Tigercat 230 240 Loader OPERATOR'S MANUAL - PDF DOWNLOAD

OPERATOR'S MANUAL Tigercat 230/240 Loader TABLE OF CONTENTS

Issue 3.1, MARCH 2003

SECTION INTRODUCTION .............................................................................................................. iii NON-APPROVED FIELD PRODUCT CHANGES ............................................................ iv SAFETY ............................................................................................................................ 1 CONTROLS AND OPERATION ........................................................................................ 2 LUBRICATION AND MAINTENANCE ............................................................................... 3

230-OM00

230/240 Available Literature Operator's Manual ................................. Part No. 8752A Service Manual, 230/240 ....................... Part No. 8753A Parts Catalog, 230 ................................. Part No. 8472A Parts Catalog, 240 ................................. Part No. 8775A Hydraulic Adapters Book ....................... Part No. 1472A Hydraulic Hose assemblies Book ......... Part No. 3707A

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

®

ii

Tigercat 230/240 Loader

INTRODUCTION An Operator's manual, Service manual and a Parts catalog are provided by Tigercat to assist the dealer, customer and operator in becoming familiar with the features of the Tigercat 230 and 240 Loaders.

The operator's manual will assist the operator with the techniques of proper and safe operation of the Loader. The service manual contains safety guidelines, a preventive maintenance schedule and servicing procedures to ensure optimum machine performance.

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

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

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

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

Tigercat Industries Inc.

iii

Tigercat 230/240 Loader

Introduction

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

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

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

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

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

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

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

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

Tigercat Industries Inc.

iv

Tigercat 230/240 Loader

SECTION 1 - SAFETY MARCH 2003

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

Tigercat 230/240 Loader

Safety

SAFETY SYMBOLS

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

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

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

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

1.2

Tigercat 230/240 Loader

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

Repair or replace damaged labels.

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

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

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

Follow all instructions from safety inspector and supervisors.

KEEP CLEAR When approaching an operating machine on foot, stay at least 300 feet (90M) away from the machine and all related attachments including the grapple, delimber, topping saw and ground saws until the operator recognizes your presence. Make sure that all equipment is shut down with grapple resting securely on stable ground before advancing to the machine.

Always avoid the discharge path of all saws.

Operators of this equipment must be fully trained by a qualified person in safety and operating procedures.

The operator must be fully aware of the capabilities and limitations of the equipment and must at no time exceed them. The machine is to be used only for its intended purpose. Learn the most efficient operating techniques.

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

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

Do not let an untrained person operate the machine.

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

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

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

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

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

Tigercat 230/240 Loader

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

GENERAL SAFETY PRECAUTIONS continued

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

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

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

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

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

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

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

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

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

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

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

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

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

Inspect the machine daily for signs of damage, unusual wear, fluid leaks, or faulty operation. Repair or replace malfunctioning parts and systems immediately.

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

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

1.4

Tigercat 230/240 Loader

Safety

OPERATING SAFETY PRECAUTIONS

Start the engine according to the instructions in this manual.

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

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

During refuelling do not leave the filler nozzle unattended.

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

Ensure that the windshield guard is installed and properly secured.

Avoid over filling and immediately clean up spilled fuel.

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

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

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

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

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

Sound the machine horn before starting the machine.

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

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

Use only prearranged and approved signalling practices.

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

1.5

Tigercat 230/240 Loader

Safety

OPERATING SAFETY PRECAUTIONS continued

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

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

WARNING Safe mounting of this loader onto a trailer or truck is the responsibility of the owner.

WARNING An unstable loader can cause serious injury or death or equipment damage. Do not operate the loader without lowering the stabilizers onto firm ground and with the loader level.

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

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

DANGER

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

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

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

Do not move the boom or load over the heads of people.

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

WARNING Do not allow the driver to remain in the truck cab during loading operations and do not move loads over the top of the truck cab.

Serious injury or death or property damage may result.

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

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

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

1.6

Tigercat 230/240 Loader

Safety

SERVICING SAFETY PRECAUTIONS

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

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

When servicing or repairing equipment, shut the engine down. Turn Master Disconnect switch OFF. Install a “DO NOT START ENGINE” sign on the operator’s cab door when making repairs to the machine.

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

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

Prior to welding on any part of the machine, it should be cleaned and a fire extinguisher should be made available at the welding location. Care must be taken in attaching the welding machine grounding clamp so current does not pass through bearings, especially the swing bearing. Also, the battery negative terminal must be disconnected.

1.7

Never use your bare hand to check for fluid leaks.

Fluid leaks under pressure may not be visible.

When searching for leaks, wear work gloves and use a wrench or piece of wood to move hydraulic hoses. Do not grab hold of hydraulic hoses. Wear safety goggles for eye protection.

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

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

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

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

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

Tigercat 230/240 Loader

Safety

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

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

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

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.

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

VERTICAL CENTERLINE

LOWER FRAME

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

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

•

COUNTERBALANCE VALVE

•

STABILIZER UP IN VERTICAL POSITION

• • •

CYLINDER

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

STABILIZER COUNTERBALANCE/CHECK VALVE CARTRIDGE REMOVAL

230-06A

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

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

1.8

Tigercat 230/240 Loader

Safety

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

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

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

1.9

Tigercat 230/240 Loader

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

FIRE PREVENTION

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

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

5.

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

6.

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

7.

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

8.

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

9.

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

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

1.

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

2.

