pump
to the swing motor and back to pump. Foot
or motor failure.
pedal operated pilot valves located in the cab
direct pilot oil to the swing pump controller. IMPORTANT:
The strainer element is NOT a filter element.
The internal charge pump provides make up
Always use the correct replacement element. Use
oil to keep the swing pump charged as well as
of an incorrect (filter type) element will result in
provide cooling and lubricating oil for the
pump damage.
pump.
The hydraulic tank is pressurized to assist pump
The swing motor is a bent axis piston type
suction, this pressure is referred to as PUMP
that is bolted to the swing gearbox. The
INLET PRESSURE. Before starting the engine
gearbox is a double reduction planetary gear
the charge tank switch should be pressed and
unit with a spring-applied, hydraulic-release
released with the key switch in the off position.
disc brake. This provides continuously
This will start the air compressor which will pump
variable swing speeds up to 9 rpm. A rotary
air into the reservoir until the pressure reaches 0.4
Bar (6 psi) at which time the green light in the
instrument panel will illuminate indicating that the
engine can be started.
4.2
RETURN
DUAL FILTER MANIFOLD
HEADS (2)
•
• ••
PRESSURE/
VACUUM
GAUGE
• •
RETURN
FILTERS (4)
•
AIR COMPRESSOR/ OIL LEVEL
VACUUM PUMP SIGHT GAUGE
ACCESS
COVER
WITH 'O'
RETURN
TUBES
•
RING SEAL •
••
•
••
COMPRESSOR/
VACUUM
•• •
SOLENOID
VALVE
RETURN
STRAINERS
• DRAIN PLUG
250BT-012 HYDRAULIC RESERVOIR
AIR COMPRESSOR/ PUMP SWITCH FRONT OF

VACUUM PUMP IN CAB ENGINE
COMPARTMENT
•
AIR VENT SHUT-OFF
FILTER VALVE
• PRESSURE/
VACUUM
COMPRESSOR/
GAUGE
••
VACUUM
SOLENOID
VALVE
• TOP RIGHT
SIDE OF
RESERVOIR
••
250B-003
HYDRAULIC RESERVOIR
HYDRAULIC PRESSURIZATION SYSTEM 250B-004 VENT AND SHUT-OFF VALVE
The engine should not be started when the green so as to minimize oil loss. The vacuum pump
light is not lit; this will result in too high a vacuum should also be used once weekly when the
in the pump suction lines which will shorten the life machine is hot to reduce any water that may have
of the pumps. This condition will be indicated by accumulated in the reservoir due to condensation.
the red pump inlet light being on.
After using vacuum pump to perform service work
The air compressor can also be used in a vacuum on pumps or motors, charge tank and purge all air
pump mode. Pressing the vacuum tank switch with out of the pump and motor case before start-up.
the key in the off position will turn the compressor
on and shift a 4-way valve so that air is pumped
out of the reservoir. This can be done before
performing service work on the hydraulic system
4.3
244-002 COMPRESSOR ELECTRICAL SCHEMATIC

The electric schematic for the air compressor is vacuum system is activated. This switch
shown above and a description of the circuit connects the voltage on wire 131 to wire 139
operation follows. which energizes the solenoid on the four-way air
The charge tank switch is a momentary switch valve and switches the air flow so that the
and when it is depressed, voltage is on wire 133 compressor pumps air out of the tank. Wire 139
which energizes the coil on relay #30. If the is also connected to the vacuum switch and, if the
pressure in the reservoir is less than 6 psi, the vacuum in the tank is less than 9 inches of
pressure switch supplies voltage to the relay mercury, the current flows to the relay #32 coil
contacts via wire 137. When the relay coil is which shifts the relay and allows current to flow
energized, the voltage on wire 137 is fed back to from wire 131 to the compressor motor. The
wire 133 which latches the relay in the on position compressor will cycle on and off to maintain a
and energizes the coil on relay #31 which vacuum of 9 inches of mercury in the tank.
provides voltage to the compressor motor. The TROUBLESHOOTING THE COMPRESSOR
motor will continue to run until the pressure in the SYSTEM
reservoir builds up to 6 psi at which point the
pressure switch will shift the voltage from wire If the compressor fails to operate in both the
137 to wire 134; this causes the green light to “charge tank” and “vacuum” mode, check the line
come on and the compressor to stop. fuse which is in wire 131 near the fuse blocks in
the main electrical panel in the cab. If the
compressor works in one mode, the problem is
VACUUM
not in the fuse. If the fuse is OK, check the
TANK voltage at wire 135 at the compressor motor
SWITCH
connection in both vacuum and charge tank
• modes. If voltage is present, check the motor
wiring connections and the motor itself. If no
voltage is present, perform the checks below.
If the charge tank system fails to operate and the
green light is not lit, check the pressure gauge at
VACUUM TANK SWITCH the hydraulic tank to determine if pressure is in
250BT-002
the tank. If pressure is in the tank, the green light
The vacuum switch is a rocker switch with is faulty, if there is no pressure in the tank, check
indicator light which is illuminated when the for voltage in wire 137 in the main electrical panel.
4.4
If there is no voltage at 137, check 131 for The hydraulic hand fill pump, located behind the
voltage. If voltage is present at 131 in the panel, front access panel, is used for adding oil to the
check the DIN connector on the pressure switch hydraulic oil reservoir via the return filters.
located by the compressor to determine if voltage STRAINER/DIFFUSER SERVICE NOTE
is present at wire 131. If voltage is present at 131
The strainer/diffusers should be checked
check the pressure switch. With no pressure in
whenever the hydraulic tank is drained at the
the tank, current should pass between pressure
intervals specified in the LUBRICATION AND
switch terminals 1 and 2 and should not pass
MAINTENANCE SCHEDULE in SECTION 3 of
between terminals 1 and 3. If there is no
THIS MANUAL.
connectivity between terminals 1 and 2, replace
the switch. If there is connectivity between CHANGING OR CLEANING THE STRAINER/
terminals 1 and 2, check the DIN connector DIFFUSERS:
attachment of wire 137 and wire 131 and then
continue checking connections on wire 137 until This should be performed in the event of a
the problem is found. pump failure or hydraulic oil contamination.
If there is voltage at wire 137, remove relay #30 1. Position machine on flat level ground with
and check for voltage on pin 30, and on pin 85 grapple resting on the ground.
with the charge switch depressed. If voltage is 2. Stop engine. Turn battery disconnect switch to
present on these pins, reinstall the relay and then the OFF position.
remove relay #31. Check for voltage at pin 30
3. Release the pressure in the hydraulic tank by
and at pin 85 with the charge tank switch
opening the air vent valve.
depressed. Release the charge tank switch and if
there is no voltage at pin 85, replace relay #30 4. Drain the hydraulic tank via a drain plug in the
with a new relay and recheck for voltage on pin 85 bottom of the tank.
of relay #31. If voltage is at pin 85, reinstall relay 5. Remove the lower access cover and 'O' ring.
#31 and check for operation. If the compressor
fails to run, check for voltage at wire 135 (after the 6. Before removing the strainers, clean any
charge tank switch is pressed) and replace relay debris from bottom of the tank and wipe it
#31 if no voltage is present. clean.
If the compressor does not run with the vacuum 7. Remove the four strainers using the hex on
switch depressed, check voltage at wire 139 in the end of strainer. Carefully clean the
the main panel. If no voltage is present, check strainers (avoid damage by rough handling).
the vacuum switch and wiring connections. If 8. Check for a buildup of foreign materials at
voltage is at wire 139, remove relay #32 and the strainer connections.
check for voltage at pin 30 and pin 85. If voltage
is not present at pin 30, check fuse and wiring. If 9. Reinstall the strainers using the hex on end.
voltage is present at pin 85 and the compressor 10. Reinstall access cover with a NEW “O” ring.
doesn’t run, replace relay #32 with a new relay. If
voltage is not present at pin 85, check the 11. Refill and check for leaks.
operation of the vacuum switch. Remove the DIN 12. Ensure that the air vent valve is closed.
connector from the vacuum switch and check for
NOTE: Changing strainer/diffusers and replacing
voltage at wire 139. If there is voltage at wire
the hydraulic oil tends to aerate the oil. For
139, check the vacuum switch; there should be
maximum pump life, the Vacuum Pump should be
continuity between pin 1 and 2 if there is no
run for 1 hour after servicing to allow entrained air
vacuum in the tank. If there is no continuity,
to escape from the oil prior to applying working
replace the vacuum switch.
pressures to the pumps.
Refer also to HYDRAULIC PRESSURIZATION
SYSTEM in SECTION 3 and SECTION 2 of the
OPERATOR'S MANUAL.
IMPORTANT: Before disconnecting any hoses,
release the pressure in the hydraulic tank by
opening the air vent ball valve.
4.5
ENGINE BELL
HOUSING
MAIN PUMP
• SWING
PUMP
••
250BT-007 HYDRAULIC PUMPS
HYDRAULIC PUMPS
ELECTRONIC
DISPLACEMENT
All hydraulic functions are powered by two pumps. SOLENOID
The main and swing pumps are mounted one VALVE
behind the other on the flywheel housing of the
engine. The first pump (main pump) is a piston
pump with load sensing, pressure compensating
and horsepower limiting controls.
PUMP 'POR'
Mounted and coupled to the main pump is the VALVE
swing pump. It is a pressure compensated piston
pump. •
••
For information on the hydraulic circuits that these
pumps are part of ; Refer to HYDRAULIC •• ••
SYSTEM OPERATION in THIS SECTION. 'LS' MARGIN
PRESSURE
ADJUSTING
SCREW MAIN PUMP
MAIN PUMP CONTROLLER
The main pump is an axial-piston, variable- MAIN PUMP CONTROLLER

H250B-009
displacement pump with load sensing, pressure
compensating, and horsepower limiting controls.
When all of the control valve sections on the main
valve are in the neutral position the pump is
destroked and the output is just sufficient to
maintain a pressure of approx. 34.5 Bar (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.
4.6
'LS' MARGIN
•• PRESSURE
ADJUSTING
SCREW
••
••
PUMP 'POR' ••
VALVE
'LS' MARGIN
PRESSURE
ADJUSTING
SCREW
250BT-013
250BT-009
MAIN PUMP CONTROLLER ADJUSTMENT
MARGIN PRESSURE NOTE: If the machine controls are not responding

When a function control lever is moved, i.e. as they should, i.e. boom is jerky or sluggish, the
joystick, to activate a function, LS pressure margin pressure setting may be out of
increases to the point where it is equal to the work adjustment.
port pressure and it shifts the LS control valve.
Also refer to ENGINE ANTI-STALL in SECTION 9
The pump then adjusts its output volume until the of this manual.
pump output pressure exceeds the LS pressure
The pump is protected by a high pressure limiting
by a small amount. This difference is known as
control which is attached to the main control valve
MARGIN PRESSURE (Also known as differential
manifold. Refer to HIGH PRESSURE LIMITING
pressure Delta P).
CONTROL in this section.
Refer to SET MARGIN PRESSURE in this
section. SWING PUMP
At this point the LS control valve shifts back to its For the operation and adjustments of this pump
previous condition and the swashplate control refer to SECTION 15 of THIS MANUAL.
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.
4.7
LOAD SENSING
BASIC PRINCIPALS
Figs. 1 & 2 Early hydraulic systems used a
fixed displacement pump, with valves to control
or adjust flow rates or speeds. This throttling or
restricting pump flow to achieve control over the
functions causes excess oil to flow over the WASTED
relief valve. This results in wasting power and at
the same time creating heat. SEE FIGS. 1 & 2.
FLOW
Figs. 3 & 4 In an attempt to recover some of
W
the wasted energy, variable volume pumps 853SM18
USED
evolved. These pumps are power regulated or FIG. 1 PRESSURE
horsepower controlled and since they reduce FIXED DISPLACEMENT PUMP FIG. 2 853SM16
the pumps output to maintain a constant system
hp, oil flow over the relief valve is less, therefore
reducing the wasted power losses and heat
generation. SEE FIGS. 3 & 4.
HP
The power wasted in the horsepower control
=CO
system is still considerable and still requires
NST
constant "throttling" by the operator if he wants
ANT
the speeds to remain as selected.
Figs. 5 & 6 The load control system was
developed to address the problems outlined
above.
WASTED
FLOW
This system combines the energy saving
benefits of flow on demand with load
W
compensation at each work port. The 853SM19
USED
compensator eliminates the need for operator PRESSURE
flow adjustments (throttling). SEE FIGS. 5 & 6. FIG. 3 HP REGULATED PUMP FIG. 4 853SM16
HP
=C
ON
ST
AN
T
FLOW
∆p LS
W
USED
PRESSURE
853SM17
FIG.6 853SM16
FIG.5 LOAD SENSING (FLOW ON DEMAND)
4.8
LOAD SENSING BASIC DESCRIPTION
OPEN CENTRE VS. CLOSE CENTRE
OPEN CENTRE SYSTEM:
853SM21
853SM20 If the oil flowing to the motor or cylinder meets

variable loads, this will upset the balance of oil
With the control valve in neutral all of the oil from
going to the tank and the load. This causes the
the pump “bypasses” through the open center
speed of the function to change with load
passage directly to tank. There is no back
changes.
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

This type of system exhibits the following
a cylinder or motor, the open center passage is
characteristics;
blocked off in proportion to the amount the lever is
moved. This creates back pressure forcing oil 1. If the load against the cylinder or motor
into the valve work port to move the load. 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
853SM20 pump.
When the control valve lever is fully shifted to the
maximum flow position the open center passage
is completely blocked, and all of the pump flow is
forced against the load.
4.9
CLOSED CENTRE SYSTEM: adjusts the flow of the pump to find a new balance
point. The stroking piston will change the pump’s
Load sensing systems use variable flow pumps and
flow until pump pressure is 21 Bar (300 psi)
only flow oil when required. Unlike the open centre
higher than load pressure.
system, the control valve does not have an open
centre passage. When in neutral, no oil flows In the figures below note that even though the
through the control valve to tank and the pump load pressure may change, (as illustrated by the
output flow is zero. The pump’s output flow is extra restriction) the flow remains constant. This
controlled by a “stroking piston” which is connected is because the difference in pressure, or
to the pump output, and to the valve’s work port or differential pressure, between the pump and
“load”. This sense line to the actual working load load pressures can be maintained by the stroking
defines the system as load sensing. piston regardless of load. It is important to
remember the pump is really responding to the
The key component in the system above is the
pressure differential resulting from flow through
spring in the stroking piston. The pump’s output
the valve, not the actual load pressure level.
pressure must be 21 Bar (300 psi) higher than the
load pressure to compress the spring and reduce
the flow of the pump. This 21 Bar (300 psi) is the
differential or margin pressure.
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 21 Bar (300 psi) of stand-by pressure
and pump flow is zero.
853sm22
The following are key differences from open

centre systems;
1. The load sensing valve’s maximum flow is not
equal to the pumps maximum flow as with the
open centre system. The valves maximum
flow is determined by the maximum size of
853sm22
opening or “orifice” it provides.
When the control valve lever is moved to actuate a 2. The speed of the load does not change as the
cylinder or motor, the control valve opens the pump load changes. If the load increases on a
to the load. In this case the load is zero and the boom cylinder the pump pressure will
pump output pressure falls as the oil escapes increase automatically to maintain the load’s
through the valve. The 21 Bar (300 psi) that was original speed. If the load stops, it is because
holding the spring in the compressed state is the load is too heavy for the boom to lift.
reduced and the spring moves the pump to Moving the lever further will not increase the
increase flow. Flow will increase to a level that lifting force.
requires 21 Bar (300 psi) to force the oil through
3. A load sensing system provides the speed the
the valve opening. At this point the load pressure
operator selects with the lever, and
combined with the spring force will be high enough
automatically adjusts the pressure to match
to oppose the pump output pressure, and the
the load. The open centre system requires the
stroking piston will stop moving.
operator to adjust the pressure to match the
Changing the control valve lever changes the size load and the speed is determined by the load.
of the opening in the valve and upsets the balance
of the stroking piston. The stroking piston then
4.10
OPERATING TIPS MAIN HYDRAULIC CIRCUIT
When using the controls on a load sensing The main hydraulic circuit utilizes a piston pump,
system think of what the system is trying to do for which supplies oil to a load sense system, which
you. If you move the lever or pedal 20% of its total operates the track drive, hoist, stick, and the
angle, the system will provide whatever pressure attachment functions. The control valve is a nine-
it takes ( up to its maximum capacity if needed) to section plus mid-inlet section, mono-block valve,
meet this speed requirement. If you move the which sends a load sense signal, from the LS
lever past the point needed in an attempt to speed port, to the pump controller whenever one of the
up the boom movement, you will only overshoot functions is activated. Its own spool supplies oil
the speed you wanted. Open centre systems for each function. When all spools are in neutral,
responded to larger lever angles with increased no oil is flowing through the valve and hence the
boom speeds, but this system will not. Relax and system is closed-centre. The pump maintains a
try to use the least amount of lever action you stand-by pressure of approximately 500 psi and
can. supplies just enough oil to make up for leakage
when all control valves are in neutral. All valve
Load sensing systems respond to rough operation
sections except the track drive utilize cylinder
by amplifying these movements. If you find the
spools, which trap oil in their circuits when the
boom is jerky or always giving “feedback”, you’re
spools are in neutral. The track drive, valve
probably too active on the controls. If slowing
sections use a motor spool which has a passage
down doesn’t eliminate the roughness, the
between the work ports and the return passage
margin pressure setting may be too high and
when the spool is in neutral.
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
FLOW ON DEMAND To make both functions move the operator would
AND LOAD COMPENSATION have to move the high load lever much more than
the low load lever. In other words, the operator
The combination of control valves and pump used
would have to restrict oil flow to one function while
in this system provides flow on demand and load
opening up the valve fully to the other. This is
compensation. Flow on demand means that only
what the load compensation system does
the required quantity of oil will be delivered to a
automatically.
function by the pump. This will save energy and
reduce heat generation in the hydraulic system. With the load compensation on this unit the
Load compensation means that all functions will operator does not need to continually adjust the
continue to receive oil regardless of their pressure control lever to move two or more functions
and without further movement of the control levers. because of pressure differences.
Without this system, an operator moving control Valves inside of the main control valve spools will
levers halfway on the boom up and stick out automatically adjust flow according to the pilot
controls would find that the lowest pressure function pressure applied to the spool to move functions
would move and the other would not move. independent of load pressure.
MAIN SWING
PUMP PUMP
•• ••
••
'LS' •• PILOT
SIGNAL PRESSURE
SIGNAL
250BTH-003
LOAD SENSING SYSTEM CIRCUIT DIAGRAM
4.12
250BT-027
250BTH-005 MAIN CONTROL VALVE