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

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

Remove debris and blow out dust regularly from the air intake doors, engine radiator, hydraulic oil cooler and A/C condenser core to prevent overheating of the engine and hydraulics. Refer to CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR in SECTION 2 of the OPERATOR’S MANUAL.

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

3.

4.

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

Blow off all debris and dust accumulated near hot engine exhaust components (turbocharger and exhaust manifold as well as exhaust pipes and muffler) at the completion of each work shift or more frequently depending on logging conditions. Visual inspection after blow off to ensure thorough cleanliness is vital. Engine exhaust systems provide numerous small pockets where saw dust, small wood chips and other flammable forest debris can gather. Even small accumulations close to hot exhaust components can ignite and smolder. If 1.10

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

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

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

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

Tigercat 230/240 Loader

Safety WHAT TO DO IN CASE OF A MACHINE FIRE

FIRE PREVENTION continued

•

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

•

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

•

Shut the engine off.

•

Activate the fire suppression system*

•

Radio or call for help (as appropriate).

•

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

•

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

•

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

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

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

EQUIPMENT FIRES ADVERSELY EFFECT YOUR ABILITY TO LOG, MAY INCREASE YOUR INSURANCE PREMIUMS DRAMATICALLY OR PREVENT YOU FROM OBTAINING INSURANCE COVERAGE AT ALL.

WHAT ELSE TO DO BEFORE YOU EXPERIENCE A FIRE •

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

•

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

•

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

•

Use the PASS method with most extinguishers.

•

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

•

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

•

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

•

•

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

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

•

•

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

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

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

•

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

•

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

Continued on page 12

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

1.11

Tigercat 230/240 Loader

Safety WHAT TO DO AFTER A FIRE

FIRE PREVENTION continued Continued from page 11

20229A

TYPICAL FIRE EXTINGUISHER ACCESS HOLE

•

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

•

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

•

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

•

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

1.12

•

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

•

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

•

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

•

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

Tigercat 230/240 Loader

SECTION 2 - CONTROLS & OPERATION DECEMBER 2000

Read and understand the entire manual including Safety section prior to operating any equipment. Read and understand all manuals for any attachments or accessories used with the Loader.

CONTENTS - SECTION 2 AIR CLEANER .............................................. 2.15 AIR CONDITIONER/HEATER ......................... 2.5

LOW COOLANT .............................................. 2.6 LOW HYDRAULIC OIL LEVEL ........................ 2.7

BATTERY DISCONNECT SWITCH .............. 2.12

MACHINE OPERATION ................................ 2.18 PRE-START CHECKS ............................... 2.18 RESTARTING AN ENGINE THAT HAS RUN OUT OF FUEL ....................................... 2.20 STARTING THE ENGINE ........................... 2.20 STOPPING THE ENGINE .......................... 2.22

CAB CONTROLS ............................................ 2.2 CARE OF THE MACHINE ............................. 2.26 CLEANING LEXAN WINDOWS .................... 2.26 CONTRLS, CAB .............................................. 2.2 DELIMBER ARMS ........................................... 2.2 ENGINE COMPARTMENT ............................ 2.12 ENGINE COMPARTMENT ACCESS ............ 2.12 ENGINE COOLANT TEMPERATURE ............. 2.7 ENGINE OIL PRESSURE ............................... 2.7 ENGINE, STARTING ..................................... 2.20 ENGINE, STOPPING .................................... 2.22 ETHER START ................................................ 2.4 FAN, CAB ........................................................ 2.8 FILTERS, A/C AND HEATER .......................... 2.6 FIRE EXTINGUISHER .................................... 2.8 FLUID LEAKS ............................................... 2.22 FOOT PEDAL .................................................. 2.3 FUEL TANK AND FILLER ............................. 2.17 FUSE AND RELAY PANEL ............................. 2.8 FUSE PANEL .................................................. 2.8 HAND FILL PUMP, HYDRAULIC OIL .. 2.13, 2.14 HEATER/AIR CONDITIONER ......................... 2.5 HORN .............................................................. 2.3 HOUR METER ................................................ 2.7 HYDRAULIC OIL TEMPERATURE ................. 2.7 HYDRAULIC RESERVOIR LEVEL ................ 2.13 IGNITION SWITCH ......................................... 2.4 JOYSTICK, L.H. .............................................. 2.2 JOYSTICK R.H. ............................................... 2.2 LIGHT - DOME ................................................ 2.8 LIGHTER ......................................................... 2.4 LIGHTS, SERVICE .......................................... 2.4 LIGHTS, WORK .............................................. 2.4 LOADER MOUNTING/INSTALLATION ......... 2.23

PILOT RESET ................................................. 2.3 PILOT SYSTEM SHUT OFF ........................... 2.4 RADIO, 2-WAY ................................................ 2.8 SEAT ............................................................. 2.10 SEAT,OPERATING AND ADJUSTING .......... 2.10 SERVICE LIGHTS ........................................... 2.4 SETTING THE MACHINE ............................. 2.21 STABILIZER OPERATION .............................. 2.3 STOPPING THE ENGINE ............................. 2.22 SWING ............................................................ 2.3 TAPE DECK .................................................... 2.8 THROTTLE CONTROL ................................... 2.5 TRANSPORTING THE LOADER .................. 2.25 VOLTMETER ................................................... 2.7 WASHER ........................................................ 2.3 WINDOWS ...................................................... 2.9 WIPER ............................................................ 2.3 WORK LIGHTS ............................................... 2.4

Tigercat 230/240 Loader

Controls and operation IMPORTANT

This manual is applicable to factory installed machine functions and controls. It does not take into account any changes or modifications made after shipment. Verify all functions before operating this machine.

CAB CONTROLS NOTE All joystick and Foot Pedal controls require pilot pressure. Refer to PILOT RESET in THIS SECTION.

1

2

• ••

156-7A

156-9A

1.

LEFT HAND JOYSTICK LEVER

reversed on some earlier models.

Hoist Boom Push the joystick lever forward to lower the Hoist Boom.

Grapple Rotate Move the joystick lever to the left to rotate the grapple counter clockwise (left)

Pull the joystick lever back to raise the Hoist Boom.

Grapple Rotate Move the joystick lever to the right to rotate the grapple clockwise (right).

Grapple Open Move the joystick lever to the left to open the grapple arms.

RIGHT HAND JOYSTICK ROCKER SWITCH* *The right hand joystick rocker switch performs two separate functions depending on the status of the delimber arms.

Grapple Close Move the joystick lever to the right to close the grapple arms.

With the delimber arms Open:

LEFT HAND JOYSTICK ROCKER SWITCH

Push the left hand side of the rocker switch to extend (cut) with slasher saw.

Push the left hand side of the rocker switch to open delimber arms.

Push the right hand side of the rocker switch to retract slasher saw.

Push the right hand side of the rocker switch to close delimber arms.

2.

OR

RIGHT HAND JOYSTICK LEVER

With the delimber arms Closed:

Stick (Jib) Boom Push the joystick lever forward to move the Stick in.

Push the left hand side of the rocker switch to extend (cut) with top saw.

Push the right hand side of the rocker switch to retract top saw.

Pull the joystick lever back to move the Stick out.

Note: The above two functions are 2.2

Tigercat 230/240 Loader 24

4

•

Controls and operation 5

6

9

7

•• ••

11

• ••

•

••

10

14

••

••

••

•• •

13

12

••

CONTROL PANEL

156-0A

SWING LEFT

8

3

10. HORN ~ SWITCH

SWING RIGHT

Depressing the Horn rocker switch (10) will sound the horn.

••

11. AUXILIARY FUNCTIONS Two spare rocker switch locations are provided to allow installation of other accessories.

FOOT PEDAL

156-8A

3.

12. WIPER ~ SWITCH

FOOT PEDAL - SWING

This switch is equipped with 3 levels, Off (Rocker switch back), Low (center position) and High (Rocker switch forward). Do Not use WIPER on a dry window, this may result in scratching.

Depress the Left Hand side of the foot pedal to swing left.

Depress the Right Hand side of the foot pedal to swing right.

13. WASHER ~ SWITCH

The foot pedal will automatically return to the center position once released. The swing will cease when the foot pedal returns to center.

4.

The front window wiper is equipped with a window washer fluid nozzle. To operate, depress and hold the Washer button and run WIPER. Release the Washer button and turn off WIPER when window is sufficiently clean.

STABILIZER OPERATION The 4 stabilizers are controlled using the buttons located on the instrument panel to the right of the seat.

•

•

The Washer fluid reservoir is located inside the cab. If the loader is to be operated or transported through a climate where freezing temperatures may occur use an anti-freeze washer fluid.

First select a direction (up or down) using the Stabilizer Direction selector switch (4). The center position on the switch turns off all stabilizers. This switch should be left in the center position whenever stabilizers are not being moved. This will prevent accidental operation of the stabilizers.

14. PILOT RESET ~ SWITCH This function is provided to prevent accidental or improper use of the controls from anywhere but the operators seat.

With the engine running and the L.H. arm rest DOWN, push this switch to REACTIVATE the pilot system after it has been deactivated by raising the L.H. arm rest, or by turning the ignition switch to the OFF position.

Next use buttons (5), (6), (7) or (8) to control each stabilizer separately or use the ALL button (9) to move all stabilizers at once. The All button should be used to ensure that each stabilizer is applying equal pressure to the ground prior to operating the loader or lifting any loads.

2.3

Tigercat 230/240 Loader

Controls and operation 20

16

17

19

••

•• ••

ARMREST

••

••

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

18

21

•

••

15 LIMIT SWITCH ACTUATING LEVER ON SEAT BASE

156-1A

20. IGNITION SWITCH

•

This is a three position switch labeled OFF/ RUN/START.

•

OFF Position - All electrical power through the ignition switch is turned OFF.

PILOT SYSTEM SHUT OFF

247-25

CONTROL PANEL

Electrical power is still available for the horn, lighter, tape deck, 2 way radio, cab dome light, defroster fan, work lights and service light.

15. PILOT SYSTEM SHUT OFF ~ LIMIT SWITCH When the L.H. arm rest is placed in the UP position, a limit switch shuts OFF the pilot system DEACTIVATING all operating functions. When the L.H. arm rest is placed in the DOWN position, the limit switch closes and turns ON the pilot system. But the operating functions are not REACTIVATED until the PILOT RESET switch (item 14) is pressed.

RUN Position - Battery is connected to all functions. Used for normal machine operation.

START Position - Connects the battery to the start relay to start the engine. Turning the key to this position starts the engine.

The key will return to RUN position when released.

16. LIGHTER Depress lighter fully into socket and wait until it pops back up. Pull lighter out of socket and use coil to light cigar(ette). CAUTION: Lighter coil reaches high temperature which can cause burns to skin and can start fire.