MAIN VALVE DESCRIPTION The main valve is a load sensing and pressure
compensated proportional valve and consists of
The main valve is located in the upper frame. It
nine* spool sections (*Note: the number of
can easily be accessed by removing the valve
sections installed in the valve will vary with
compartment cover on the left side of the upper
options selected). The valve also includes an
frame.
inlet section, mid inlet section and an end section.
4.13
MAIN VALVE DESCRIPTION CONT'D
INLET SECTION
The inlet section is equipped with connection
ports to the main pump, tank, a load sense signal
(‘LS’) to the main pump. Integrated into the inlet
section are the main valve main pressure relief, a
load sense signal copy valve, and a counter
pressure valve.
PILOT PRESSURE SUPPLY
Pilot pressure supply is provided as an internal
function of the Main Valve. Pressure is regulated
internally to 35 bar (508 psi).
MAIN PRESSURE RELIEF VALVE

The inlet section of the main valve houses a 330
bar (4785 psi) direct acting port relief. This
pressure relief valve is intended to protect the
main pump and main valve from pressure peaks
in the system. The cartridge also has a make-up
function that allows oil to flow from the tank
gallery to the pump gallery in the event of
underpressure in the pump circuit. The relief
cartridge is not adjustable. Refer to REPLACING
MAIN PRESSURE RELIEF VALVE CARTRIDGE
in THIS SECTION.
250BTH-041
INLET SECTION SCHEMATIC
OUTLET
INLET (TO RETURN
(FROM MAIN PUMP) MANIFOLD)
• •
PRESSURE COUNTERPRESSURE
MAIN RELIEF VALVE
VALVE •
•
PILOT PRESSURE
RELIEF AND
LOAD
SIGNAL
COPY
•• SAFETY VALVE
VALVE
• • •
‘PS’ PORT
• • (FROM PILOT
SYSTEM FILTER)
‘PL’ TEST PORT

(NOT COPIED)
‘LS’ TEST PORT
‘PX’ TEST PORT (COPIED)
(PUMP PRESSURE)
250BTH-012A INLET SECTION
4.14
MAIN VALVE DESCRIPTION CONT'D gallery. Raising the counter pressure reduces the
LOAD SENSING SYSTEM risk of cavitation damage (which decreases the
risk of damaging cylinder seals).
Shuttle valves installed in each spool section of
the main valve provide the load sense signal from END SECTION
the main valve function sending the highest The end section is equipped with a separate tank
pressure signal. The load sense signal is then connection for the pilot circuit. The main tank
copied by the load signal copy valve located in the gallery in the boom valve and the pilot circuit tank
inlet section of the main valve. The load sense gallery are not connected. The T1 port is
signal is sent from the LS port in the main valve to connected to the return filter manifold.
PL port on the main pump.
LSP is connected to P2 of the pilot manifold to
COUNTER PRESSURE VALVE create LS signal to keep pump maintaining pilot
The counter pressure valve, housed in the inlet pressure.
section, raises the pressure in the valve’s tank
250BTH-006 SCHEMATIC DIAGRAM OF "LS" CONTROL & VALVE SECTION
4.15
SPOOL SECTIONS MAIN VALVE DESCRIPTION CONT'D
PORT RELIEF FEED PORT RELIEF 24V PROPORTIONAL
‘B’ SIDE REDUCTION ‘A’ SIDE ELECTRO-HYDRAULIC
SIDE ‘A’ SPOOL ACTUATORS
FEED
REDUCTION • • •
SIDE ‘B’ •
‘B’ ‘A’
• •
‘A’ ‘B’
SPOOL
PRESSURE
250BTH-013 COMPENSATOR
SPOOL SECTION WITH PROPORTIONAL ELECTRO-HYDRAULIC SPOOL ACTUATORS
Three of the main valve spool sections (Pump 1 and two spares) are equipped with proportional, electro-
hydraulic spool actuators. The actuators are spring centered to the neutral position, and are shifted by
sending a 24 volt proportional current signal to the appropriate solenoid.
•
•• • ‘B’ ‘A’ •
•• ••
•• ••
SPOOL SECTION WITH PROPORTIONAL PILOT OPERATED SPOOL ACTUATORS
Six of the main valve spool sections (Hoist, Stick, Head Rotate, Track Drive and Pump 2) are equipped
with proportional, pilot operated hydraulic spool actuators. The actuators are spring centered to the
neutral position, and are shifted by sending a hydraulic signal to the appropriate hydraulic spool actuator.
4.16
MAIN VALVE DESCRIPTION CONT'D HIGH PRESSURE LIMITING CONTROL
SPOOLS
The main pump is protected by a POR valve set
Each of the spools installed in the main valve is to 310 bar (4500 psi) (Gauge at 'PX' test port on
selected specifically for the function it is the inlet section of the main valve) .
controlling. For example, the hoist boom section
Also, as previously mentioned, the inlet section of
spool has different characteristics than the track
the main valve houses a non adjustable 330 bar
drive spool. These spools cannot be
(4785 psi) direct acting main relief. This pressure
interchanged.
relief valve is intended to protect the main pump
PRESSURE COMPENSATION and main valve from pressure peaks in the
system.
The primary purpose of pressure compensation is
to maintain a constant flow rate to function (ie: The differential pressure (or the difference
maintain the same speed of movement), between 'PX' port pressure and 'PL' port
regardless of pressure variations in the system. pressure, observed while a function is operating is
The pressure compensator also contains a load- set to 26 Bar/375 psi) is known as margin
hold check valve. An orifice is installed pressure.
immediately down stream of the pressure
NOTE: 'PL' and 'LS' are the same pressure. The
compensator to smoothly regulate the response of
'PL' port is equipped with a test fitting for testing
the compensator.
'LS' pressure.
PORT RELIEFS
See SET MARGIN PRESSURE in THIS
The main valve is equipped with port reliefs on SECTION.
some spool sections (Hoist, Stick, Rotate, Spare)
(NO Port Reliefs on L.H. Track, R.H. Track, P2,
Spare, P1). The function of the port relief is to
protect the valve and the function cylinder or
motor from pressure peaks in the system. The
port reliefs also act as anti-cavitation valves, which
means they allow oil to flow from the tank gallery
in the valve to the service ports in the event of
underpressure. The port reliefs cannot be
adjusted. Port reliefs installed in each section are
specifically designed for use in that section should
not be interchanged with port reliefs from other
valve sections.
4.17
•
'POR'
ADJUSTING SCREW
(Turn OUT to decrease
pressure)
•
MARGIN PRESSURE
ADJUSTING SCREW
(Turn OUT to decrease
Margin pressure)
•
LOAD SENSE
PRESSURE
250BT-012A
MAIN PUMP CONTROL VALVE
SET MARGIN PRESSURE Margin pressure is set at the factory to 26 Bar
MARGIN PRESSURE is the difference (375 psi) If required the margin pressure can
between the LOAD SENSE pressure and the be adjusted as follows:
PUMP OUTPUT pressure with engine at Idle 1. Use a differential pressure gauge (preferably
and pilot circuit engaged. For the load a differential gauge with ten psi increments).
sensing system to operate correctly the
differential pressure at 'PX' should be 26 Bar
(375 psi) higher than 'LS'
**NOTE: If the margin pressure is not set
correctly, the machine controls response may
be jerky or sluggish.
ELECTRONIC
DISPLACEMENT
SOLENOID
VALVE
PUMP 'POR'
VALVE
•
••
•• ••
'LS' MARGIN
PRESSURE
ADJUSTING
SCREW MAIN PUMP
CONTROLLER
250BT-030
MAIN VALVE TEST PORTS
MAIN PUMP CONTROLLER 250BTH-010 - INLET SECTION
H250B-009
The margin pressure adjustment is made at 2. With hydraulic oil at operating temperature,
the main pump controller attached to the main Connect one side of the differential pressure
pump. The pressure gauge connections are gauge to the 'PL' gauge test port located on
the 'PL' and 'PX' gauge test ports on the main the inlet section of the main control valve and
valve inlet section. the other side of the gauge to the pressure
'PX' gauge test port.
4.18
ELECTRONIC
DISPLACEMENT
SOLENOID
VALVE
PUMP 'POR'
VALVE
••
•
•• ••
'LS' MARGIN
PRESSURE
ADJUSTING
SCREW MAIN PUMP
CONTROLLER
H250B-009 MAIN PUMP CONTROLLER
3. Start the engine and and set engine speed to

Low Idle.
4. Press PILOT RESET button to activate pilot
system with anti-stall switch OFF.
5. Observe gauge.
6. Loosen locknut on margin pressure adjusting
screw on main pump controller and turn
adjusting screw until the differential reading
on gauge/s is 26 Bar (375 psi)**. (Turn OUT
to decrease Margin pressure).
NOTE: This is a sensitive adjustment,
significant changes in pressure will be noticed
with only a small movement of the adjusting
screw.
**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.
4.19
MAIN PUMP POR VALVE SETTING
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 tracks
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.
CHECKING 'POR' VALVE SETTING

Main pump POR setting ...... 310.3 Bar/4500 psi
Main relief setting ................... 330 Bar/4785 psi 250BT-030
MAIN VALVE 'PX' TEST PORT
250BTH-014 - INLET SECTION
Hoist up port relief setting .... 330 Bar/4785 psi
Hoist down port relief setting 330 Bar/4785 psi
NOTE: The main and port relief valves are not
adjustable, the following procedure is for checking
main pump 'POR' pressure only.
1. Position machine on flat level ground.
2. Ensure that the hydraulic oil is at operating
temperature.
3. Connect a0-350 Bar ( 0 - 5000 psi) pressure
gauge to the "PX" valve test port on the inlet
section of the main control valve.
4. Start the engine, and put the throttle control to
the FULL position. Lower left arm rest and
depress the pilot reset switch to activate the
pilot system.
5. While holding the L.H. joystick in the HOIST
UP position (fully extended), check gauge
pressure reading. Should be 310.3 Bar (4500
psi).
While holding the L.H. joystick in the HOIST
DOWN position (fully retracted), check gauge
pressure reading. Should be 310.3 Bar (4500
psi).
4.20
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.
If less than set value in one direction but OK

in the other direction the port relief valve for
the low reading circuit is malfunctioning,
replace the port relief valve.
ELECTRONIC
DISPLACEMENT
SOLENOID
VALVE
PUMP 'POR'
VALVE
••
••
•• ••
'LS' MARGIN
PRESSURE
ADJUSTING MAIN PUMP
SCREW CONTROLLER
250BT-008 MAIN PUMP CONTROLLER
If less than set value in both directions turn

pump POR valve adjusting screw in (the
pressure reading should increase if the POR
was set too low) until set value is obtained on
gauge.
If when adjusting POR setting the pressure
does not change then the main relief is
malfunctioning and should be replaced.
6. After checking pressures and if POR valve
was adjusted reset the POR to 310.3 Bar
(4500 psi). Tighten locknut on POR adjusting
screw taking care not to turn the adjusting
screw.
7. Stop engine. Remove pressure gauge and
wipe up any excess oil from test port area.
4.21
PRESSURE SETTINGS
Engine RPM ....................................................................... 1875 rpm @ Full throttle (no load)
............................................................................................. 900 rpm @ Idle (no load)
Pilot System
Main Relief ....................................... 34.5 Bar (500 psi) + 1/2 turn in @ Full throttle
Main Valve High Pressure Limiting Control
MAIN PUMP P.O.R. (‘PX’ port) ........................... 310 Bar (4500 psi) @ Full throttle
Margin Pressure (‘PX’ - ‘PL’) ................................. 26 Bar (375 psi) @ Full throttle
Main Valve Port reliefs
Hoist DOWN ...................................................... Spool out 4.5 turns 8 Seconds
Hoist UP ................................................................ Spool out 8 turns 8.5 Seconds
R.H. Track Forward ........................................................ See Note 6
R.H. Track Reverse ........................................................ See Note 6
Feed Reducer A **Rotate CW ......................... 110.3 Bar (1600 psi) 34 L/m 30 rpm
Feed Reducer B **Rotate CCW ...................... 110.3 Bar (1600 psi) 34 L/m 30 rpm
L.H. Track Forward ......................................................... See Note 6
L.H. Track Reverse ........................................................ See Note 6
Stick IN ............................................................. Spool out 5.25 turns 6 Seconds
Stick OUT .............................................................. Spool out 7 turns 6.75 Seconds
Feed Reducer A - **Pump 2 Return ........................... *0 Bar (*0 psi) Spool out 0.5 turns
Feed Reducer B - **Pump 2 Pressure ............. *283 Bar (*4100 psi) Spool out 8 turns
Feed Reducer A - Pump 1 Return .............................. *0 Bar (*0 psi) Spool out 0.5 turns
Feed Reducer B - **Pump 1 Pressure ............. *262 Bar (*3800 psi) Set Saw Speed 9500 rpm
Drive Brake Release Pressure ............................ 34.5 Bar (500 psi)
Drive Begin Of Regulation (See Note 7) ............ 214 Bar (3100 psi)
* Set pressure with gauge on 'PL' port
** Dependent on Head
Cab Tilt
Cab Tilt Main Relief ............................................. 207 Bar (3000 psi)
Cab Tilt Counterbalance Valves ....................... 241.3 Bar (3500 psi)
Swing Pump
Swing Pump Charge Pressure ................................ 24 Bar (350 psi)
Pump POR ...................................... 310 Bar (4500 psi) + 1/2 turn in
HIGH PRESSURE RELIEF Swing CCW ......***352 Bar (***5100 psi)
HIGH PRESSURE RELIEF Swing CW..........***352 Bar (***5100 psi)
***Swing machine slowly 5 times in each direction before setting pressures. Do not hold pressure over
relief more than 8 seconds at a time. Wait 5 seconds to avoid overheating.
ALL PRESSURES MUST BE SET WITH HYDRAULIC OIL AT OPERATING TEMPERATURE.

NOTE: The above values are for reference purposes only,
SEE SERVICE MANUAL FOR SETTING PROCEDURE.
4.22
PRESSURE SETTINGS
NOTES:
1. SYSTEM TO BE AT OPERATING TEMPERATURE WHEN SETTING PRESSURES.
2. ALL PRESSURES MEASURED IN PSI. ALL SPEEDS MEASURED IN SECONDS.
3. F - DENOTES PRESSURES SET AT FULL ENGINE RPM.
I - DENOTES PRESSURES SET AT ENGINE IDLE.
4. PORT RELIEFS CANNOT BE ADJUSTED. EACH PORT RELIEF HAS A SPECIFIC SETTING
AND SHOULD NOT BE INTERCHANGED WITH OTHER PORT RELIEFS.
5. SET MARGIN PRESSURE WITH PILOT SYSTEM ACTIVATED (DO NOT USE ANY
FUNCTIONS). THIS IS THE BOTTOM (LARGE) ADJUSTMENT ON THE MAIN PUMP.
6. TRACK SPEEDS SET TO 12 RPM LOW (10 RPM LOW FOR SHOVEL LOGGER
UNDERCARRIAGE OPTION) AND 28 RPM HIGH BY MAKING ADJUSTMENTS IN THE
FOLLOWING ORDER:
A) SET MOTOR MAXIMUM DISPLACEMENT TO 105cc.
B) SET LOW FORWARD (VALVE FLOW SETTING).
C) SET HIGH FORWARD (MOTOR MINIMUM DISPLACEMENT).
D) SET HIGH REVERSE (VALVE FLOW SETTING).
7. TRACK DRIVE BEGIN OF REGULATION VALVES TO BE SET AT ENGINE IDLE USING THE
FOLLOWING PROCEDURE:
A) DISCONNECT AND PLUG BOTH MOTOR BRAKE RELEASE LINES.
B) LOWER MAIN PUMP P.O.R. TO 214 BAR/3100 PSI. AT IDLE.
C) OPERATE TRACK IN HIGH SPEED (TRACK SHOULD NOT MOVE).
D) ADJUST BEGIN OF REGULATION VALVE ON EACH MOTOR TO GIVE PRESSURE
BEWTEEN 800 AND 1000 PSI AT MOTOR TEST PORT.
E) RESET MAIN PUMP P.O.R. AT FULL ENGINE RPM AND RECONNECT BRAKE LINES.
8. TILT CAB NOTES:
A) TURN COUNTERBALANCE VALVES OUT FULLY, THEN IN 1 TURN.
B) TILT VALVE IS FACTORY PRESET.
37884B.AI R0 MAIN AND PILOT VALVE FUNCTION DESCRIPTION AND DESIGNATIONS

4.23
MAIN VALVE ASSEMBLY
AT264 VALVE ASSEMBLY

FEED
REDUCTION • • • •
SIDE ‘B’
‘B’ ‘A’
• •
‘A’ ‘B’
SPOOL
PRESSURE
COMPENSATOR
250BTH-013 SPOOL SECTION WITH ELECTRO-HYDRAULIC SPOOL ACTUATOR