Handle with care. DO NOT use in presence of explosive or flammable liquids or vapor.

Serious injury, death and/or property damage may result.

17. ETHER ~ NOT USED 18. SERVICE LIGHTS This switch controls the service light located in the engine enclosure. The circuit draws current directly from the battery and is protected by a fuse located in the fuse box.

19. WORK LIGHTS This switch controls the work lights located on the front of the cab and on the stick boom. The circuit draws current directly from the battery and is protected by a fuse located in the fuse box.

2.4

Tigercat 230/240 Loader

Controls and operation

21. THROTTLE CONTROL

21

The throttle control should not be moved unless the ignition key is in the RUN position otherwise damage to the fuel control solenoid and linkage may result.

••

B

A

C

••

The throttle control is adjusted by pushing the button in the center end knob and raising or lowering the throttle control.

279-20A

D

•

•• •

For LOW IDLE engine RPM, push the center button and lower the throttle control completely.

E

•

A/C HEATER CONTROL PANEL

AIR CONDITIONER/HEATER

To INCREASE engine RPM, push the center button and raise the throttle control until the engine speed required is reached.

The controls on this panel are used to adjust the heating and air conditioning temperature for operator comfort in the operator's cab.

Maintaining Correct Engine Speed The engine RPM should checked regularly with a hand tachometer and adjusted as necessary.

A. FAN SPEED - OFF/LOW/MED/HIGH This is a rotary, four position switch for the fan speed.

Low Idle - 950 rpm (No Load)

B. AIR SOURCE

High Idle - 2400 rpm Max (No Load)

This is a variable, rotary dial to select either, outside fresh air or to re-circulate inside air.

The above values are taken with the hydraulic and engine oil at normal operating temperature and without any functions operating.

C. A/C ON/OFF SWITCH This is a push/on push/off power switch.

D. HEAT - VARIABLE

WARNING

This is a variable, rotary dial to adjust the amount of heated air for the cab. Make sure this control is off, when using the air conditioning.

At no time should the high idle speed exceed the recommended value as serious damage to the pumps will result.

E. AIR CONDITIONING - VARIABLE This is a variable, rotary dial to adjust the temperature of cooled air for the cab.

NOTE: To maximize the efficiency of the air conditioning, the heat control dial on the control panel must be rotated to the "OFF" position. Refer to HOT WATER SHUT OFF VALVE in THIS SECTION.

2.5

Tigercat 230/240 Loader

Controls and operation 24

•

156-0A CONTROL PANEL 24. LOW COOLANT - INDICATOR LIGHT

RECIRCULATION AIR FILTER

This light provides a warning that the coolant has dropped below a safe operating level. If this light turns on, immediately turn off the engine and correct the fault. The sensor is located in the side of the radiator surge tank.

The coolant surge tank (reservoir) can be filled through the access panel located on top of the engine compartment. Ensure that the engine has cooled down sufficiently and loosen pressure cap slowly to first stop, releasing any pressure prior to removing the cap fully. Use the proper solution of coolant antifreeze to fill the surge tank.

•

A/C HEATER UNIT

68-7C

23. FILTERS Two filters are provided with the heating & A/C unit. One is for filtering recirculated air from the cab. This is located at the bottom of the heater unit and should be inspected and

EXTERNAL AIR FILTER ACCESS PANEL

•

LOWER RIGHT SIDE OF OPERATOR'S CAB

205-12A

EXTERNAL AIR FILTER

cleaned on a regular basis. The second is for filtering outside air being drawn into the heater unit. This is located under an access panel on the right hand side of the cab and must be inspected and cleaned/replaced on a regular basis.

2.6

Tigercat 230/240 Loader 25

27

26

••

Controls and operation 31

•

•• ••

30

28

29

32

•

••

•

•

247-16

ENGINE OIL PRESS. & COOLANT TEMP. GAUGES 25. LOW HYDRAULIC OIL LEVEL ~ RED LIGHT This light will come on when the oil level falls 13 gal. When the light first comes on stop engine and look for signs of broken hoses or other leaks. Repair leaks and refill the tank to FULL mark on the sight gauge. Restart engine and inspect for leaks.

26. ENGINE OIL PRESSURE ~ GAUGE This oil pressure gauge indicates the engine oil pressure while the engine is running.

The oil pressure must be greater than 15 psi at all times. If the oil pressure drops below 15 psi at any time, stop the engine and determine cause. Check engine oil pressure every time the engine is started.

The oil pressure at high idle and full load should normally operate between 30 and 60 psi.

NOTE: At low idle rpm the oil pressure will be low. This is not an abnormal condition, however it must be closely monitored.

27. LOW ENGINE OIL PRESSURE ~ RED LIGHT

247-14

GAUGES AND HOUR METER

30. HYDRAULIC OIL TEMPERATURE ~ GAUGE The gauge labeled OIL TEMPERATURE displays the current temperature of the hydraulic oil in the hydraulic reservoir.

If the hydraulic oil temperature rises beyond 180°F, check the following: • • • •

Plugged oil cooler Low hydraulic oil level Malfunction in a hydraulic circuit High loads on the hydraulic system Do not continue to operate the machine if temperature remains above 180°F. Operation at high hydraulic oil temperature will shorten the life of hydraulic components.

31. VOLT METER ~ GAUGE Normal operating range is between 12-13.5 volts.

A reading in excess of 15 volts indicates a possible faulty voltage regulator.

A reading of less than 12 Volts indicates a possible faulty battery or alternator.

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.

32. HOUR METER Powered through the engine oil pressure switch, this meter records the total number of hours the engine has run.

28. ENGINE COOLANT TEMP. ~ GAUGE The gauge labelled WATER TEMPERATURE displays the current engine coolant temperature.

The normal operating range is between 181°F and 203°F. If the temperature rises beyond 210°F, reduce the load on the engine and check for a plugged radiator. If the temperature does not drop, stop engine and determine cause. Do not continue to operate machine.

29. ENGINE COOLANT TEMP. ~ RED LIGHT This light will come ON when the engine coolant temperature rise above 215°F If this light comes ON stop engine and determine cause. Do not continue to operate machine.

2.7

Tigercat 230/240 Loader

Controls and operation 34

36

37

35

•

••

•

•

206-13A

34. FAN A three position switch; LOW, OFF and HIGH. is located on the base of the fan. The fan orientation is adjusted manually.

279-15A

35. LIGHT - DOME Push the switch on the side of the dome to turn the light ON and OFF. 36. TAPE DECK Consult the operators manual for the tape deck.

37. 2 WAY RADIO 9654A

Consult the radio operators manual for the 2 way radio.

FUSE AND RELAY PANEL

33. FUSE AND RELAY PANEL 38

The fuse panel is located inside the control panel behind a removable cover.

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

•

247-23

PORTABLE FIRE EXTINGUISHER

38. FIRE EXTINGUISHER A portable fire extinguisher is provided and is located in operator's cab. The extinguisher should be checked daily to ensure that it is charged. The pointer on the charge gauge should point to the green region. If the indicator falls out of this green area, the extinguisher should be serviced immediately.

2.8

Tigercat 230/240 Loader

Controls and operation

39

205-9A

SLIDING WINDOWS HANDLE R.H. WINDOW AND CAB WINDOW

39. WINDOWS The right hand window and cab door window are sliding windows and can be opened by pushing on the handle and sliding the window open. To close, slide the window closed firmly allowing the handle to latch on the frame.

2.9

Tigercat 230/240 Loader

Controls and operation RIDES TOO SOFT OR BOTTOMS OUT PINCHES OPERATOR’S BUNS OR BACK/BACK SLAPS

40

The seat Ride Adjustment knob has not been tightened (turned counter-clockwise) enough. Insufficient ride adjustment exaggerates the knee-action movement of the seat. This usually happens because the operator is trying to lower the seat by decreasing the amount of ride adjustment instead of using the yellow Height Adjustment lever. Refer to HEIGHT ADJUSTMENT PROCEDURES.

••

SEAT TOO HIGH/SEAT TOO LOW

206-11A1

There are several things which can cause improper seat height. Refer to the height adjustment procedures and adjust seat to the desired position. If the proper height cannot be reached using one of the four height adjustment settings, it may be necessary to install the seat on an optional riser base. Seat height can be increased with optional risers available in 1 1/2”, 3 1/4" and 4" heights.

SEAT

40. SEAT The following is an extract from the manufacturers seat operating instructions document.

OPERATOR’S LEGS FALLING ASLEEP The seat is adjusted too high, and the Ride Adjustment knob has not been tightened (turned counter-clockwise) enough, resulting in the operator sitting in a “bucket”. Refer to the HEIGHT ADJUSTMENT PROCEDURES.

CAUTION: Windows and door must remain closed while operating machine to prevent debris from entering cab and causing personal injury or property damage.

OPERATING THE MAGNUM 200TM SEAT

ARMRESTS TOO HIGH OR TOO LOW Refer to armrest adjustment bolt on the back of each armrest. Rotate the 9/16" bolt head clockwise to raise, or counter-clockwise to lower the armrest.

RIDES TO STIFF/SEAT TENDS TO PUSH OR THROW OPERATOR FORWARD The Ride Adjustment knob has been tightened (turned counter-clockwise) too much. This typically happens because the operator is trying to use additional Ride Adjustment rather than the yellow Height Adjustment lever to raise the seat. Operator is riding the seat in the low height position setting. Refer to HEIGHT ADJUSTMENT PROCEDURES.

2.10

Tigercat 230/240 Loader

Controls and operation RIDE ADJUSTMENT

4-WAY LUMBAR VERTICAL ADJUSTMENT

After adjusting height, the ride adjustment should be made by turning the Ride Adjustment knob counter-clockwise until the seat cushion is level.

•

4-WAY LUMBAR HORIZONTAL ADJUSTMENT

ISOLATOR ADJUSTMENT To activate, turn engagement lever clockwise.

To lockout, turn engagement lever counterclockwise.

RIDE ADJUSTMENT KNOB

4-WAY ADJUSTABLE LUMBAR

••

To position lumbar mechanism vertically, move vertical adjustment knob up or down.

For fore-and-aft displacement, rotate horizontal adjustment knob.

•• BACK ANGLE ADJUSTMENT KNOB

• ••

HEIGHT ADJUSTMENT LEVER (YELLOW)

•• OPTIONAL GLIDE-ALATORTM FORE/AFT ISOLATOR ENGAGEMENT LEVER (RED) SEATINC1

•

FORE/AFT SLIDE LEVER (BLACK)

SEAT ADJUSTMENTS

ADJUSTMENTS HEIGHT ADJUSTMENT PROCEDURES The SPRING-ASSISTED height adjustment is controlled by the yellow Height Adjustment lever located on the front left side of the seat chassis. The four height settings: top, bottom and two in-between, provide a total height adjustment of 3”.