4.24
SECTION 5 - PILOT SYSTEM

AUGUST, 2007
CIRCUIT DIAGRAM ............................................................................... 5.5, 5.6
ELECTRICAL CIRCUIT .................................................................................. 5.5
PILOT SYSTEM COMPONENTS ................................................................... 5.2
GENERAL DESCRIPTION ......................................................................... 5.2
JOYSTICKS AND FOOT PEDALS ............................................................. 5.4
PILOT MANIFOLD ...................................................................................... 5.2
PILOT SUPPLY VALVE .............................................................................. 5.2
PRESSURE SETTINGS ................................................................................. 5.5
Tigercat H250B Harvester Pilot system
PILOT SYSTEM COMPONENTS GAUGE
TEST PILOT
GENERAL DESCRIPTION PORT MANIFOLD
The pilot circuit is supplied with oil by the main
pump via the attachment valve. A pilot supply ••
valve located in the main valve reduces and
maintains the pressure of the oil from the main
pump to 34.5 Bar (500 psi) for the pilot system.
The pilot oil (34.5 Bar/500 psi) is then supplied to •
the pilot pressure filter and then to the pilot •
manifold. Pilot oil is distributed by the pilot
manifold to the various pilot actuated functions of PILOT RELIEF
VALVE
the machine. Solenoid operated pilot valves, 250BT-011 PILOT MANIFOLD
within the pilot manifold, control the flow of pilot oil
to various functions. Joysticks and foot pedals PILOT MANIFOLD
also distribute oil to shift spools in their The pilot manifold is located below the floor plates
corresponding control valves. in the hydraulic valve compartment.
PILOT SUPPLY VALVE The pilot manifold distributes oil to the following
(pressure reducing/relieving valve) circuits:
The pilot supply valve is a pressure reducing relief • Joysticks (both) (P1) port
valve built into the inlet section of the main control
• Gauge test port (P3) port
valve. The reducing/relieving valve is not
adjustable and is set at 34.5 Bar (500 psi). Refer • Pressure Sensor port (G) port
• Track Drive Enable (A) solenoid valve
• Travel Speed Low (B) solenoid valve
• Swing Brake Release (B) solenoid valve
LOCATED LOWER
Pilot oil enters the manifold through the inlet port.
LEFT SIDE OF
ENGINE The pilot shut off valve, which is an integral part
COMPARTMENT
of the pilot manifold, controls the flow of oil from
the INLET port to the four outlet ports labelled (
P1, P2, P3 and G) and to the three solenoid
•• PILOT
FILTER
operated pilot valves. The pilot shut off valve is
ELEMENT
activated by pressing the pilot reset switch in cab
(with the left armrest down).
Two outlet ports ('P1 and P2') on each end of the
250B-016 HYDRAULIC PILOT FILTER
pilot manifold, feed the main control valve PS and
to SET PILOT PRESSURE in THIS SECTION. LSP ports, the main pump PSV port, both
PRESSURE FILTER joysticks and pump 2 solenoid valve. A gauge test
This filter is a cartridge filter with a built-in port (P3) has a quick connect fitting installed for
differential pressure relief valve, if the pressure connecting a pressure gauge to perform pressure
differential at the oil filter exceeds 3.5Bar (50 psi) setting procedures.
this valve will bypass the pilot oil back to the tank. Three solenoid operated pilot valves on the
This will also result in lower pilot pressure. If a manifold, when energized, supply "on demand"
loss of controls or slow response is experienced pilot oil to the corresponding functions. These
the filter element may need to be changed. valves are activated by controls in the cab.
Two tank ports ('T1 and T2') drain return oil to
the reservoir.
5.2
250BTH-020 PILOT HYDRAULIC GROUP
'P1' TO MAIN
'P2' TO MAIN VALVE GAUGE SWING LOW SPEED TRACK DRIVE PILOT SHUT VALVE 'LSP' AND
'PS' PORT AND BRAKE TRAVEL ENABLE OFF VALVE
TEST PORT JOYSTICK PILOT
MAIN PUMP 'Psv' SUPPLY
PORT
•• •• • •• PRESSURE
SENSOR
PORT
INLET
•• •• •• PILOT ••
RELIEF
VALVE •
RETURN OIL •• •• •
TO TANK
'T' RETURN OIL, JOYSTICK AND
250BT-10A PILOT MANIFOLD SWING FOOT PEDAL TO TANK
5.3
JOYSTICKS AND FOOT PEDALS
1
These pilot valves are manually operated, •
directional control valves and operate on the 5
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 3
oil to the main control valve pilot end caps. The
corresponding spool valve then shifts from its •
4
centre position and directs pump flow to operate a • •
TANK
function. PORT 8
OPERATING DESCRIPTION • •
•
In the neutral position the joystick lever, or foot 2
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 WORK PRESSURE WORK
PORT PORT PORT
time the regulating spool (2) is moved down
against the regulating spring (3). When the AW015 JOYSTICK PILOT VALVE
regulating stroke begins, there is a connection
made between the pressure port, via holes (8) in
the spool and work ports in the base of the valve.
Pilot pressure is directly proportional to the
operator position of the joystick or foot pedal and
the regulating spring characteristics.
1
•
5
•
3
•
• •
TANK
PORT
4
• 8
•
•
2
• •
WORK PRESSURE WORK
PORT PORT PORT
FOOT PEDAL PILOT VALVE

AW017
5.4
PILOT SYSTEM ELECTRICAL CIRCUIT
CIRCUIT "OFF"
PILOT VALVE
CIRCUIT "ON"
PILOT VALVE
250BT-022
250BT-023 PILOT SYSTEM ELECTRICAL CIRCUIT DIAGRAM
PILOT
Refer to circuit diagram;
SET PILOT PRESSURE
The pilot shut off valve solenoid is not energized
until the armrest is down and the pilot reset switch 1. With hydraulic oil at operating temperature,
is pushed. Wire 33 connects the armrest switch to connect a 0-70 Bar (0-1000 psi) gauge to the
the pilot shut off valve solenoid. Wire 95 connects gauge test fitting on the pilot manifold.
the pilot reset switch to the armrest switch. When 2. Loosen locknut and turn adjusting screw all
the pilot reset switch is pushed ON with the the way OUT on pilot relief valve, tighten
armrest DOWN, the coil on the pilot shut off relay locknut on adjusting screw.
is energized closing the circuit between wires 6
and 11 to energize the coil in the pilot shut off 3. Start engine and set throttle in FULL position.
valve. With the coil energized the valve spool in 4. Loosen locknut on pilot relief valve and turn
the pilot shut off valve is shifted to supply oil to the adjusting screw IN until pressure gauge at
pilot circuit. At the same time wire 95A from the pilot manifold reads 34.5 Bar (500 psi) then
pilot reset switch is connected back to the pilot turn adjusting screw IN an additional 1/2 turn.
shut off relay through a diode and thus latches the
5. Stop engine, and remove pressure gauge.
pilot shut off relay in the energized position.
PILOT
The diode in the circuit prevents the flow of MANIFOLD
BODY RELIEF VALVE
current to the pilot shut off valve solenoid when CARTRIDGE
the armrest switch is open (armrest up). Even if •
LOCKNUT
the pilot reset switch is held down, it will not
operate. Whenever the arm is raised and the ADJUSTING
SCREW
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 OUT • •
normally closed position. This prevents pilot oil •
from reaching the controls. IN
240B-01 PILOT RELIEF VALVE
5.5
250BTH-009 PILOT SYSTEM CIRCUIT DIAGRAM

5.6
SECTION 6 - ELECTRICAL, GAUGES & ALARMS
AUGUST, 2007
CAB WIRING AND ELECTRICAL COMPONENT LOCATIONS .................... 6.6
DISPLAY MODULE ........................................................................................ 6.4
COMPONENT DESCRIPTION ................................................................... 6.4
KEYPAD FUNCTIONS ............................................................................... 6.4
START-UP OPERATION ............................................................................ 6.4
ELECTRICAL SCHEMATIC
SHEET 1 ................................................................................................... 6.14
SHEET 2 ................................................................................................... 6.15
SHEET 3 ................................................................................................... 6.16
SHEET 4 ................................................................................................... 6.17
FUSE AND RELAY PANEL .......................................................................... 6.10
GAUGES AND ALARMS ................................................................................ 6.2
GAUGES AND WARNING LIGHTS ....................................................... 6.6, 6.9
INSTRUMENT PANEL WIRING DIAGRAM ............................... 6.6, 6.11, 6.13
SENSOR LOCATIONS ................................................................................... 6.3
WARNING LIGHTS ................................................................................ 6.6, 6.9
Tigercat H250B Harvester Electrical, Gauges and Alarms
GAUGES AND ALARMS
The H250B Harvesters are monitored for proper
operation by sensors located in the hydraulic system
and on the engine. These sensors are connected to
the Plus 1 Electronic Control, PowerView Display
and warning lights.
The operator may sound the warning horn at any
time.
For operation of the PowerView Display and warning
lights listed in the sensor chart below, refer to
SECTION 2 of the OPERATOR'S MANUAL.
For replacement parts information, refer to GAUGES
AND SENDERS in GROUP 600 of the PARTS
CATALOG.
SENSOR DISPLAY LIGHT INFORMATION

FUNCTION
Engine oil pressure PowerView YES RED Light comes ON below 15psi. *
STOP engine below 15 psi
Engine coolant temp. PowerView YES 181°F-203°F operating range (Cummins engine)
RED light comes ON above 215°F *
Engine coolant level NONE YES RED light comes ON when level in surge tank is LOW
Hydraulic oil temp. PowerView YES RED light comes ON above 205°F *
Hydraulic oil level LOW SIGHT GLASS YES Red light comes ON indicates 13 gallons below FULL *
Pilot Pressure NONE NONE Sensor provides pilot pressure signal for Plus 1
Control Module (Idle Down function)
Wait to start PowerView YES YELLOW light turns ON when grid heater elements ON
Fuel Level Sight Gauge YES YELLOW light turns ON when fuel level drops to 20 L
Pump Inlet NONE YES RED light turns ON when pump inlet is below
0.14 Bar (2 psi)
Water in fuel NONE YES YELLOW light comes ON when fuel/water separator
needs to be drained
Safety Alert HORN NONE NONE Switch on control panel - press to sound horn
Track Drive Signal NONE NONE Switch provides track drive signal for Plus 1
Control Module (Overrides Idle Down function
when machine is travelling)
*NOTE:
Panel buzzer sounds when engine oil pressure too
low OR engine coolant temperature too high OR
hydraulic oil temperature too high OR hydraulic oil
level too low.
6.2
CONTROL
PANEL
•
PILOT
MANIFOLD
AND
•• SOLENOIDS
PUMP 2
SOLENOID
•• ••
CONTROL JOYSTICKS
VALVE •••
•• •• PILOT
••
PRESSURE PILOT
SENSOR SHUT-OFF
SOLENOID
ACTIVATED
CONTROL
•• SWITCH
VALVES (3) TRAVEL

SIGNAL
SWITCH
CAB TILT
SWITCH
FUSE & RELAY

••
ELECTRICAL
BOX (SHOWN
MOVED OVER • •• A/C
PRESSURE
SWITCH
& TURNED UP) PLUS 1
CONTROLLER • ••
• •• • COOLANT
LEVEL PROBE
BATTERY
DISCONNECT A/C
SWITCH
• • COMPRESSOR
SWING
PUMP
ANTI-DRIFT
SWITCH
MAIN PUMP
DISPLACEMENT
••
CONTROL
SOLENOID
• •• • •• •
SAFETY
STARTER ALTERNATOR
•• ALERT
HORN
• • 12 VOLT
BATTERIES
24 VOLT
(SWITCH
ON
SYSTEM CONTROL
PANEL)
SENSOR- HYDRAULIC
OIL TEMPERATURE MAIN PUMP
INLET TRAVEL
SIGHT GAUGE/SWITCH - PRESSURE ALARM
HYDRAULIC OIL LEVEL SWITCH
(RED LIGHT)
250BTH-027 SENSORS AND ELECTRICAL COMPONENT LOCATIONS
6.3
POWERVIEW DISPLAY MODULE
1 7
• ••
2
3
••
•• •• •
•
6
4 5
244-007 POWERVIEW DISPLAY MODULE
COMPONENT DESCRIPTION
1. Amber Warning LED
244-046 POWERVIEW DISPLAY MODULE 2. Display
The PowerView Display Module is the operator 3. Menu Key

interface with the electronic engine controls.The 4. Left Arrow Key
PowerView is a multifunction tool that enables the
operator to view various engine parameters and 5. Right Arrow Key
service codes. The PowerView includes a 6. Enter Key
graphical backlit LCD screen controlled via menu
7. Red Shutdown LED
selection. The display can show either a single
parameter or a quadrant display showing 4 START-UP OPERATION
parameters simultaneously. Diagnostic
capabilities include fault codes with text KEYPAD FUNCTIONS
translation for the most common fault conditions. MENU KEY - This key is pressed to enter or
The PowerView has four buttons used to navigate exit menu screens.
the display with ease. LEFT ARROW KEY - This key is pressed to
DISPLAY PARAMETERS scroll through the screen either moving the
parameter selection toward the left or down.
The following are some of the functions displayed
by the PowerView Display Module: RIGHT ARROW KEY- This key is pressed to
scroll through the screen either moving the
Engine RPM parameter selection toward the right or up.
Engine Hours
Machine Hours ENTER KEY - This key is pressed to select
System Voltage the parameter that is highlighted on the
% Engine Load at the current RPM screen.
Coolant Temperature Refer to manufactures Operations Manual
Oil Pressure (supplied with the machine) for detailed
Fuel Economy information.
Throttle Position
Engine Manifold Air Temperature When power is first applied to the PowerView, the
Current Fuel Consumption “Logo Screen” will be displayed, the “Wait to Start”
Active Service Codes message will be displayed. Once the “Wait to Start”
Stored Service Codes from the engine message is no longer displayed the operator may
Set Units for display (English or Metric) start the engine. When the engine has started the
Engine Configuration Parameters display will show the single engine parameter
display.
6.4
NOTE: The fault can only be cleared by correcting
the cause of the fault condition.
Some of the display and warning functions are:
LOW ENGINE OIL PRESSURE - RED LED
This light will come ON when the engine oil
pressure falls below 15 psi. If this light comes ON
stop the engine and determine cause.
ENGINE COOLANT TEMP. - RED LED
244-007 SINGLE PARAMETER DISPLAY
This light will come ON when the engine coolant
MAIN MENU NAVIGATION temperature rises above 215°F If this light comes
1. Starting at the single or four engine parameter ON stop engine and determine cause. Do not
display, depress the “Menu Button”. continue to operate machine.
TACHOMETER
This display indicates the RPM. of the engine.
HOUR METER
There are two options available for displaying
hours:
TOTAL ENGINE HOURS - displays total hours the
244-047 engine has run as provided by the engine
2. The first seven items of the “Main Menu” will computer.
be displayed. MACHINE HOURS - displays the total hours the
3. Depressing the “Arrow Buttons” will scroll engine has run as calculated by the display
through the menu selections. module.
4. Pressing the right arrow button will scroll ENGINE OIL PRESSURE
down to reveal the last items of “Main Menu” Oil pressure must be greater than 15 psi at all
screen highlighting the next item down. times. If the oil pressure drops below 15 psi, stop
5. Use the arrow buttons to scroll to the desired the engine and determine cause. Check engine oil
menu item or press the “Menu Button” to exit pressure every time the engine is started.
the Main menu and return to the engine The oil pressure at high idle and full load should
parameter display. normally operate between 30 and 60 psi.
FAULTS AND WARNINGS NOTE: At low idle rpm the oil pressure will be low.
During normal operation the single or four This is not an abnormal condition, however it must
parameter screen will be displayed. When the be closely monitored.
PowerView receives a fault code from an engine ENGINE COOLANT TEMP.
control unit the single or four parameter screen Normal operating range is between 181°F and
will be replaced with the “Active Fault Codes” 203°F. If the temperature rises beyond 210°F,
message. reduce the load on the engine and check for a
To acknowledge and “Hide” the fault and return to plugged radiator. If the temperature does not
the single or four parameter display press the drop, stop engine and determine cause. Do not
“Enter Button”. The display will return to the single continue to operate machine.
or four parameter screen. VOLTAGE DISPLAY
! - Indicates Auxiliary Gage Fault. Normal operating range is between 24-28 volts. A
reading in excess of 30 volts indicates a possible
! - Indicates Fault Warning faulty voltage regulator. A reading of less than 23
! - Indicates Derate or Shutdown Fault Volts indicates a possible faulty battery or
alternator.
Pressing the “Enter Button” will redisplay the Refer to manufactures Operations Manual
hidden fault. Pressing the “Enter Button” once (supplied with the machine) for detailed
again will hide the fault and return the screen to information.
the single or four parameter display.
6.5
250BT-033
DEFROSTER CB RADIO DOME LIGHT

FAN
GAUGES AND WARNING LIGHT PANEL
• ••
••
DIAGNOSTIC INSTRUMENT
CONNECTOR PANEL
• •
ELECTRICAL
•• CONNECTORS
(SEE INSTRUMENT
PANEL WIRING
DIAGRAM ON
PAGE 6.9)
FUSE AND RELAY

PANEL (SEE DETAILS
ON PAGE 6.8) •
250BTH-028 CAB WIRING AND ELECTRICAL COMPONENT LOCATIONS
6.6
250BTH-031 PILOT HARNESS - CAB TO PILOT SOLENOID CONTROLS
6.7
250BTH-030A
28762B-R3 ENGINE WIRING HARNESS
6.8
GAUGES AND WARNING LIGHTS
1 2 3 4 5 6
•• •• ••
•
••
••
250BT-014 GAUGES AND WARNING LIGHTS

Component description
1. Windshield Wiper Switch 4. Low Hydraulic Oil Light - Red
2. PowerView Display Module 5. Low Fuel Light - Yellow
3. Bulb Test Switch 6. Pump Inlet Light - Red
250BT-033 REAR VIEW OF GAUGES AND WARNING LIGHT PANEL
6.9
250BTH-012 FUSE AND RELAY PANEL
••
NOTE: REFER
TO HEAD
MANUFACTURE'S
MANUAL FOR
FUSE CAPACITY
FUSE AND RELAY PANEL
FUSE AND RELAY PANEL Each circuit of the machine is protected by a fuse.
The fuse panel is located inside the control panel If a fuse is blown it must be replaced by one of the
behind a removable cover. same value. If the fuse blows again, the circuit
should be inspected for possible short circuit or
other malfunction.
6.10
NOTE: See also Harvester