TO RAISE Firmly lift up on the yellow Height Adjustment lever. When the yellow lever releases, hold it up while partially lifting the operator’s body weight from the seat. When the seat is at the desired height, FIRMLY PUSH DOWN on the yellow lever until the seat locks (a click should be heard).

TO LOWER Firmly lift up on the yellow Height Adjustment lever. When the lever releases, partially apply operator body weight to the seat until the seat is at the desired height.

FIRMLY PUSH DOWN on the yellow lever.

Hold lever down until the seat locks into position (a click should be heard).

2.11

Tigercat 230/240 Loader

Controls and operation

ENGINE COMPARTMENT

205-24A

ENGINE COMPARTMENT ACCESS FRONT BATTERY DISCONNECT SWITCH

•• 281-13

ENGINE COMPARTMENT ACCESS LEFT SIDE RADIATOR

HINGE OUT A/C CONDENSER

••

205-16A BATTERY DISCONNECT SWITCH ENGINE COMPARTMENT ACCESS

••

OIL COOLER

206-6A

There are 3 access doors, 2 on the sides and one on the rear of the machine, and one access panel located on the platform beside the cab. The doors can be opened by unscrewing the retaining knob on the door.

The access panel is removed by lifting the latches outwards, tuning them 90° and then lifting the panel up and out.

••

ENGINE COMPARTMENT ACCESS RIGHT SIDE

BATTERY DISCONNECT SWITCH This switch completely disconnects all electrical circuits on the machine from the battery and is located just inside the front access panel. It is good practice to turn this switch to OFF whenever the machine is left idle for an extended period of time (overnight etc.).

153-0A

ENGINE COMPARTMENT ACCESS REAR

2.12

Tigercat 230/240 Loader

Controls and operation HYDRAULIC OIL RESERVOIR LEVEL

••

HYDRAULIC OIL FILTERS

The hydraulic oil reservoir is located at the rear left of the engine compartment.

• SUCTION TUBES

A sight gauge on the front of the reservoir is visible from the front access panel or the left hand access door. The hydraulic oil level must be kept between the HIGH and LOW limits at all times. On later machines a low level switch is incorporated into the level indicator, when the hydraulic oil reaches this level the switch turns a warning light ON in the operator's cab.

• •

••

RESERVOIR

Allowing the level to drop below the LOW limit can result in severe damage to hydraulic components.

• ••

HYDRAULIC OIL SIGHT GAUGE/ SENDER

If the oil level drops, inspect the machine including all fitting and hydraulic components for leaks. Once the source of the oil loss is located and repaired, oil can be added to the reservoir.

SENDER HYD. OIL TEMP.

••

PILOT SUPPLY TO PUMP SHUT-OFF VALVE

•

••

•• ••

281-12

OIL FILL SHUT-OFF VALVE HYDRAULIC PUMPS

HYDRAULIC OIL RESERVOIR

• HAND FILL PUMP

•

SIGHT GAUGE

••

SUCTION HOSE IN STORED POSITION

•• LOW LEVEL SENDING UNIT 206-17A

HYDRAULIC HAND FILL PUMP

HYDRAULIC HAND FILL PUMP

248-16

The hydraulic hand fill pump is used to add oil to the hydraulic reservoir and is located inside the engine compartment near the front left corner. It is accessible from both the front access panel and the left hand door.

•

HYDRAULIC OIL SIGHT GAUGE/SENDER

2.13

Tigercat 230/240 Loader

Controls and operation

ADDING OIL - Prior to adding oil to the reservoir, determine and repair the source of the oil loss. Open the oil fill shut off valve (ball valve located on top of the hand pump).

Clean the suction hose thoroughly, remove the plug and insert end into supply drum.

Operate the pump by moving the handle back and forth at medium speed and a steady motion. The oil passes through the filters on the return lines of the hydraulic system.

When the sight gauge reads between LOW and HIGH cease pumping and return handle to upright position. Close the oil fill shut off valve.

•

SINGLE FILTER

••

••

•

HYDRAULIC RETURN FILTERS

281-14

AIR VENT

DOUBLE FILTER

CHECK VALVE

••

TOP RIGHT SIDE OF RESERVOIR

LOCATED LOWER LEFT SIDE OF ENGINE COMPARTMENT

• 206-18A

PILOT FILTER ELEMENT

AIR BREATHER VENT, HYDRAULIC RESERVOIR 205-23A

HYDRAULIC RESERVOIR BREATHER The Hydraulic Reservoir Breather prevents pressure build up in the Hydraulic Reservoir.

It is located at the top of the right hand side of the reservoir and is accessible through the rear door.

HYDRAULIC PILOT FILTER

a Red pop-up indicator that signifies that the filters elements require replacing.

The pilot supply line also contains a hydraulic filter. This filter should be checked and replaced as per the maintenance schedule in SECTION3 of THIS MANUAL.

HYDRAULIC FILTERS There are two hydraulic return lines. One line contains a double filter and the other has one single filter providing filtration of 7 microns.

Each line has a bypass valve with a 20 psi cracking pressure such that oil can bypass the filters if they become restricted. Each filter head is equipped with a pressure gauge indicator which represents the degree of restriction the filters are contributing. On the single filter the indicator has green and red ranges. When the indicator reaches anywhere in the red range, the filter element is to be changed. The double filter head has

2.14

IMPORTANT Contaminated hydraulic fluid can lead to premature failure of hydraulic components and costly repairs. Filters must be replaced at the recommended time intervals, See SECTION 3 in THIS MANUAL. Only Tigercat replacement filters must be used.