Head specific wiring.
250BTH-021
INSTRUMENT PANEL WIRING DIAGRAM
6.11
244-043
MAIN FUSE AND RELAY ELECTRICAL BOX
31300B.AI
FUSES AND RELAYS - ELECTRICAL BOX

This Main Fuse and Relay electrical box is located in the engine compartment.
6.12
250BTH-029
28929B-R5
ELECTRICAL BOX WIRING DIAGRAM
6.13
250BTH-023
28485B-R4
6.14
250BTH-024
28485B-R4
6.15
250BTH-025
28485B-R4
6.16
250BTH-026
28485-R4
6.17
6.18
SECTION 7 - ENGINE START AND STOP

AUGUST, 2007
CIRCUIT DESCRIPTION ............................................................................... 7.2
ENGINE START CIRCUIT ............................................................................. 7.2
START CIRCUIT DIAGRAMS ........................................................................ 7.3
Tigercat H250B Harvester Engine start and stop
ENGINE START CIRCUIT
For detailed engine information, refer to the
engine manufacturer's manual.
For engine starting and stopping procedures refer
to STARTING ENGINE and STOPPING ENGINE
in SECTION 2 of the OPERATOR’S MANUAL.
For correct engine speeds, refer to THROTTLE
CONTROL in SECTION 2 of the OPERATOR'S
MANUAL.
To start engine; Turn battery disconnect switch to
the ON position. Turn ignition key to the START
position and releasing it to the RUN position after
the engine starts.
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 wire (16) through the
vacuum switch (when hydraulic tank is
pressurised) to wire (17) to energize the coils of
the start solenoid relay. The start solenoid relay
contacts also close and current flows from the
alternator + RED wire (1) through wire (12) to the
starter solenoid coil to close the contacts and
operate the start motor to crank the engine.
For the engine computer module (ECM) to supply
fuel, there needs to be power at the vehicle key
switch input pin (39) on the 50 pin ECM
connector. Key input relay (10) and 3 fuses
control the signal to the ECM, which together with
the start motor, start the engine.
In order to operate the machine functions after
starting the engine, the arm rest must be in the
latched DOWN position and the PILOT RESET
button pushed. This will energize the pilot shut off
relay, close the contacts and allow current to flow
through wires (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
250BT-038
START CIRCUIT - AT REST
7.3
START CIRCUIT - AT REST

250BT-039 BATTERY DISCONNECT SWITCH - ON
7.4
START CIRCUIT - START

250BT-040 IGNITION KEY - START POSITION
7.5
START CIRCUIT - RUN

240B-041 IGNITION KEY - RUN POSITION
7.6
START CIRCUIT - RUN

IGNITION KEY - RUN POSITION
PILOT RESET SWITCH - DEPRESSED
240B-042
ARM REST DOWN/ARM REST SWITCH - ON
7.7
START CIRCUIT - RUN

IGNITION KEY - RUN POSITION
PILOT RESET SWITCH - RELEASED
250BT-043
ARM REST DOWN/ARM REST SWITCH - ON
7.8
SECTION 9 - ENGINE ANTI-STALL
AUGUST, 2007
ANTI-STALL SYSTEM COMPONENTS ........................................................ 9.2
BLINK CODES ............................................................................................... 9.7
CIRCUIT SCHEMATICS ................................................................................ 9.5
CONTROL POD ON ARMREST, R.H.
ELECTRICAL SCHEMATIC - PLUS 1 CONTROL ......................................... 9.4
ELECTRONIC CONTROLLER BLINK CODES ............................................. 9.7
FAULT FINDING PROCEDURE ~ ANTI-STALL QUICK CHECK .................. 9.5
FAULT FINDING PROCEDURES, ADDITIONAL .......................................... 9.6
HORSEPOWER LIMITING CONTROL ......................................................... 9.2
GENERAL DESCRIPTION ......................................................................... 9.2 SEE ALSO SECTION 4
LOAD SENSE; SET MARGIN PRESSURE ............................ SEE SECTION 4
PLUS 1 CONTROL MODULE CONNECTOR PIN ASSIGNMENT ................ 9.3
SET PILOT PRESSURE ......................................................... SEE SECTION 5
VERIFY ANTI-STALL SETTING ............................................. SEE SECTION 4
Tigercat H250B Harvester Engine anti-stall
HORSEPOWER LIMITING
CONTROL (ANTI-STALL)
GENERAL DESCRIPTION
In the past it was common to lug an engine down
when several functions with high loads were used at
the same time and engine stalling was avoided only
by the operator. In order to prevent engine over
loading, the Tigercat machine is equipped with an
ANTI-STALL
electronic system which detects any drop in engine SWITCH
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. ••
The system incorporates the following components:
• A 'Plus 1' control module mounted beside the
electrical box in the engine compartment.
• A speed sensor and Engine (ECM) Electronic
Control Module (Cummins engine components).
• An electronic solenoid valve mounted on the
main pump.
• An anti-stall switch mounted on the instrument
panel.
• A wiring harness.
250BT-002 INSTRUMENT PANEL
ENGINE (ECM) ENGINE PLUS 1 ELECTRICAL

ELECTRONIC CONTROL BOX
CONTROL MODULE
MODULE
• •
•
SWING
PUMP
• ELECTRONIC
SOLENOID
CONTROL
VALVE
••
••
•• •
•• MAIN
WIRING PUMP
HARNES
HORSEPOWER
CONTROL
TEST PORT
250BT-016 ANTI-STALL SYSTEM COMPONENTS
9.2
The horsepower control can be turned OFF when • Pin C1-P10 is connected to "ANTI-STALL
required for maintenance work by switching the SWITCH".
anti-stall switch in the cab to the off position; the
• Pin C1-P11 is connected to the "KEY INPUT
engine may then be used at less than full throttle.
RELAY" terminal 85.
During normal operation of this machine the
engine speed should be at High Idle and the anti- • Pin C1-P12 is connected to the "SWING
stall switch should be ON. PUMP ANTI DRIFT PRESSURE SENSOR".
The Plus 1 control module in the engine • Pin C2-P2 is connected to "ANTI-STALL
compartment receives and distributes signals PILOT PRESSURE SENSOR".
through two 12 pin connectors which are attached • Pin C2-P7 is connected to "HYDRAULIC OIL
to the CAN BUS (Operating on J1939 protocol) TEMPERATURE SENSOR".
engine wiring harness and the main wiring
harness. • Pin C2-P11 is connected to "MAIN PUMP
DISPLACEMENT CONTROL SOLENOID".
The pins on the two 12 pin connectors are
connected as follows: • Pin C2-P12 is connected to "RELAY #11 ANTI
DRIFT".
Refer to Horsepower limiting control diagrams;
The system control module constantly monitors
• Pin C1-P1 is connected to "power ground". the engine speed and any drop below 1800 RPM
• Pin C1-P2 is connected to "power Supply". will result in a reduction of the signal current being
sent to the main pump solenoid via wire 29 from
• Pin C1-P3 is connected to "CAN HIGH +".
pin C2-P11. Above 1800 rpm the signal current
• Pin C1-P4 is connected to "CAN LOW -". value is 700 mA and as the engine speed drops
the signal current will drop proportionately. This
• Pin C1-P5 is connected to "CAN Shield".
signal causes the solenoid valve to shift, causing
• Pin C1-P6 is connected to the "IDLE DOWN" the pump to destroke. This electrical signal is a
solenoid. pulse width modulated signal which provides for
• Pin C1-P9 is connected to the sensor ground precise modulation of the hydraulic valve and the
terminals. resulting smooth control of the main pump
displacement.
PLUS 1
CONTROL
MODULE
••
250BT-019 PLUS 1 CONTROL MODULE CONNECTOR PIN ASSIGNMENT 250BT-017
9.3
250BT-018A PLUS 1 CONTROL ELECTRICAL SCHEMATIC
9.4
FAULT FINDING ~ ANTI-STALL QUICK 2. Start engine and run at LOW IDLE.
CHECK 3. Place anti-stall switch in the OFF position.
The following is a quick procedure to detemine if
4. Engage pilot reset switch and activate
the anti-stall is functioning properly. If the
each function 1 at a time.
machine fails any of these tests, then a more
detailed diagnosis is necessary. However, there Expected Results:
can still be other problems that are not related to • All functions should operate (Engine may
the anti-stall system which are being masked. stall).
IMPORTANT: Always ensure that the hydraulic oil • Guage pressure should be 0 - 0.7 Bar (0-
is at operating temperature when performing all of 10 psi).
the following diagnosis.
C. ANTI-STALL ON
A. WHEN DOES THE PROBLEM OCCUR ?
1. Connect a 0-1000 psi gauge to the
Does the problem occur with the anti-stall ON or OFF? ‘Horsepower Control’ gauge test port on
ANSWERS: the main pump.
• Occurs with the system ON or OFF 2. Start engine and run at LOW IDLE.
The problem is likely hydraulic related. This 3. Engage pilot reset switch
also includes the anti-stall solenoid valve on 4. Place anti-stall switch in the ON position,
the main pump. Guage should read 31-34.5 Bar (450-500
• Occurs only with the system ON. psi) at LOW IDLE.
The problem is either related to the hydraulic 5. Slowly increase engine speed.
system, the engine, or the anti-stall system. Expected Results:
B. ANTI-STALL OFF • Guage pressure should begin to decrease
1. Connect a 0-70 Bar (0-1000 psi) gauge to as engine speed increases.
the ‘Horsepower Control’ gauge test port • Gauge pressure should be 0 - 0.7 Bar (0-
on the main pump. 10 psi) at full throttle.
•• ••
2
1
• HORSEPOWER
CONTROL
2 TEST PORT
1
250BT-009 MAIN PUMP
250BT-013 HORSEPOWER LIMITING CONTROL CIRCUIT
9.5
ADDITIONAL FAULT FINDING
PROCEDURES
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.
A. PILOT PRESSURE.
1. Ensure pilot pressure is correct.
To verify PILOT PRESSURE refer to
PILOT SYSTEM in SECTION 5 of THIS
MANUAL.
B. MARGIN PRESSURE
1. Ensure margin pressure is correct.
To verify MARGIN PRESSURE refer to
HYDRAULIC SYSTEM in SECTION 4 of
THIS MANUAL.
C. ELECTRICAL POWER TO ANTI-STALL
CONTROL MODULE.
1. Remove grey connector from anti-stall
control module.
2. Turn ON battery disconnect and an
assistant lower armrest and reset pilot
switch.
3. Measure DC voltage across pins C1-P1
and C1-P2 on grey connector 1.
• The electrical power should be 24.0 to
25.5 VDC.
D. SOLENOID VALVE WIRES (AT
CONNECTORS)
1. Remove both connectors from anti-stall
control module.
2. Measure resistance between pins C1-P1
on grey connector 1 and C2-P11 on black
connector 2.
• The resistance should be 17.0 to 19.5
ohms (at 21 °C to 52 °C/70 °F to 125 °F
hyd oil temp).
E. SOLENOID VALVE COIL (AT COIL)
1. Remove connector from anti-stall solenoid
valve.
2. Measure resistance of solenoid coil.
• The resistance should be 17.5 to 19.5
ohms (at 21 °C to 52 °C/70 °F to 125 °F)
hyd oil temp).
9.6
ELECTRONIC CONTROLLER BLINK CODES
GREEN
LED
The Plus 1 electronic controller has two LED lights
on the front top left side of the controller. A GREEN RED
••
LED
LED is used to indicate that power is ON and the
controller is activated. The RED LED is used to
provide a visual warning in the form of BLINK
CODES whenever the controller senses a fault in
the system.
The following chart can be used for BLINK CODE
TRANSLATION AND DIAGNOSTICS.
724E-018 PLUS 1 ELECTRONIC CONTROLLER
250B Antistall/Idle Down Blink Code Translation
RED LED RED LED

Fault Code Flash Bit Sequence Device at Fault
1 •• 1 sec • PWM Coil Fault (Feedback current is out of Operating Range)
2 •• 1 sec •• Pilot Pressure Sender Fault (Voltage is out of Operating Range)
3 •••• 1 sec •••• Hydraulic Oil Temperature Sender (Resistance is out of Operating Range)
4 •••• 1 sec •••••• J1939 CAN BUS Fault (Engine J1939 broadcasts not present or Faulted)
Note: If multiple faults are present a 5 second delay will separate the Fault Code Sequences.
GREEN LED ON Steady indicates System is Activated/ON
9.7
9.8
SECTION 10 - OIL COOLER, RADIATOR AND FAN
AUGUST, 2007
CHARGE AIR COOLER ...................................................................................... 10.3, 10.7
COOLING SYSTEM
COOLANT FLOW DIAGRAM ..................................................................................... 10.5
COOLANT FLOW DURING OPERATION ................................................................... 10.5
FILLING THE SYSTEM WITH COOLANT ................................................................... 10.5
OIL COOLER
CIRCUIT DESCRIPTION ............................................................................................ 10.6
CIRCUIT DIAGRAM ......................................................................................... 10.6, 10.7
OIL COOLER, RADIATOR AND FAN ............................................................................ 10.2
RADIATOR ................................................................................................................... 10.3
Tigercat H250B Harvester Oil Cooler, Radiator and Fan
OIL COOLER, RADIATOR AND FAN FILLER CAP
••
The charge air cooler, hydraulic oil cooler and

radiator are mounted in front of the engine. The A/C
condenser core is mounted in front of the cooler
assembly. The fan draws air through the A/C
condenser and cooler assembly. 248-25 CHECK ENGINE COOLANT LEVEL
AIR CHARGE HINGE OUT A/C
COOLER CONDENSER
••
RADIATOR
•
•
SERPENTINE
•
FAN BELT
•
OIL COOLER H250B-007
CHARGE AIR COOLER/RADIATOR/OIL ••

COOLER/AC CONDENSER COMPARTMENT
The A/C condenser core and cooler assembly A/C
COMPRESSOR
should be checked every 8 hours (every shift) for BELT
accumulation of twigs, leaves, pine needles and 250B-034 CHECK ENGINE BELT(S)
dust. All of the engine enclosure doors should also The cooling fan is belt driven and belt tension is
be kept clean. automatically tightened by a spring loaded
tensioner. The belt condition and tension should be
Part of the engine cooling system is the surge tank.
checked every 8 hours (every shift).
The coolant surge tank (reservoir) can be filled
through the access panel located on top of the
JAM
engine compartment. A level sight gauge is NUTS
conveniently located in the side of the surge tank. •• ••
WARNING
Shut off engine. Only remove filler cap
when cool enough to touch with bare
220-051
hands. Slowly loosen cap to first stop to
relieve pressure before removing A/C COMPRESSOR BELT TIGHTENER
The A/C compressor is belt driven and belt tension
Ensure that the engine has cooled down sufficiently is tighten by an adjuster on the mounting bracket.
before removing radiator cap. Prior to removing cap, Check belt condition and tension every 8 hours
relieve pressure in radiator by loosening cap slowly (every shift).
to first stop. Use the proper solution of coolant Loosen jam nuts and adjust belt to obtain a belt
antifreeze when filling the surge tank. deflection of 6.5 mm to 9.5 mm (1/4" to 3/8") in the
middle of the belt span between the pulleys.
10.2
CHARGE AIR
COOLER A/C
CONDENSER
CORE
RADIATOR
•
RAD
CAP ••
SURGE
TANK
• • ••
••
SIGHT
GAUGE
OIL
COOLER
250B-032
250B-035
CHARGE AIR COOLER, OIL COOLER, RADIATOR AND A/C CONDENSER CORE ASSEMBLY
10.3
250B-037 ENGINE COMPARTMENT ACCESS REAR
250B-010 ENGINE COMPARTMENT ACCESS FRONT

10.4
ENGINE COOLING SYSTEM The engine vent discharges air directly from the top
of the engine to the surge tank.
COOLANT FLOW DURING OPERATION
Additional coolant stored in the surge tank flows
The water pump circulates coolant through the
slowly down the shunt hose to the water pump
radiator, engine oil cooler, the engine block and
inlet replacing the air removed from the cooling
cylinder head. If the thermostat is closed, coolant
system.
is returned to the water pump through a bypass
inside the engine. FILLING THE SYSTEM WITH COOLANT
The thermostat opens when the coolant reaches The coolant is added through the filler neck in the
operating temperature. Then the coolant flows surge tank. This coolant fills the bottom radiator
across the radiator core to the outlet and back to hose at the water pump through the shunt hose
the water pump through the bottom radiator hose. and then fills the radiator from the bottom upwards.
Air is displaced through the vent tubes to the surge
A surge tank is located above the radiator. A small
tank. As the radiator is filled, coolant flows
vent tube is connected between the surge tank and
through the water pump and engine oil cooler to fill
the thermostat housing. The anti-freeze/water
the engine. Coolant will flow out the top radiator
solution used in the cooling system always contains
hose through the thermostat bypass and into the
small amounts of gas produced by combustion
engine once the radiator has filled. The engine and
leakage. This gas must be vented to the outside to
rad vent discharge air directly from the engine and
prevent cavitation of the engine water pump and to
rad to the surge tank.
promote efficient heat transfer between the engine
block and the coolant. These gases separate from When the engine has been run up to operating
the coolant in the radiator top tank and are carried temperature and the thermostat has opened, any
up through the vent tube where they collect in the remaining air is purged through the vent tube and
surge tank and eventually discharge through the the engine vent. The system will then require more
pressure cap. coolant to fully top off both the engine and the
radiator.
FLOW OF COOLANT WITH ENGINE

RUNNING AT OPERATING
TEMPERATURE AND THERMOSTAT
OPEN
TOP
RADIATOR
HOSE
••
••
THERMOSTAT
HOUSING
•
ENGINE OIL
••
COOLER
BOTTOM
RADIATOR
HOSE
250B-037 ENGINE COOLING SYSTEM
10.5
OIL COOLER CIRCUIT DESCRIPTION
The oil cooler is situated down stream from the A 3.45 Bar (50 psi) relief valve, installed in the line
main valve. Approximately half the oil returning to between the cooler inlet and outlet at the filter,
the hydraulic tank is directed to the oil cooler inlet provides a bypass route for oil to flow in the event
through the cooler to the return filter and on to the the oil cooler has high resistance.
hydraulic tank.
Cooling of the oil occurs as air is drawn over the oil
cooler cooling fins by the engine fan. Cooled oil then
passes through the return filter and into the
hydraulic tank.
AIR
CHARGE
COOLER
RADIATOR
•
OIL
••
COOLER
••
250B-037 OIL COOLER CIRCUIT DIAGRAM
10.6
FLOW OF AIR WITH

ENGINE RUNNING OUTLET INLET CHARGE AIR
COOLER
••
•• •
250B-038 CHARGE AIR COOLER SYSTEM AND AIR FLOW
FLOW OF COOLANT WITH ENGINE TOP

RUNNING AT OPERATING RADIATOR
TEMPERATURE AND THERMOSTAT SURGE HOSE THERMOSTAT
OPEN TANK HOUSING
RAD • •
CAP
RAD VENT
•
HOSE
••
ENGINE •
VENT
HOSE
••
SHUNT
HOSE •
•
••
•
BOTTOM
ENGINE OIL SHUNT RADIATOR
COOLER HOSE HOSE
250B-038 ENGINE COOLING SYSTEM COMPONENTS AND COOLANT FLOW

10.7
10.8
SECTION 11 - TRACK DRIVE
AUGUST, 2007
BRAKE RELEASE PRESSURE .................................................................... 11.15

CIRCUIT DESCRIPTION ................................................................................ 11.6
CIRCUIT DIAGRAM ...................................................................................... 11.11
CONTROL VALVES
FOOT PEDAL CONTROL VALVE ................................................................ 11.3
TRACK CONTROL VALVES ........................................................................ 11.4
TRAVEL AND DRIVE ENABLE SOLENOID VALVES ................................... 11.4
DRIVE MOTOR
DESCRIPTION ............................................................................................ 11.8
START-UP PROCEDURE .......................................................................... 11.12
DRIVE MOTOR AND GEARBOX ASSEMBLY ................................................ 11.7
GEARBOX AND DRIVE MOTOR ASSEMBLY ................................................ 11.7
IMPORTANT TRACK DRIVE NOTES
NEW MACHINE ........................................................................................... 11.2
STRAIGHT TRAVEL .................................................................................... 11.2
TRACK SAG ................................................................................................ 11.2
PRESSURE SETTINGS, DRIVE SYSTEM
BEGIN OF REGULATION, SET, FOR DRIVE MOTOR .............................. 11.13
CROSSOVER RELIEF VALVES ................................................................. 11.14
SET STRAIGHT TRAVEL .............................................................................. 11.17
SET TRACK SPEED ..................................................................................... 11.16
STEERING ...................................................................................................... 11.5
TRACK COMPONENTS
MEASURING TRACK SAG ........................................................................ 11.18
TRACK SAG ADJUSTMENT ................................................................. 11.19
OPERATING THE MACHINE ..................................................................... 11.18
ROLLER RETAINING BOLTS .................................................................... 11.20
TORQUING UNDERCARRIAGE BOLTS ................................................... 11.19
TRACK SHOE RETAINING BOLTS ........................................................... 11.19
WEAR LIMITS
BUSHING WEAR, OUTSIDE DIAMETER .............................................. 11.21
IDLER WEAR ......................................................................................... 11.22
PIN AND BUSHING WEAR .................................................................... 11.21
ROLLER WEAR ..................................................................................... 11.21
TRACK LINK WEAR .............................................................................. 11.20
TRACK SHOE GROUSER HEIGHT WEAR ........................................... 11.20
TRACK DRIVE ASSEMBLY ............................................................................ 11.2
TRACK DRIVE BRAKE RELEASE PRESSURE ........................................... 11.15
Tigercat H250B Harvester Track drive
IMPORTANT TRACK DRIVE NOTES
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
SAG
track sag must be adjusted once a machine has UNDERSIDE OF DIMENSION
TRACK GUARD
been delivered to the job sight and operating in •
the accumulated soil buildup in the undercarriage. •
TRACK SAG UPPER SURFACE
OF TRACK SHOE
The track sag dimension is very important and
should be checked regularly. A 50% increase in 853ILL8 MEASURING SAG DIMENSION
the life of the track assembly can be realized,
particularly in bushing O/D wear and 'track pitch'
STRAIGHT TRAVEL
by maintaining the correct amount of track sag. A
track that is too tight will wear out significantly If the machine does not travel straight, the right
faster due to increased tension in the chain. Refer and left track speeds are not set the same. Refer
to MEASURING TRACK SAG in THIS SECTION. to TRACK SPEED SET-UP PROCEDURE in THIS
SECTION.
Check the speed of each track and follow the set-
up procedures closely to obtain straight travel.
UPPER ROLLERS ROTARY MANIFOLD

IDLER
• ASSEMBLY
UNDERCARRIAGE
• LOWER HINGED
ACCESS COVER
UNDERCARRIAGE
• •
LOWER
• • ROLLERS
•
INSPECTION
COVERS
•
DRIVE MOTOR
• •
TRACK DRIVE
GEARBOX
•
•
DRIVE SPROCKET TRACK ASSEMBLY
TRACK ACCESS
COVER
240T-13 TRACK DRIVE ASSEMBLY
11.2
TRACK DRIVE COMPONENTS
ENGINE BELL
HOUSING
••
MAIN PUMP
•• SWING
PUMP
••
HYDRAULIC PUMPS
1
All hydraulic functions are powered by two pumps.
The main and swing pumps are mounted one
•
5
engine. The first pump (main pump) is a piston •
and horsepower limiting controls.
3
Mounted and coupled to the main pump is the swing •
pump. It is a pressure compensated piston pump. • •
TANK
PORT
The track drive circuit utilizes the main pump to 4
supply hydraulic oil to both the left and right track
drive motors via two valve sections in the main 8
control valve. •
•
For a more detailed description of the main pump, 2
refer to SECTION 12 in THIS SERVICE MANUAL. • •
WORK PRESSURE WORK
PORT PORT PORT
FOOT PEDAL CONTROL VALVE
FOOT PEDAL PILOT VALVE
The drive function is controlled by two center foot AW017
pedal valves which send proportional pilot signals to

For a detailed description of the foot pedal control
the left and right track drive spool sections in the
valves, refer to SECTION 5 in THIS MANUAL.
main control valve which supply oil to the track drive
motors.
11.3
TRACK CONTROL VALVES
For a detailed description of the "hoist" and "stick"
The right track forward and reverse function is
control valves, refer to the applicable section in
controlled by one of nine spool sections in the
THIS MANUAL.
main control valve and the left track forward and
reverse function is controlled by one of nine spool
sections in the main control valve. The control
valves are located in the upper frame below the
floor plates inside the valve compartment.
FORWARD
FORWARD
TRACK
TRACK
LEFT
RIGHT
REVERSE
REVERSE
250BTH-005 MAIN CONTROL VALVE

11.4
TRAVEL,
HIGH/LOW
TRACK DRIVE
ENABLE
Travelling
• • Travel is accomplished by turning the track drive
switch to the ON position and depressing both
foot pedals simultaneously. Travel over distances
should be done in the forward direction to reduce
the wear on track components. Track drive
gearboxes are considered to be at the rear of the
machine when travelling in the forward direction.
250BT-044 PILOT MANIFOLD ASSEMBLY Steering
TRAVEL AND DRIVE ENABLE Steering the machine is achieved by operating the
SOLENOID VALVES tracks at different speeds and should only be
Pilot oil flows to both track drive foot pedals via done when moving; rotating the tracks in opposite
the track drive enable solenoid valve located on directions should be avoided where possible.
the pilot manifold assembly. A track drive switch in
the operator's cab when in the ON position
energizes this solenoid valve and allows pilot oil to
flow out 'B' on pilot manifold to the 'P' port on the
foot pedal control valves. When the switch is in the
'OFF' position, the valve is de-energized and pilot 2 1
oil is blocked from reaching the foot pedal control
valves.
•• ••
A travel high/low solenoid valve located next to
the drive enable solenoid valve on the pilot
manifold assembly controls the flow of pilot oil to
the drive speed change valve in both track drive
motors. A track speed switch in the operator's cab
when in the "LOW" position energizes this
solenoid valve and allows pilot oil out port 'C' on 250BT-002 TRACK DRIVE SWITCHES
the pilot manifold to shift the spool in the drive
speed change valve and place the motor at TRACK DRIVE ~ SWITCH (1)
maximum displacement (slower speed). When the Placing this switch in the OFF position will prevent
switch is in the "HIGH" position, the solenoid valve the machine from being accidentally driven during
is de-energized preventing pilot oil from reaching processing operations.
the drive speed change valve in the motor which
places the motor at minimum displacement Place this switch in the ON position to drive the
(higher speed). machine. The light in the switch will be ON.
DRIVE SPEED ~ SWITCH (2)
Two drive speed ranges are possible.
• LOW position will provide a slow driving
speed.
• HIGH position provides a faster speed with
reduced driving torque.
Place this switch in the LOW position when
maneuvering around the work site.
The HIGH position should only be used with the
machine on flat solid ground. A flat bed trailer
should be used to transport the machine over
greater distances.
11.5
TRACK DRIVE HYDRAULIC CIRCUIT MAIN PUMP
DESCRIPTION
The power is transmitted to the tracks by a variable
displacement piston motor 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.
In order to control the machine movement in
situations where the machine 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. SWING
PUMP
In the motor schematic diagram it is shown in the
centre, closed position.
CIRCUIT DESCRIPTION
The main pump is an axial-piston, variable-
displacement pump with load sensing, pressure
When all of the control valve sections on the main
valve are in the neutral position the pump is
destroked and the output is just sufficient to
maintain a pressure of 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.
The track drive circuit utilizes the main pump to
supply hydraulic oil flow to the left and right
hydraulic track motor 'A' and 'B' ports via two spool
sections in the main control valve.Two foot pedal
control valves in the cab when operated in the
FORWARD or REVERSE direction direct pilot oil to
the DRIVE SIGNAL VALVE through the valve to
240T2- 015
each end of the track spool sections of the main
TRACK DRIVE MOTOR SCHEMATIC
control valve. A drive enable solenoid valve on the
The valve will remain in the closed position as long pilot manifold assembly controlled by a DRIVE ON/
as there is no oil pressure in the line from the track OFF switch in the cab, controls the supply of pilot
control valve. When the track control valve spool is oil to the drive foot pedals. With the switch ON and
shifted and oil flows to the motor, a check valve in the foot pedals depressed, the track spools in the
the counterbalance valve (G) opens and oil main control valve will shift directing oil from the
pressure builds up in the motor pistons. pumps to the track drive motors. Return oil from the
motors is directed back through the spool sections,
The motor cannot move until the oil pressure shifts
to the outlet section, through the dual head return
the counterbalance spool to permit the oil on the
oil filter and back to tank.
low pressure side of the motor to flow back through
the counterbalance valve to the track control valve
and then to tank.
The hydraulic motor is equipped internally with a
drive speed change valve which is controlled by a
switch in the cab (TRACK DRIVE HIGH/LOW) and
a solenoid operated control valve on the pilot
manifold assembly. For further information refer to
TRAVEL AND DRIVE ENABLE SOLENOID
VALVES in THIS SECTION.
11.6
PLANETARY TRACK • LOWER FRAME

TRACK DRIVE
GEARBOX
SPROCKET
••
• TRACK DRIVE
MOTOR
(AQ019 SHOWN)
••
BRAKE
ASSEMBLY
BK004-822 TRACK DRIVE MOTOR AND GEARBOX ASSEMBLY
11.7
DRIVE MOTOR DESCRIPTION (1) with nine pistons (2) and an output shaft (3)
The drive motor is a variable displacement that is splined to the cylinder block.
swashplate design. The motor is interchangeable Supply oil from the drive control valve enters the
from side to side. motor through the cover (4) to the pistons. During
The motor rotating group consists of a cylinder block operation, high pressure supply oil enters the
SLIPPER RETAINER BALL GUIDE PISTON 2 CYLINDER

BLOCK
6 1
SWASHPLATE PIN
MAXIMUM
5 DISPLACEMENT
SEAL PISTON
8
SPACER
•• •• •• •
9 MINIMUM
DISPLACEMENT
••
ADJUSTMENT
•• • ••
RETAINING
RING STOP
••••• •• • SHIMS
•• 4 COVER
•• •
•• ••
10 MAXIMUM
SHAFT 3 • • •• DISPLACEMENT
ADJUSTMENT
STOP
WEAR
SLEEVE
AQ019-2 CROSS SECTION
BEARING OF DRIVE MOTOR
SHELL
MINIMUM
7 DISPLACEMENT
SPRING
PISTON
MINIMUM CROSSOVER
DISPLACEMENT 11 RELIEF VALVES
ADJUSTMENT
STOP
4 COVER
9
BEGIN OF
REGULATION
ADJUSTMENT
• •
•
••
••
'B' PORT
PRESSURE
PORTS
• 'A' PORT
•
PRESSURE
REGULATOR
VALVE
BLOCK
MAXIMUM
DISPLACEMENT
10 AQ019-1 • DRIVE MOTOR
ADJUSTMENT STOP COUNTERBALANCE VALVE FRONT COVER
11.8
piston bores in the cylinder block (1). This forces NOTE: Swashplate angle (motor displacement) is
the pistons against an angled swashplate (5). limited by the minimum and maximum
Piston sliding action causes the rotating group to displacement pistons contacting the minimum (9)
turn. The cylinder block is splined to the output and maximum (10) displacement adjustment
shaft (3) which causes the output shaft to turn. stops. For minimum displacement, the maximum
During the second half of the motor rotation, low displacement piston contacts the minimum
pressure is discharged as the pistons ride up to a displacement adjustment stop. For maximum
higher position on the swashplate. To reverse displacement, the minimum displacement piston
rotation, oil flow is reversed. During operation a contacts the maximum displacement adjustment
small amount of supply oil flows through the stop.
centre of each piston. This oil lubricates the Refer to front cover illustration;
piston to slipper (6) joint and the slipper to
The drive motor cover (4) consists of several
swashplate area.
components to operate the drive functions.
High pressure supply oil also flows through a tube
The minimum displacement adjustment stop (9)
to lubricate the swashplate to bearing shell area.
limits the minimum angle the swashplate can
Normal leakage and lubrication oil aid in flushing
move. The maximum displacement adjustment
and cooling the motor during drive operation.
stop (10) limits the maximum angle the
The swashplate (5) angle is changed by the swashplate can move. The crossover relief
minimum displacement piston (7) and maximum valve(s) (11) protects the motor circuit from
displacement piston (8). When supply oil acts on pressure spikes.
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.
BEGIN OF MINIMUM
DISPLACEMENT CROSSOVER CYLINDER PRESSURE
REGULATION RELIEF VALVES 'B' REGULATOR MIN. AND MAX.
ADJUSTMENT ADJUSTMENT BLOCK 'J'
STOP 'A' VALVE BLOCK ADJUSTING
COVER 'L' PISTON 'I' STOPS 'A' & 'E'
PRESSURE
REGULATOR • • SWASHPLATE 'E'
VALVE •
BLOCK • BEARING
SHELL 'R'
• • ••
•
•
•
••
'B' PORT
•
'A' PORT
•
••
'A'
SHAFT 'A' ••
BRAKE • 'A' SLIPPER 'F'
RELEASE
PRESSURE
REDUCING MAXIMUM
VALVE DISPLACEMENT
TUBE •
ADJUSTMENT ADJUSTMENT COUNTERBALANCE
STOP 'E' VALVE
PRESSURE
DRIVE MOTOR CROSS SECTION 'A' 'A' PORTS 'A', 'B'
AQ019
FRONT COVER (AQ019) DRIVE MOTOR (AQ019)
11.9
The drive motor may be operated in two ranges;
MAXIMUM DISPLACEMENT = 105cc/rev.
MINIMUM DISPLACEMENT = app. 50cc/rev. DRIVE
SPEED
These two ranges are controlled by a solenoid CHANGE
VALVE
pilot valve on the pilot manifold which is operated
by the TRACK DRIVE SPEED switch (1) in the
cab.
250BT-002 TRACK DRIVE SWITCHES
240T2- 015
In the LOW position the solenoid on the pilot
TRACK DRIVE MOTOR SCHEMATIC
valve is energized and the motor is in its
maximum displacement mode which will give the This increase in motor displacement is controlled
slowest speed and maximum tractive effort. by the drive speed change valve (located in the
drive motor). This valve controls the hydraulic
For faster travelling modes the TRACK DRIVE
pressure signal to the maximum displacement
SPEED switch can be put in the HIGH position
piston. The piston increases motor displacement
and the motor will be in its minimum
as the pressure rises above the drive speed
displacement position which will give the fastest
change valve setting.
speed. When in this high speed mode the motor
will automatically increase motor displacement in
the event that a high load is encountered, e.g. a
short grade or obstacle.
BEGIN OF MINIMUM
DISPLACEMENT CROSSOVER CYLINDER PRESSURE
REGULATION RELIEF VALVES 'B' REGULATOR MIN. AND MAX.
ADJUSTMENT ADJUSTMENT BLOCK 'J'
STOP 'A' VALVE BLOCK ADJUSTING
COVER 'L' PISTON 'I' STOPS 'A' & 'E'
PRESSURE
REGULATOR • • SWASHPLATE 'E'
VALVE •
BLOCK • BEARING
SHELL 'R'
• • ••
•
•
•
••
'B' PORT
•
'A' PORT
•
••
'A'
SHAFT 'A' ••
BRAKE • 'A' SLIPPER 'F'
RELEASE
PRESSURE
REDUCING MAXIMUM
VALVE DISPLACEMENT
TUBE •
ADJUSTMENT ADJUSTMENT COUNTERBALANCE
STOP 'E' VALVE
PRESSURE
DRIVE MOTOR CROSS SECTION 'A' 'A' PORTS 'A', 'B'
AQ019
FRONT COVER (AQ019) DRIVE MOTOR (AQ019)
11.10
250BTH-032 TRACK DRIVE CIRCUIT DIAGRAM