Do not substitute with other cheaper inferior brands. Tests have shown that Tigercat filters can have twice the filtering capacity as that of other name brands.

Tigercat 230/240 Loader

Controls and operation

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

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

AIR INTAKE GRILL

INDICATOR

AIR CLEANER UNLOADER VALVE

AIR INTAKE TUBE AIR FILTER

•

••

205-18A

• AIR CLEANER

•• 1/4" HOSE CONNECTION

•• 283-7A

••

FILTER RESTRICTION INDICATOR

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

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

After servicing the filter, re-set the indicator by pressing down on the re-set button.

205-19A

AIR CLEANER PRIMARY ELEMENT

AIR CLEANER UNLOADER VALVE This rubber valve on the tube of the air cleaner housing should be checked at the beginning of every shift. (8 hours) If this valve is missing, damaged or has become hard, it will cause the air cleaner to become ineffective. The unloader valve should be replaced every 1000 hours.

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

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

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

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

2.15

205-22A

AIR CLEANER SAFETY ELEMENT

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

OVERSERVICING Filter elements increase in dust cleaning efficiency as dust builds up on the media.

Looks can be deceiving. A filter that is dirty is actually more efficient than one that is clean.

A filter with dust build up on the media reaches nearly 100% dust cleaning efficiency.

Only when a filter is so clogged with dirt that air restriction goes beyond the engine manufacturer’s guidelines, should be replaced.

IMPROPER SERVICING Engine exposure to dust during servicing is

Tigercat 230/240 Loader

Controls and operation

the largest single factor contributing to engine damage due to dust. Abrasive dust can easily enter the intake system once the air cleaner element has been removed for replacement. The safety element reduces the risk, however it must also be replaced at every third primary element change.

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

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

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

4. Always clean the inside of the outlet tube.

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

6. Inspect the new filter for damage.

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

8. Check connection and ducts for air tight fit. Ensure that all clamps, bolts and connections are tight. Leaks here send dust directly to the engine.

2.16

Tigercat 230/240 Loader

Controls and operation

FUEL TANK AND FILLER

To add fuel to the tank on current machines place the fill nozzle in the inner fill tube, air from the tank will vent out via the air vent passage.

The tank is located underneath the cab and has a capacity of 90 US gallons. The fuel filler is located on the front of the machine below the cab.

AIR VENT PASSAGE

••

FILLER SCREEN

INNER FILL TUBE

•

• FILLER TUBE

••

FUEL FILL TUBE

248-20

205-E

FUEL TANK AND FILLER (earlier machines)

•• FUEL SIGHT GAUGE

FILLER TUBE

BREATHER

••

• ENGINE COMPARTMENT, FRONT/LEFT SIDE OF ENGINE 206-23A

248-18

FUEL TANK AND FILLER

2.17

FUEL TANK BREATHER (earlier machines)

Tigercat 230/240 Loader

Controls and operation

MACHINE OPERATION Prior to operating the machine, ensure that the proper lubrication and maintenance schedule has been performed as outlined in SECTION 3 of THIS MANUAL. For the Diesel Engine supplied with the machine, Refer to the engine manufacturer's operator's manual.

Any personnel who is to operate this machine must be fully trained in safety and operating procedures by a competent person.

•

SIGHT GAUGE

Read and understand this entire manual prior to operating machine.

PRE-START CHECKS 1.

Ensure ignition switch is in the OFF position.

2.

Check fire extinguisher is sufficiently charged.

3.

Check fuel level.

REMOVE FILLER CAP AND VISUALLY CHECK FUEL LEVEL IN FILLER TUBE

LOW LEVEL SENDING UNIT

FILLER TUBE

• CHECK HYDRAULIC OIL LEVEL Check that the hydraulic oil level is between the HIGH and LOW marks on the level gauge.

248-16

•

4.

ENGINE OIL LEVEL DIPSTICK

• 206-19A

CHECK FUEL LEVEL (earlier machines)

205-17A

•

248-20

FUEL SIGHT GAUGE

CHECK FUEL LEVEL (later machines) 2.18

CHECK ENGINE OIL LEVEL

5.

Check that the engine oil level is between the ADD and FULL marks on the dipstick.

6.

CAUTION: Do Not start engine by shorting across starter terminals. Start engine only from the operator’s seat.

Tigercat 230/240 Loader

Controls and operation

AIR FILTER RESTRICTION INDICATOR

AIR CLEANER RESERVOIR

•

•

••

CHECK WINDSHIELD WASHER LEVEL 12. Check windshield washer fluid level.

249-24

CHECK AIR FILTER

283-7AA

7.

Check air filter restriction indicator.

8.

Check tension and condition of all engine belts.

HALF FILL RESERVOIR WITH RECOMMENDED OIL AS SPECIFIED IN SECTION 3 OF THIS MANUAL

••

FILLER CAP

CONNECTING HOSE TO GEARBOX

•

206-16A

SWING DRIVE GEARBOX OIL RESERVOIR

•• CONNECTING HOSE FROM OIL RESERVOIR

CHECK ENGINE COOLANT LEVEL Check engine coolant level.

248-25

9.