11.11
DRIVE MOTOR START-UP PROCEDURE
DRAIN LINE
IMPORTANT:
The drive motor will be damaged if is not filled • 'U' PORT
DRAIN
with oil before operating the drive function. This CONNECTION
procedure must be performed whenever a new
drive motor or drive pump is installed or whenever GAUGE
TEST
oil has been drained from the motor. PORT 'Y1'
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. 822-D61 DRIVE MOTOR TOP VIEW
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.
GAUGE TEST PRESSURE

PORT Y1 REGULATOR
VALVE BLOCK
SYSTEM
PRESSURE
PORT 'A' •
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
'A'
BEGIN OF
REGULATION
ADJUSTING
SIDE
SCREW ••
•• 6mm WRENCH
13mm WRENCH
CROSSOVER •
RELIEF VALVES
5mm ALLEN KEY
'L' PORT DRAIN
CONNECTION
•
17mm WRENCH (FOR L.H. SIDE)
860-079 DRIVE MOTOR (AQ019) - R.H. SIDE SHOWN

11.12
SET BEGIN OF REGULATION GAUGE TEST PRESSURE
REGULATOR
(DRIVE SPEED CHANGE VALVE) PORT Y1
VALVE BLOCK
1. Ensure hydraulic oil is at operating

temperature. ••
MAXIMUM
2. Remove both LEFT and RIGHT drive motor
inspection covers.
DISPLACEMENT
ADJUSTMENT STOP •
6mm ALLEN KEY
3. Disconnect LEFT and RIGHT brake line at 19mm WRENCH
port on final drive gearbox. Plug hose with ••

size 06 JIC plug and cap port adapter on MINIMUM
DISPLACEMENT
gearbox. ADJUSTMENT STOP
6mm ALLEN KEY
4. Install a 0 to 350 Bar (0 to 5,000 psi) gauge
on drive motor gauge test ports 'Y1', and the
19mm WRENCH
••
'PX' test port on the main control valve, size
04JIC quick connect. BEGIN OF
REGULATION
5. Start engine and set throttle to LOW IDLE. ADJUSTING
SCREW •
6. Lower left arm rest and depress the pilot reset 6mm WRENCH
13mm WRENCH
switch to activate the pilot system.
7. Place DRIVE HIGH/LOW switch to LOW
position. 822-D62
8. Activate LEFT track drive foot pedal in both DRIVE MOTOR R.H. SIDE SHOWN
FORWARD and REVERSE directions to
If adjustment is required, loosen locknut on
ensure that the track does not move.
begin of regulation adjusting screw and turn
screw in to increase pressure or out to
ELECTRONIC decrease pressure. Tighten locknut.
DISPLACEMENT
SOLENOID
VALVE 11. Repeat steps (4) through (9) for the right drive
motor.
12. Reset main pump POR to 310 Bar (4500 psi).
PUMP 'POR'
VALVE
•• 11. Re-connect brake line(s) to both gearboxes.
12. Remove pressure gauges and wipe up any
•• spills.
13. Replace both LEFT and RIGHT drive motor
•• •• inspection covers.
'LS' MARGIN
PRESSURE
ADJUSTING MAIN PUMP
SCREW CONTROLLER
9. With the aid of an assistant, activate LEFT

track drive foot pedal in the FORWARD
direction and set the main pump POR to 248
Bar (3600 psi).
10. With the aid of an assistant, activate LEFT
direction and check pressure reading on
gauge at motor gauge test port 'Y1' it should
show between 55 to 69 Bar (800 and 1,000
psi).
11.13
SET CROSSOVER RELIEF VALVES 10. With the aid of an assistant, activate RIGHT
1. Ensure hydraulic oil is at operating track drive foot pedal in the FORWARD
temperature. direction. Loosen lock nut and adjust forward
crossover relief valve adjusting screw out until
the releif valve cracks open and a hissing
inspection covers.
sound is heard. Turn adjusting screw IN 1/8
3. Disconnect LEFT and RIGHT brake line at turn and tighten lock nut.
port on final drive gearbox. Plug hose with
11. Repeat step (10) for the right drive motor
size 06 JIC plug and cap port adapter on
reverse crossover relief valve adjustment.
gearbox.
12. Repeat step (10) for LEFT track drive motor
4. Install a 0 to 350 Bar (0 to 5,000 psi) gauge
FORWARD and REVERSE crossover relief
on the 'PX' test port on the main control valve,
valve adjustments.
size 04JIC quick connect.
12. Reset main pump POR to 310 Bar (4500 psi)
5. Start engine and set throttle to LOW IDLE.
at 'PX' test port on the main control valve.
6. Lower left arm rest and depress the pilot reset
11. Re-connect brake line(s) to both gearboxes.
12. Remove pressure gauges and wipe up any
7. Place DRIVE HIGH/LOW switch to LOW
spills.
position.
13. Replace both LEFT and RIGHT drive motor
8. Activate RIGHT track drive foot pedal in both
inspection covers.
FORWARD and REVERSE directions to
ensure that the track does not move.
9. With the aid of an assistant, activate RIGHT
direction and set the main pump POR to 324
Bar (4700 psi) at 'PX' test port on the main
control valve.
GAUGE TEST PRESSURE

PORT Y1 REGULATOR
VALVE BLOCK
SYSTEM
PRESSURE
PORT 'A' •
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
REV 'A'
SIDE
BEGIN OF
REGULATION
ADJUSTING
FWD
SCREW ••
•• 6mm WRENCH
13mm WRENCH
CROSSOVER •
RELIEF VALVES
5mm ALLEN KEY
'L' PORT DRAIN
CONNECTION
•
17mm WRENCH (FOR L.H. SIDE)
860-079 DRIVE MOTOR (AQ019) - R.H. SIDE SHOWN

11.14
TRACK DRIVE BRAKE RELEASE
PRESSURE
1. Ensure hydraulic oil is at operating
temperature.
inspection covers.
3. Disconnect LEFT and RIGHT brake line at
port on final drive gearbox. Install a plug in
both brake line ports on final drive gearboxes.
4. Install a 0 to 70 Bar (0 to 1,000 psi) gauge on
both brake lines.
5. Start engine and set throttle to FULL
THROTTLE.
6. Lower left arm rest and depress the pilot reset
BRAKE
7. With the aid of an assistant, activate LEFT RELEASE
PRESSURE
••
track drive foot pedal in the FORWARD REDUCING
direction and check brake pressure reading VALVE
ADJUSTMENT
on gauge at brake line it should show 34.5
Bar (500 psi). 860-079 RIGHT TRACK DRIVE MOTOR
If adjustment is required, loosen locknut on
brake pressure reducing valve and turn screw
BRAKE
in to increase pressure or out to decrease RELEASE
PRESSURE
pressure. Tighten locknut. REDUCING
VALVE
8. Repeat step (7) for the right track drive brake ADJUSTMENT
pressure adjustment. •
9. Set engine speed to low idle, shut engine off
and remove test gauges and plugs.
10. Reinstall LEFT and RIGHT brake line at port
on final drive gearbox. Wipe up any spilled oil.
11. Reinstall both LEFT and RIGHT drive motor
inspection covers.
822-D60 LEFT TRACK DRIVE MOTOR
11.15
TRACK SPEED SET-UP PROCEDURE 7. With an assistant depressing the LEFT TRACK
drive pedal FORWARD, record the track drive
IMPORTANT:
sprocket speed. A reading of 12 rpm is desired.
• Ensure hydraulic oil is up to operating
temperature. 8. Turn the maximum displacement adjustment
screw on the left drive motor IN to speed up or
1. Remove both left and right final drive OUT to slow down the final drive. Continue
inspection covers to access track drive adjusting the motor and checking the track drive
motors. sprocket speed until 12 rpm is obtained.
LEFT TRACK ADJUSTMENT
MINIMUM
POSITION MACHINE: DISPLACEMENT
ADJUSTING SCREW
2. Swing boom to LEFT side of machine. 6mm ALLEN KEY
19mm WRENCH
3. Place grapple on solid ground and by
forcing down with boom controls, lift track
clear of ground. (Hoist down and stick out)
••
HARD
SURFACE
SUPPORT
• MAXIMUM
DISPLACEMENT
BLOCK ADJUSTING SCREW
6mm ALLEN KEY
19mm WRENCH
• 822-D60 LEFT TRACK DRIVE MOTOR

•
240T-17
LIFTING TRACK MAXIMUM
DISPLACEMENT
ADJUSTING SCREW
4. Use blocks to firmly support track frame in 6mm ALLEN KEY
raised position. DO NOT place arms, legs 19mm WRENCH
or body under track while in the raised
position.
SET LOW SPEED (motor maximum displacement)
•
MINIMUM
NOTE: Turn the maximum displacement DISPLACEMENT
adjusting screw either IN (clockwise) to speed

ADJUSTING SCREW
6mm ALLEN KEY
•
up or OUT (counterclockwise) to slow down the 19mm WRENCH
final drive. 822-D61 RIGHT TRACK DRIVE MOTOR
5. Set TRACK HIGH/LOW switch to LOW. SET HIGH SPEED
6. Set throttle to FULL. (motor minimum displacement)
9. Turn HIGH/LOW switch to HIGH.
10. Set engine to full throttle.
A TIMING MARK,
VISIBLE FROM THE 11. With an assistant depressing the left track drive
CAB CAN ALSO BE
PLACED ON THE pedal forward record the track drive sprocket
TRACK speed. A reading of 28 rpm is desired.
12. Turn the minimum displacement adjustment
screw on the left drive motor OUT to speed up
or IN to slow down the final drive. Continue
adjusting the motor and checking the track drive
ROTATION
sprocket speed until 28 rpm is obtained.
IMPORTANT: DO NOT exceed 30 rpm since
TO RECORD TRACK
SPEED, PLACE TIMING over speeding will damage the drive motor.
MARKS ON TRACK FRAME
AND GEARBOX HOUSING
84-18
SET TRACK SPEED
11.16
RIGHT TRACK ADJUSTMENT
13. Lower the left track onto the ground, swing
the boom around to the right side of the
machine and proceed to raise the right track
clear of the ground.
14. Use blocks to firmly support track frame in
raised position. DO NOT place arms, legs or
body under track while in the raised position.
15. Follow steps 5 through 12 from LEFT TRACK
ADJUSTMENT.
16. Lower machine down onto the ground, stop
the engine and replace the final drive
inspection covers.
SET STRAIGHT TRAVEL

Following completion of TRACK SPEED SET-
UP PROCEDURE, try driving machine in both
forward and reverse directions with the
‘DRIVE/LOW’ switch in both ‘HIGH’ and ‘LOW’
positions.
If machine does not travel straight, the right
and left track speeds are not set the same,
therefore the above set-up procedures need
to be rechecked.
11.17
TRACK COMPONENTS
IMPORTANT:
New machine: Before driving a new machine HARD
ensure that track sag is set correctly. Track sag may SURFACE
SUPPORT
be set less than specified for shipping purposes. BLOCK
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. 240T-17
LIFTING TRACK
TRACK SAG NOTE: MEASURING TRACK SAG
The track sag dimension is very important and
1. Swing boom to side of machine.
should be checked regularly, 50% increase in the
life of the track assembly can be realized, 2. Place grapple on ground as shown and by
particularly bushing O/D wear and track pitch by forcing down with boom controls, lift track
maintaining the correct amount of track sag. A track clear of ground.
that is too tight will wear out significantly faster due 3. Rotate track in forward and reverse several
to increased tension in the chain. times. Stop the track while in reverse. Do not
Track components operate under varying terrain clean the track.
conditions, most of which cause excessive wear. 4. Stop engine.
Wear to one component can quickly spread to the
rest of the track assembly. 5. Measure distance between top surface of
track shoe at centre of lower surface of track
To ensure that the track components are always in frame.
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 UNDERSIDE OF
SAG
DIMENSION
MAINTENANCE SCHEDULE in SECTION 3 OF TRACK GUARD
THIS MANUAL. •
•
UPPER SURFACE
OF TRACK SHOE
853ILL8 MEASURING SAG DIMENSION

DRIVE
SPROCKET
6. This dimension should be between 152.4mm
to 203mm (6" and 8") for normal operations.
IDLER
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
240T-16 GRAPPLE OVER IDLERS
OPERATING THE MACHINE
Whenever possible the machine should always be
operated with the felling head 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.
11.18
IDLER
TORQUING UNDERCARRIAGE BOLTS
ADJUSTING 4 •
CYLINDER 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
3 the EVERY 125 HOURS SCHEDULED
MAINTENANCE time period.
DO NOT
REMOVE
•
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.
CW001-3 1 2
Both the bolt and the nut on the track shoes
CW001-2 TRACK ADJUSTMENT
should be lightly lubricated with SAE 30 oil and
TRACK SAG ADJUSTMENT tightened using the Torque-turn method.
To tighten track, attach adjustment fitting adapter The torque-turn method involves torquing the
(3) onto valve body (1). Connect a grease gun to bolt to an initial predetermined value, plus an
the grease fitting (2) on the adjustment fitting additional 1/3 turn (not the value shown in the
adapter (3). Add grease until track sag dimension torque charts). This ensures a more accurate and
is within recommended limits. Remove adjustment consistent torquing of the bolts, with less
fitting adapter. likelihood of the bolt/nut coming loose later.
CAUTION: The grease is under very high When checking the torque values at the first 100
pressure, DO NOT REMOVE the adjustment hours and every 125 hours thereafter use the
fitting valve body (1) from the idler adjusting CHECKING TORQUE values listed in the
cylinder (4). following paragraphs.
To loosen track, slowly loosen valve body (1) until If loose shoes or under torqued bolts are
grease begins to escape via a relief passage in discovered during the FIRST 100 HOUR check,
the valve body housing, grease will be seen they should be removed, surfaces cleaned, and
escaping from around valve body threads. When reused using the torque-turn method. If the shoe
track sag is correct, tighten valve body. is not loose but a single bolt is low on torque,
loosen the bolt and re torque-turn.
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
11.19
Track shoe bolts and nuts are designed
specifically for this purpose and should not be
substituted with standard off the shelf hardware. SINGLE GROUSER
Only bolts with grade '12.9' or '170' designation BERC-9
forged in the head are approved.
When checking the torque values at the first 100
hours and every 125 hours thereafter use the DOUBLE GROUSER
checking torque value.
BERC-10
Track shoe bolts ~ 3/4" UNC
TORQUE-TURN 298Nm/220LBF/FT. + 1/3 TURN.
CHECKING TORQUE .......... 610Nm/450 LBF/FT. TRIPLE GROUSER
ROLLER RETAINING BOLTS BERC-1
The rollers must be fastened to the lower frame GROUSER WEAR (HEIGHT)
applying the exact torque values shown below. WEAR LIMITS
When installing new rollers, apply "NEVER-SEEZ" TRACK SHOE GROUSER HEIGHT WEAR
to the bolt.
WEAR LIMITS
When checking the torque values at the first 100 New 75% wear 100% wear
hours and every 125 hours thereafter use the Single 2.82"(71.62mm) ... 1.37" (34.8mm) ....... 0.93" (23.62mm)
torque value(s) shown below. Double 1.37"(34.8mm) ..... 0.71" (18.03mm) ..... 0.43" (10.92mm)
Triple 1.06"(26.92mm) ... 0.51" (12.95mm) ..... 0.36" (9.14mm)
Roller bolts ~ 7/8" UNC
TORQUE ............................. 610Nm/450 LBF/FT. NOTE: Allowable wear for soft ground conditions
is 100%. Allowable wear for rocky ground
For a complete maintenance check Refer to the
conditions is 75%.
PREVENTIVE MAINTENANCE SCHEDULE in
SECTION 3 of this manual.
BERC-2 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)
11.20
PIN AND BUSHING WEAR BUSHING WEAR, OUTSIDE DIAMETER
To obtain the track internal wear, i.e., the wear Use a calliper to measure the wear of the bushing
between the pin and the internal diameter of the O.D. in three places.
bushing, measure the track pitch over four
sections of track (5 pins).
45° 45° REVERSE

FORWARD SIDE
SIDE VERTICAL WEAR
WEAR WEAR
BERC-3 MEASURING TRACK PITCH MEASURING BUSHING WEAR BERC-5
To take this measurement, NOTE: Bushing outside diameter is measured at

1. Remove slack by placing a steel pin between three places because of the forward and reverse
sprocket and chain, then slowly move travel of the machine and a vertical wear that
machine in reverse to tighten chain. takes place.
2. Measure pitch across two four link sections, WEAR LIMITS

except section on each side of the master pin, New bushing O.D. ........................ 2.62" (66.6mm)
to find average chain wear. 75% worn ..................................... 2.5" (63.5mm)
100% worn ................................... 2.43" (61.7mm)
INTERNAL PIN & NOTE: Allowable wear in rocky ground is 75%
BUSHING WEAR
180° ROLLER WEAR

EXTERNAL TURN
BUSHING PIN &
Measure the roller diameter on the tread contact
WEAR ROTATION BUSHING surface with a large calliper to obtain the worst
180°
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 BERC-6 MEASURING ROLLER WEAR
75% or less in rocky ground.
If accessibility to the rollers is impaired by guards,
4. There is at least 0.008" (0.2mm) press fit then concentrate on the front and rear rollers,
available between pin and bushing and link. these will be the most worn.
WEAR LIMITS WEAR LIMITS
New length of four sections ............. 32" (813.0mm)
75% worn ......................................... 32.37"(822.2mm) New roller. ................................... 6.61" (168.0mm)
100% worn ....................................... 32.50"(825.5mm) 75% worn .................................... 6.10" (155.0mm)
100% worn .................................. 5.91" (150.0mm)
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.
11.21
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)
11.22
SECTION 12 - BOOM
AUGUST, 2007
CIRCUIT DESCRIPTION ............................................................................. 12.4
CIRCUIT DIAGRAM ..................................................................................... 12.6
CONTROL VALVES
JOYSTICK CONTROL VALVE. SEE SERVICE MANUAL SECTION 5
FILTERS
HYDRAULIC RETURN ............................................................................. 12.3
HOIST VALVE RELIEF VALVE SETTINGS ................................................. 12.7
PRESSURE SETTINGS
SUMMARY ..................................................................................... 12.7, 12.8
STICK VALVE RELIEF VALVE SETTINGS .................................................. 12.8
Tigercat H250B Harvester Boom functions
BOOM SYSTEM COMPONENTS
1
HYDRAULIC PUMPS •
All hydraulic functions are powered by two pumps. 5
The main and swing pumps are mounted one •
engine. The first pump (main pump) is a piston
3
and horsepower limiting controls. •
4
• •
MAIN PUMP TANK
PORT 8
• •
•
• 2
• •
WORK PRESSURE WORK
PORT PORT PORT
AW015 JOYSTICK PILOT VALVE
• JOYSTICK CONTROL VALVE
The hoist boom and stick boom functions are
SWING controlled by the left and right joysticks which
PUMP
when operated send proportional pilot signals to
the two boom control valves which supply oil to
250BT-007 HYDRAULIC PUMPS the two boom cylinders.
Mounted and coupled to the main pump is the For a detailed description of the joystick control
swing pump. It is a pressure compensated piston valve refer to SECTION 5 in THIS MANUAL.
pump.
BOOM VALVE SPOOL SECTIONS
HOIST STICK
SECTION SECTION Six of the main valve spool sections (Hoist, Stick,
Grapple, Track Drive and Live Heel Option) are
• •• equipped with proportional, pilot operated
hydraulic spool actuators. The actuators are
spring centered to the neutral position, and are
shifted by sending a hydraulic signal to the
appropriate hydraulic spool actuator.
Spools
Each of the spools installed in the main valve is
selected specifically for the function it is
MAIN CONTROL VALVE controlling. For example, the hoist boom section
spool has different characteristics than the track
The boom circuit utilizes the main pump to supply
drive spool. These spools cannot be interchanged
hydraulic oil to the HOIST and STICK circuits via
two valve sections in the main control valve. Pressure Compensation
For a more detailed description of the main The primary purpose of pressure compensation is
pump, refer to SECTION 4 in THIS SERVICE to maintain a constant flow rate to function (ie:
MANUAL. maintain the same speed of movement),
regardless of pressure variations in the system.
The pressure compensator also contains a load-
hold check valve. An orifice is installed
immediately down stream of the pressure
compensator to smoothly regulate the response
of the compensator.
12.2
•
•• • ••
•• ••
••
• ••
CROSS SECTION OF SPOOL SECTION

Port Reliefs
The main valve is equipped with port reliefs on
each side of all spool sections except the track
drive sections. The function of the port relief is to
protect the valve and the function cylinder or
RETURN
motor from pressure peaks in the system. The MANIFOLD 1-WATER
port reliefs also act as anti-cavitation valves, ABSORBING
RETURN FILTER
which means they allow oil to flow from the tank (COLOUR BLUE)
gallery in the valve to the service ports in the ••
event of underpressure. The port reliefs cannot be
adjusted. Port reliefs installed in each section
are specifically designed for use in that section
should not be interchanged with port reliefs from
•
other valve sections .
HYDRAULIC 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 3-HYDRAULIC
filters are rated 10m abs). RETURN FILTERS
Each filter head has a bypass valve with a 25 psi 250B-014 HYDRAULIC RETURN FILTERS
cracking pressure so that oil can bypass the filters
if they become restricted. The "in" side of the filter condition of the filter elements; With the hydraulic
heads are connected to a return manifold. A filter oil at normal operating temperature, place
restriction indicator and an oil sampling connector engine throttle control to FULL and with boom
are mounted onto the manifold. To check the functions extending, the filter restriction indicator
should be in the GREEN zone. If the pointer is in
the RED zone replace all four filter elements.
12.3
DOWN
IN
STICK
HOIST
OUT
UP
250BT-030
250BT-031
250BTH-005
MAIN CONTROL VALVE
BOOM CIRCUIT DESCRIPTION

The boom circuit is supplied with oil from the main the hoist or stick hydraulic cylinders to raise or
pump. The two boom valves receive oil at the inlet lower to booms. Return oil from the cylinders is
ports of the main control valve and direct the oil directed back through the spool sections, to the
through the spool sections when either of the outlet port, to the oil cooler and through the return
joysticks are actiavte. manifold to the two dual head return oil filters and
back to tank.
Moving either of the joysticks in the cab will direct
pilot oil to the spool actuator end of the hoist or
stick spool sections in the boom valves to shift the
spools and direct hydraulic oil from the pump to
12.4
250BTH-033
250BT-046
HOIST AND STICK CIRCUIT (OTHER SECTIONS REMOVED FOR CLARITY)
12.5
250BTH-034 BOOM CIRCUIT

12.6
PRESSURE SETTINGS
IMPORTANT
CAUTION Approach the gauge reading slowly and
Use caution when in the cab as a slight deliberately by turning the adjusting screw in
touch of the controls can cause a little at a time. The pressure setting must
sudden rotation of the upper frame and not exceed the above value.
booms or movement of the tracks
If less than 310 Bar/4500 psi in one direction
but OK in the other direction the port relief
CAUTION valve for the low reading circuit is
Be aware of other personnel in the area. malfunctioning. Replace the port relief valve.
operation of the machine. ELECTRONIC
DISPLACEMENT
SOLENOID
VALVE
WARNING
grapple during this procedure. PUMP 'POR'
VALVE
••
IMPORTANT ••
Avoid blowing oil over relief for longer
than five seconds, as this will cause •• ••
excessive heating of the hydraulic fluid. 'LS' MARGIN
PRESSURE
ADJUSTING MAIN PUMP
HOIST VALVE RELIEF VALVE SETTINGS SCREW CONTROLLER
Main pump POR setting ......... 310 Bar/4500 psi

Main relief setting ................... 330 Bar/4785 psi If less than 310 Bar/4500 psi in both
Hoist up port relief setting .... 330 Bar/4785 psi directions turn pump POR valve adjusting
screw in (the pressure reading should
Hoist down port relief setting 330 Bar/4785 psi increase if the POR was set too low) until 310
NOTE: The main and port relief valves are not Bar/4500 psi is obtained on gauge.
adjustable, the following procedure is for checking If when adjusting POR setting the pressure
pressure only. does not change then the main relief is
1. Position machine on flat level ground. malfunctioning and should be replaced.
2. Ensure that the hydraulic oil is at operating 6. After checking pressures and if POR valve
temperature. was adjusted reset the POR to 310 Bar/4500
psi. Tighten locknut on POR adjusting screw
3. Connect a 0 - 5000 p.s.i. pressure gauge to taking care not to turn the adjusting screw.
the "PX" valve test port on the inlet section of
the main control valve. 7. Stop engine. Remove pressure gauge and
4. Start the engine, and put the throttle control to
the FULL position. Lower left arm rest and
pilot system.
5. While holding the L.H. joystick in the HOIST
UP position (fully extended), check gauge
pressure reading. Should be 310 Bar/4500
psi.
While holding the L.H. joystick in the HOIST
DOWN position (fully retracted), check gauge
psi.
12.7
CAUTION IMPORTANT
Use caution when in the cab as a slight Approach the gauge reading slowly and
touch of the controls can cause deliberately by turning the adjusting screw in a
sudden rotation of the upper frame and little at a time. The pressure setting must not
booms or movement of the tracks exceed the above value.
CAUTION If less than 310 Bar/4500 psi in one direction

but OK in the other direction the port relief
Be aware of other personnel in the area. valve for the low reading circuit is
Operator is responsible for the safe malfunctioning, replace the port relief valve.
ELECTRONIC
DISPLACEMENT
WARNING SOLENOID
VALVE
grapple during this procedure.
IMPORTANT
PUMP 'POR'
VALVE
••
Avoid blowing oil over relief for longer ••
than five seconds, as this will cause
excessive heating of the hydraulic fluid.
•• ••
'LS' MARGIN
STICK VALVE RELIEF VALVE SETTINGS PRESSURE
ADJUSTING MAIN PUMP
Main pump POR setting ......... 310 Bar/4500 psi SCREW CONTROLLER
Main relief setting ................... 330 Bar/4785 psi

Stick out port relief setting .... 330 Bar/4785 psi If less than 310 Bar/4500 psi in both
directions turn pump POR valve adjusting
Stick in port relief setting ...... 330 Bar/4785 psi
screw in (the pressure reading should
1. Position machine on flat level ground. increase if the POR was set too low) until 310
Bar/4500 psi is obtained on gauge.
temperature. If when adjusting POR setting the pressure
does not change then the main relief is
3. Connect a 0-350 Bar (0 - 5000 psi) pressure
malfunctioning and should be replaced.
gauge to the "PX" valve test port on the inlet
section of the main control valve. 6. After checking pressures and if POR valve
was adjusted reset the POR to 310 Bar/4500
4. Start the engine, and put the throttle control
psi. Tighten locknut on POR adjusting screw
to the FULL position. Lower left arm rest and
taking care not to turn the adjusting screw.
pilot system. 7. Stop engine. Remove pressure gauge and
5. While holding the R.H. joystick in the STICK
OUT position (fully extended), check gauge
psi.
While holding the L.H. joystick in the STICK
IN position (fully retracted), check gauge
psi.
12.8
SECTION 15 - SWING
AUGUST, 2007
CIRCUIT DIAGRAM ..................................................................................... 15.6
GEARBOX, SWING DRIVE ......................................................................... 15.5
HYDROSTATIC DRIVE MOTOR
DESCRIPTION ......................................................................................... 15.4
PRESSURE SETTINGS
SET SWING RELIEF VALVES ................................................................. 15.7
SWING BEARING
SEAL KIT .................................................................................................. 15.9
WEAR LIMITS .......................................................................................... 15.8
SWING MOTOR ........................................................................................... 15.4
MOTOR REMOVAL NOTE ....................................................................... 15.4
SWING PUMP .............................................................................................. 15.2
Tigercat H250B Harvester Swing
SWING DRIVE COMPONENTS
ENGINE BELL
HOUSING
MAIN PUMP
•• SWING
PUMP
CHARGE
PUMP
•
••
CHARGE
PUMP
SUCTION
HOSE
•
SWING PUMP side of the closed loop is a high pressure supply
All hydraulic functions are powered by two pumps while the other side is a low pressure return. The
mounted one behind the other on the flywheel supply and return will alternate from side to side
housing of the engine. The first pump (main of the closed loop as the direction of swing
pump) is a piston pump with load sensing, rotation is changed from left to right.
pressure compensating and horsepower limiting The swing drive pump is actually two separate
controls. hydraulic pumps mounted in a common case and
Mounted and coupled to the main pump is the driven by the same input drive shaft.
swing pump. The primary components of the The primary pump is a variable displacement,
swing system are the hydraulic pump, hydraulic swashplate, in line axial piston type pump. The
motor and swing drive gearbox. The hydraulic volume and direction of oil flow from the piston
pump and hydraulic motor are connected together pump is determined by the angle of the tiltable
by two hydraulic hoses. The pump converts the swashplate. When the swashplate is stroked to a
mechanical power of the diesel engine into maximum displacement angle, the piston pump
hydraulic power. This high pressure flow of will produce maximum flow in one direction in the
hydraulic oil is then transmitted to the hydraulic closed loop. As the swashplate is de-stroked, the
motor through a connecting hose. The motor then flow smoothly decreases until there is no flow at
reconverts the hydraulic power back into an angle of zero (0°). Continuing to angle the
mechanical power to drive the swing gearbox swashplate past this neutral position steplessly
used to swing the upper frame. Low pressure reverses the direction of flow from the piston
hydraulic oil flow then returns from the motor to pump.
the pump through the other connecting hose
The secondary pump of the drive pump is a fixed
thereby completing a continuous closed loop
displacement, internal gear type pump that
hydraulic circuit.
provides charge oil (cooling, lubricating and
A hydraulic system is termed closed loop when make-up oil) for the hydrostatic pump and motors
the hydraulic oil returning from the motor is fed in the closed loop system. The charge pump also
straight back to the pump without first returning to provides initial pilot oil for the pilot system.
tank. When the swing system is operating, one
15.2
SWING
MOTOR SWING PUMP
CONTROLLER
•
SWING
GEARBOX
••
• ••
SWING
PUMP
••
SWING
BEARING
250BTH-018 SWING DRIVE CONTINUOUS CLOSED LOOP HYDRAULIC CIRCUIT

FOOT PEDAL CONTROL VALVE
1
The swing function is controlled by the L.H. •
Joystick valve which sends proportional pilot 5
signals to the swing pump controller to stroke the •
pump swashplate producing oil flow to the swing
motor.
3
In the neutral position the joystick is held centered
by return springs (4). When the lever (1) is •
operated, the plunger (5) is pushed against its 4
• •
return spring (4). At the same time the regulating TANK
PORT 8
spool (2) is moved down against the regulating
spring (3). When the regulating stroke begins, • •
there is a connection made between the pressure •
2
port, via holes (8) in the spool and work ports in
the base of the valve. • •
Pilot pressure is directly proportional to the WORK PRESSURE WORK
PORT PORT PORT
operator position of the joystick and the regulating JOYSTICK PILOT VALVE
AW015
spring characteristics.
15.3
SWING MOTOR
250BT-018
SWING MOTOR CROSS SECTION
SWING
PUMP
'MA' TEST
PORT A ••
'MB' TEST
PORT ••
•
250BT-017
••
SWING MOTOR AND GEARBOX
•• B
'G' TEST
PORT
The swing motor is mounted directly onto the CHARGE
PRESSURE
input of the swing planetary gearbox. The motor
is a fixed displacement, bent axis, axial piston 250BT-052
type. SWING PUMP TEST PORTS
High pressure oil from the swing pump enters the
motor via port A or port B depending on the
direction of swing required. This oil is then
directed to a set of pistons inside the motor
rotating group cylinder housing. These pistons
push against the back of the output shaft at an
angle, causing the shaft to rotate.
MOTOR REMOVAL NOTE:
Before removing the drive motor, drain the oil
from the reservoir bottle by disconnecting the
hose at the oil fill tube. Replace the oil fill tube.
IMPORTANT: Do not allow dirt to enter the
gearbox during and after the motor has been
removed.
After the motor has been replaced, partly fill the
reservoir with correct oil. Bleed swing gearbox by
loosening air bleed plug. Add oil to reservoir until
half full.
15.4
SWING DRIVE GEARBOX
Power is transmitted from the motor to a double RESERVOIR
reduction planetary gearbox. The swing gearbox
upper gearing is lubricated by oil stored in a
reservoir attached to the side of the gearbox
••
cover. The reservoir must remain half full of oil* at CONNECTING
HOSE TO
all times. The lower bearing area is lubricated by GEARBOX
grease where the cavity is filled with grease at
assembly, a grease fitting is not provided since
additional greasing is not necessary. ••
206-16A SWING DRIVE LUBRICATION
MOTOR
FILL
HOSE AIR
ON THIS BLEED
SIDE PLUG
PLANETARY
GEARBOX
DRAIN DRAIN HOSE

HOSE ATTACHED
ON 180°
THIS (OPPOSITE
SIDE SIDE)
250BT-053
SWING MOTOR AND GEARBOX
To fill the gearbox with oil, unscrew the air bleed

plug located on the motor flange, remove the cap
on the reservoir and add oil to the reservoir.
When oil begins to come out of the air bleed hole
replace the plug and continue to add oil until the
reservoir is half full. Replace the cap on the
reservoir.
To drain the gearbox unscrew the drain plug and
allow oil to drain into a suitable container. To
facilitate draining, the oil should be warm.
*For correct oil specification and maintenance
schedule, refer to SECTION 3 in THIS MANUAL.
15.5
250BTH-017
SWING DRIVE CIRCUIT
15.6
PRESSURE SETTINGS
'POR'
VALVE
CAUTION
Use caution when in the cab as a slight
touch of the controls can cause 'A' PRESSURE
RELIEF VALVE
••
sudden rotation of the upper frame and
booms or movement of the tracks. •• A
CAUTION
'MA' TEST
CHARGE PORT
Be aware of other personnel in the area. PRESSURE
ADJUSTING
SCREW
••
• 'MB' TEST
PORT
•
WARNING ••
B
grapple during this procedure. • • SWING
PUMP
'G' TEST
SET SWING RELIEF VALVES PORT 'B' PRESSURE
CHARGE RELIEF VALVE
Swing pump POR . 310 Bar/4500 psi + 1/2 turn PRESSURE
250BT-007
Swing ccw relief ..................... 352 bar/5100 psi SWING PUMP TEST PORTS
Swing cw relief ...................... 352 Bar/5100 psi 10. Tighten locknut on adjusting screw taking
care not to turn the adjusting screw.
Swing charge relief ................... 24 Bar/350 psi
11. Press and hold the swing foot pedal in the
1. Position machine on flat level ground. SWING RIGHT position, check gauge
2. Ensure that the hydraulic oil is at operating pressure reading should be 352 bar/5100 psi.
temperature. If required loosen locknut and turn swing right
relief valve adjusting screw in to increase
3. Install a 0-5000 psi pressure gauge on the
pressure or out to decrease pressure.
'MA' and 'MB' test ports on the swing pump.
12. Tighten locknut on adjusting screw taking
4. Install a 0-1000 psi pressure gauge on the 'G'
test port on the swing pump.
13. Repeat steps 9 and 11 to verify settings.
5. Start engine and place throttle control in
IDLE. set POR relief valve:
6. Lower left arm rest and depress the pilot reset 14. Increase engine speed to FULL throttle.
switch to activate the pilot system. 15. Loosen locknut on swing POR relief and
7. Place the swing brake switch in the ON unscrew adjusting screw until gauge reads
position. 310 Bar/4500 psi and then turn screw in 1/2
turn.
8. Observe the gauge on the 'G' test port,
charge pressure should be 24 Bar/350 psi. If 16. While holding the foot pedal in the SWING
required loosen locknut and turn adjusting LEFT position, check gauge pressure
screw in to increase pressure or out to reading, should be 352 bar/5100 psi +/- 1.4
decrease pressure. Bar/20 psi.
9. Press and hold the swing foot pedal in the 17. Tighten locknut on adjusting screw taking
SWING LEFT position, check gauge pressure care not to turn the adjusting screw.
reading should be 352 bar/5100 psi. If 18. Shut engine off, remove gauges and wipe up
required loosen locknut and turn swing left any spilled oil.
relief valve adjusting screw in to increase
pressure or out to decrease pressure.
15.7
SWING BEARING WEAR LIMITS The following procedure will verify the amount of
wear in the ball race:
It is important that the swing bearing be
periodically inspected for wear. Any significant 1. Position machine with boom extended as in
wear will be noticeable by observing too much position 1.
"tilting" of the upper frame relative to the lower
2. Set dial indicator (A) to zero.
frame. A small amount of designed-in clearance in
the bearing is normal and is present in a new 3. Lower boom as in position 2.
machine. 4. Note tilt reading on dial indicator.
Too much clearance will affect the backlash 5. Return machine to position 1.
between the ring gear and the drive pinion and if
left unchecked will cause damage to the gear 6. Check to see if reading on dial indicator has
teeth and ultimately the swing drive gearbox. returned to zero, if not repeat steps 1 thru 4.
The main cause of wear in the ball race can be 7. Rotate upper frame 90 deg. and repeat
due to a lack of lubricant or not following the steps 1 thru 6.
proper lubricating procedure. A damaged or 8. The bearing is considered to be worn when
missing peripheral seal will also contribute to early the total play is 0.105" or greater.
wear by allowing dirt particles to enter the ball
race.
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.
250BTH-016
250BTH-015
UPPER FRAME
UNDERCARRIAGE
FRAME
15.8
SWING BEARING SEAL KIT SEAL
INSTALLATION INSTRUCTIONS ••
1. Remove all traces of former seal and glue
from the seal groove.
Groove should then be cleaned with a non-
residue commercial solvent.
2. Wipe the seal with the same solvent.
3. Apply a bead of adhesive (BN157) to the seal
groove (avoid the adhesive from being
extruded into the bearing cavity as the seal is ••
installed.)
SEAL
4. Insert the seal into the groove ( the length of
seal provided is longer than required), trim the 860C-0004 SWING BEARING SEAL
excess with a sharp knife or pruning shears in
such a manner to smoothly meet the
adjoining end. Place a drop of crazy glue
(BN158) on the end so that the two ends will
be joined.
5. Immediately butt the two ends together,
aligning them as quickly as possible. Hold
together without movement (motion weakens
and may destroy the bond). After 2 minutes
the joint will be strong enough.
NOTE: Read the precautions on adhesive
container. Avoid getting adhesive on your
fingers. It will bond them together.
6. Coat joint with grease from bearing. Moisture
or high humidity may weaken bond unless
protected with grease.
7. Examine seal for contact with seal surface on
race ring.
8. Re-grease the bearing until grease extrudes
from under the seal to remove any foreign
matter.
15.9
ADJUST SWING BEARING BACKLASH
Make up adjustment tool from a 101.6x101.6mm
(4" x4") piece of 6.35mm (0.25") thick steel plate.
0.25"
6.35mm
Loosen swing bearing outer race bolts, and adjust
the hex head bolt to decrease the backlash or
swing the upper 180° and adjust the hex head
bolt to reposition swing bearing to obtain
acceptable backlash of 0.43mm to 0.66mm
4" 4" (0.017" to 0.026").
101.6mm 101.6mm Torque four pairs of swing bearing outer race
860C-186 ADJUSTMENT TOOL bolts located at 90° to each other to 610 Nm (450
lbs. ft.)
Weld a 1" nut on the plate as shown.
Position the adjustment tool up against the

underside of the turntable 12.7mm (1/2") away
from the bearing. Weld the tool to the turntable as
shown using 6.35mm (1/4") fillet weld.
Recheck and adjust backlash every 45° of gear
rotation to obtain acceptable backlash of 0.43mm
to 0.66mm (0.017" to 0.026").
Install a 1" x 6" hex head bolt in the nut.
Check the backlash between the pinion gear and Apply Loctite 242 to all bolts and torque swing
swing bearing gear teeth. Should be 0.43mm to bearing mounting bolts to 542-610 Nm ( 400-450
0.66mm (0.017" to 0.026"). lbs.ft.) with sequence shown above.
15.10
SECTION 17 - ATTACHMENT
AUGUST, 2007
HEAD ROTATE CONTROL VALVE ............................................................. 17.5
MAIN CONTROL VALVE ............................................................................. 17.2
MAIN PUMP ................................................................................................. 17.2
PRESSURE SETTINGS
HEAD ROTATE CONTROL VALVE ......................................................... 17.9
PUMP 1 CONTROL VALVE ...................................................................... 17.7
PUMP 2 CONTROL VALVE ...................................................................... 17.8
PUMP 1 CONTROL VALVE ......................................................................... 17.2
PUMP 2 PILOT VALVE ................................................................................ 17.4
Tigercat H250B Harvester Attachment
ATTACHMENT SYSTEM COMPONENTS
ENGINE BELL
HOUSING
••
MAIN PUMP
•• SWING
PUMP
••

MAIN PUMP
The main pump is an axial-piston, variable- HEAD ROTATE PUMP 2 PUMP 1
displacement pump with load sensing, pressure SECTION SECTION SECTION

The main pump supplies hydraulic oil to the
• •• ••
attachment via the Head Rotate, Pump 1 and
Pump 2 spool sections of the main control valve.
For a more detailed description of the main pump,
refer to SECTION 4 in THIS SERVICE MANUAL.
MAIN CONTROL VALVE

Three spool sections of the main control valve,
head rotate, pump1 and pump 2 are used to MAIN CONTROL VALVE
operate the attachment. The head rotate and PUMP 1 CONTROL VALVE
pump 2 sections have hydraulic pilot operated
spool actuaors and the pump 1 section has Pump 1 is activated when the pilot reset switch on
electro-hydraulic spool actuators. the control panel is turned on and the head power
is turned ON and a pump 1 function on the head
For a more detailed description of the main is operated. In the ON position the 'A 'side
control valve, refer to SECTION 4 in THIS solenoid of pump 1 control valve is activated
SERVICE MANUAL. allowing internal pilot oil to shift the spool
providing flow from the main pump through pump
1 control valve to the head.
17.2
PORT RELIEF FEED PORT RELIEF

‘B’ SIDE REDUCTION ‘A’ SIDE
SIDE ‘A’
FEED •
SIDE ‘B’
‘B’ ‘A’ HYDRAULIC
SPOOL
ACTUATOR
SPOOL
ACTUATOR
•• ••
SPOOL
PRESSURE
250BTH-036 COMPENSATOR
HEAD ROTATE AND PUMP 2 SPOOL SECTION - PILOT OPERATED SPOOL ACTUATOR

FEED
SIDE ‘B’ •
‘B’ ‘A’
• •
‘A’ ‘B’
SPOOL
PRESSURE
COMPENSATOR
PUMP 1 SPOOL SECTION

250BTH-013 SPOOL SECTION WITH ELECTRO-HYDRAULIC SPOOL ACTUATOR
17.3
PUMP 2 PILOT VALVE PUMP 2
SECTION
As previously mentioned, pump 2 section has
hydraulic pilot operated spool actuators and pump
1 section has electro-hydraulic spool actuators.
•
MAIN CONTROL VALVE
H250B-013 PUMP 2 PILOT VALVE

A remote mounted pilot valve is used to activate
1. VALVE
pump 2 control valve. The pilot valve is located on 2. PILOT
the upper frame below the floor panel in the 3. TANK
hydraulic compartment.
Pump 2 pilot valve is a solenoid-operated, 3-way,
direct-acting, spool-type, screw-in hydraulic
directional valve.
OPERATION
250BTH-040
Pump 2 control valve is activated when the pilot PUMP 2 PILOT VALVE CARTRIDGE
reset switch on the control panel is turned on and
the head power is turned ON and a pump 2
function on the head is operated. 1
When de-energized, the valve allows flow from 1

(valve) to 3 (tank) while blocking flow at 2 (pilot).
When energized, the cartridge’s spool shifts to
•• 3
open flow from 2 (pilot) to 1 (valve) activating
pump 2 control valve allowing flow from the main •
pump to be directed through the valve to the
head, while blocking flow at 3 (tank). The pilot •
valve is energized when the pilot reset switch on
the control panel is activated and the head power 2
is turned ON and a pump 2 function is operated.
H250B-013 PUMP 2 PILOT VALVE
17.4
HEAD ROTATE CONTROL VALVE
The head rotate section of the main control valve HEAD ROTATE
SECTION
has hydraulic pilot operated spool actuators. The
R.H. joystick is used to activate the head rotate
control valve. ••
Refer to section 5 of this manual for details of the
pilot operated joystick valves.
OPERATION
During machine operation the attachment can be
rotated left or right by moving the R.H. joystick to
the left to rotate the attachment left (CCW ) or
MAIN CONTROL VALVE
moving the joystick to the right to rotate the
attachment to the right (CW ).
17.5
250BTH-037 ATTACHMENT HYDRAULIC CIRCUIT - TIGERCAT TH575 SHOWN
17.6
PRESSURE SETTINGS
CAUTION
Pressure settings for a harvesting attachment will
vary depending on the manufacturer and model of Be aware of other personnel in the area.
attachment in use. Refer to attachment Operator is responsible for the safe
manufacturer's service and installation information. operation of the machine.
The main pump supplies hydraulic oil for all the
attachment functions as follows:
WARNING
• Pump 1 Functions via Pump 1 Control Valve Ensure that no one is standing near the
• Pump 2 Functions via Pump 2 Control Valve attachment during this procedure.
• Head Rotate via Head Rotate Control Valve 5. With the aid of an assitant, start the engine,
lower left armrest, depress pilot reset switch,
The following pressure settings will verify that the turn computer and head power ON and
control valve pressures meet the specified pressure increase engine speed to full throttle.
required for each of the control valve functions.
NOTE: The pressure stated in this adjustment
PUMP 1 CONTROL VALVE is a standard factory setting, pressures and
1. Park machine on level ground, lower the flow rate will vary depending on manufacturer
attachment to the ground, engage the swing and model of attachment. Refer to attachment
brake, turn anti-stall OFF and stop engine. manufacturer's specifications for details
before setting any pressures.
2. Block attachment from operating as per method
outlined in attachment manufacturer’s manual. 'B' PORT FEED
REDUCER
temperature.
PUMP 1
CONTROL
VALVE
6. Operate a pump 1 function and observe

gauge on 'PL' test port. Reading should be
228 Bar (3300 psi).
7. If pressure is lower or higher then 228 Bar
(3300 psi) loosen locknut on 'B' port feed
reducer and screw adjuster IN to increase
pressure or screw adjuster OUT to decrease
pressure.
9. Release pump 1 function, turn head power
off, set engine speed to low idle and shut
engine off.
250BTH-043
MAIN VALVE 'PL' TEST PORT
- INLET SECTION 10. Remove pressure gauge.
4. Install a 0-350 Bar (0-5000 psi) pressure gauge
on main control valve 'PL' gauge test port.
17.7
PRESSURE SETTINGS CONT'D
CAUTION
PUMP 2 CONTROL VALVE
1. Park machine on level ground, lower the Be aware of other personnel in the area.
attachment to the ground, engage the swing Operator is responsible for the safe
brake, turn anti-stall OFF and stop engine. operation of the machine.
2. Block attachment from operating as per

method outlined in attachment WARNING
manufacturer’s manual.
3. Ensure that the hydraulic oil is at operating attachment during this procedure.
temperature.
'B' PORT FEED
REDUCER
PUMP 2
CONTROL
VALVE
7. If pressure is lower or higher then 283 Bar

pressure.
9. Release pump 2 function, turn head power
off, set engine speed to low idle and shut
engine off.
250BTH-043
- INLET SECTION 10. Remove pressure gauge.
4. Install a 0-5000 PSI pressure gauge on main

control valve 'PL' gauge test port.
5. With the aid of an assitant, start the engine,
lower left armrest, depress pilot reset switch,
turn computer and head power ON and
increase engine speed to full throttle.
NOTE: The pressure stated in this adjustment
is a standard factory setting, pressures and
flow rate will vary depending on manufacturer
and model of attachment. Refer to attachment
manufacturer's specifications for details
6. Operate a pump 2 function and observe
gauge on 'PL' test port. Reading should be
283 Bar (4100 psi).
17.8
PRESSURE SETTINGS CONT'D
CAUTION
HEAD ROTATE CONTROL VALVE
1. Park machine on level ground, lower the Be aware of other personnel in the area.
attachment to the ground, engage the swing Operator is responsible for the safe
brake and stop engine. operation of the machine.
2. Block attachment from operating as per

method outlined in attachment WARNING
manufacturer’s manual.
3. Ensure that the hydraulic oil is at operating attachment during this procedure.
temperature.
'A' PORT FEED 'B' PORT FEED
REDUCER (CCW) REDUCER (CW)
HEAD ROTATE
CONTROL VALVE
7. If pressure is lower or higher then 110.3 Bar

(1600 psi) loosen locknut on 'A' port feed
pressure.
9. Move R.H. joystick to the right (head rotate
CW) and observe gauge on 'PL' test port.
Reading should be 110.3 Bar (1600 psi).
250BTH-043
- INLET SECTION 10. If pressure is lower or higher then 110.3 Bar
4. Install a 0-5000 PSI pressure gauge on main reducer and screw adjuster IN to increase
control valve 'PL' gauge test port. pressure or screw adjuster OUT to decrease
pressure.
5. With the aid of an assitant, start the engine,
lower left armrest, depress pilot reset switch 11. Tighten locknut on adjusting screw taking
and increase engine speed to full throttle. care not to turn the adjusting screw.
NOTE: The pressure stated in this adjustment 12. Release joystick, set engine speed to low idle
is a standard factory setting, pressures and and shut engine off.
flow rate will vary depending on manufacturer
13. Remove pressure gauge.
and model of attachment. Refer to attachment
manufacturer's specifications for details
6. Move R.H. joystick to the left (head rotate
CCW) and observe gauge on 'PL' test port.
Reading should be 110.3 Bar (1600 psi).
17.9
PUMP 1 AND PUMP 2 PRESSURE AND
RETURN HOSES ARE CONNECTED
TOGETHER HERE VIA TEE FITTINGS
•• •
ELECTRICAL
••
•• •• ••
PRESSURE
RETURN
CASE DRAIN
RETURN
250BTH-039 BOOM TUBE CONNECTIONS TO ATTACHMENT
17.10
DEUTSCH CONNECTOR
AM412 - LOCK.................QTY 1
AM429 - CONTACT..........QTY 2
AM430 - CONNECTOR....QTY 1
AMP CONNECTOR
AM796 - CONNECTOR..QTY 1
250BTH-031 PILOT HARNESS - CAB TO PILOT SOLENOID CONTROLS
17.11
17.12

Service Manual: Tigercat H250B Harvester

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Service Manual: Tigercat H250B Harvester

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SERVICE MANUAL

Tigercat H250B Harvester

NON-APPROVED FIELD PRODUCT CHANGES ............................................................ iv

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

OIL COOLER, RADIATOR AND FAN ............................................................................. 10

TRACK DRIVE ................................................................................................................ 11

BOOM FUNCTIONS ....................................................................................................... 12

NON-APPROVED FIELD PRODUCT CHANGES

Tigercat Industries Inc.

BATTERY DISCONNECT SWITCH ........................................................... 1.6, 1.8

This safety alert symbol means ATTENTION!

DANGER indicates an imminently hazardous

WARNING indicates a potentially hazardous

CAUTION indicates a potentially hazardous

Use the handrails and steps provided when mounting

Keep the cab door closed when operating the machine

For engine starting and stopping procedures refer

Before leaving operator's cab, lower the attachment

Turn the battery disconnect switch off if the vehicle

When servicing or repairing equipment, shut the LIMIT SWITCH

Install a “DO NOT START ENGINE” sign on the

WARNING, HOT FLUIDS AND HOT MACHINE

• Before servicing the machine, allow the

SERVICING SAFETY PRECAUTIONS

Never use your bare hand to check for fluid leaks.

SERVICING SAFETY PRECAUTIONS

Dispose of all fluids properly according to all

If the engine is running inside a building, ensure that

SERVICING SAFETY PRECAUTIONS WARNING

SERVICING SAFETY PRECAUTIONS

EQUIPMENT FIRES ADVERSELY EFFECT YOUR

WHAT TO DO TO PREPARE FOR A MACHINE FIRE

TYPICAL FIRE EXTINGUISHER

*INITIAL PRE-DELIVERY INSPECTION:-

*FIRST 50-100 HOUR INSPECTION AND SERVICE REPORT:-

*IMPORTANT: TO QUALIFY FOR CONTINUED WARRANTY,

NOTE: Use of filters other than genuine Tigercat

TIGERCAT OIL SAMPLING PROGRAM

TIGERCAT OIL ANALYSIS KITS

Contact your Tigercat Dealer Parts Department to order Kits.

TIGERCAT OIL SAMPLING PROGRAM

*OIL LOST FROM LEAKAGE

• Replace engine fuel/water separator. And in addition check:~

• Hyd. Oil pilot pressure filter †

† NOTE: Use of filters other than genuine Tigercat

LUBRICATION AND SERVICE POINTS

APPROVED HYDRAULIC OILS

3-HYDRAULIC SQUARE SECTION GASKET INSTALLATION

HYDRAULIC RETURN FILTERS Square Section Gasket

250B-016 HYDRAULIC PILOT FILTER

AIR CLEANER MAINTENANCE

IMPORTANT STEPS TO FOLLOW

should be present in the system and must be used