••

••

SWING DRIVE MOTOR

RADIATOR HINGE OUT A/C CONDENSER

••

•• ••

OIL FILL TUBE

••

SWING DRIVE GEARBOX 206-15A

OIL COOLER 206-6A

• SWING DRIVE GEARBOX

13. Check swing drive gearbox oil level.

CLEAN RADIATOR AND OIL COOLER

14. Inspect machine for leaks, damaged or loose components or any other abnormal conditions.

10. Clean radiator/oil cooler and all screens and doors.

11. Ensure all doors and access panel are closed and/or securely fastened.

2.19

15. Perform SCHEDULED MAINTENANCE as shown in SECTION 3 of THIS MANUAL.

Tigercat 230/240 Loader

Controls and operation RESTARTING AN ENGINE THAT HAS RUN OUT OF FUEL 1. If the engine has run out of fuel the fuel line must be primed.

STARTING THE ENGINE 1.

Ensure Pre-Start Checks have been performed and that the area is clear of personnel prior to starting the machine.

2.

Sound horn to warn personnel of machine start-up.

2.

Ensure key ignition is turn to OFF.

3.

Refill fuel tank completely.

3.

Turn keyed ignition switch to the ON position.

4.

4.

Move the throttle control to LOW IDLE position

Remove engine fuel filter and fill with clean fuel.

5.

Turn keyed ignition switch to the START position to crank the engine.

Bleed the system according to the engine manufacturer’s operator’s manual.

6.

Crank the engine until it starts. Do Not crank longer than 20 seconds. Wait 2 minutes between each attempt.

5.

CAUTION Do not start engine by shorting across starter terminals. Start engine only from operator's seat.

WARNING Do not attempt to operate any function or accessory while starting the engine.

Serious injury or property damage may result.

CAUTION To prevent damage to starter, do not engage starter motor for more than 15 to 20 seconds. Wait 2 minutes between each attempt to start the engine.

If engine fails to start, refer to engine manufacturers operator's manual.

CAUTION After engine has started, keep engine speed low until engine oil pressure registers on gauge. If it does not register within 10 seconds, stop engine and investigate cause.

Allow a cold engine to warm up at LOW IDLE for at least five minutes before applying any load. Check all gauges often during the warmup period.

2.20

Tigercat 230/240 Loader

Controls and operation

SETTING THE MACHINE

WARNING

The loader must be located and firmly set in place prior to operating.

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

Refer to the following steps to ensure safe operation. (a) Locate the loader on firm level ground only.

VERTICAL CENTERLINE

LOWER FRAME

(b) Lower the stabilizers to set them firmly on stable ground. If the loader is mounted to a trailer, the stabilizers should be used to raise the rear of the trailer off the ground. Ensure loader is sufficiently stable to perform all log loading operations.

•

COUNTERBALANCE VALVE

•

STABILIZER UP IN VERTICAL POSITION

• • •

DANGER Moving stabilizers can cause serious injury or death. Ensure area is clear of all personnel prior to operating stabilizers.

CYLINDER

STABILIZER COUNTERBALANCE/CHECK CARTRIDGE REMOVAL

WARNING

230-06A

An unstable loader can cause severe injury, death or property damage. Do not operate unless stabilizers have been lowered and set firmly on stable and level ground.

For further information on the STABILIZERS, refer to SECTION 1 in THIS MANUAL and SECTION 14 in the 230/240 SERVICE MANUAL

2.21

Tigercat 230/240 Loader

Controls and operation the top saw. With the delimber arms open the button operates the slasher saw.

MACHINE PREPARATION Prior to commencing any log loading operations follow steps (a) through (p) to accomplish the following: •

Warm up the hydraulic system.

•

Test all systems for proper operation.

•

Inspect for hydraulic oil leaks.

(m) Continue testing and operating various functions until engine and hydraulic oil has warmed up to near normal operating temperatures. Never load the machine until it has sufficiently warmed up. Doing so may cause damage to the engine and hydraulic components.

CAUTION If any system or function fails to respond correctly to the controls, stop the machine preparation procedure and notify a mechanic. Failure to do so may result in damage to hydraulic pumps and other components. (a)

Perform Pre-Start Checks, Starting the Engine and Setting the Machine procedures as outlined in THIS SECTION.

(b)

Sound horn to warn personnel of machine operation.

(c)

Ensure gauges and warning lights are indicating normal operating conditions.

(d)

Check that all personnel are safe and clear of the machine.

(e)

Ensure both armrests are in the lowered position and press the Pilot Reset button.

(f)

Raise the throttle control to MID position.

(g)

Ensure all stabilizers are firmly set on level, stable ground.

(h)

Ensure grapple and booms are not attached, chained or clamped around trailer or any other stationary object.

(i)

Slowly raise and lower the hoist boom and stick boom and check for proper operation.

(j)

With the grapple raised slightly off the ground, test the grapple rotate in both directions and test the open and close. functions

(k)

Operate the swing in both direction to ensure proper operation.

(l)

Test all accessory equipment including delimber, top saw, slasher saw etc.

(n)

Lower the grapple onto the trailer or stable ground ensuring grapple and booms are fully supported.

(o)

Lower the throttle control to LOW IDLE.

(p)

Exit cab and visually inspect machine for leaks or other machine damage. Ensure that machine is in proper working order and is in safe condition before continuing operation.

WARNING

Never use your bare hand to check for fluid leaks.

Fluid leaks under pressure may not be visible.

When searching for leaks, wear work gloves and use a wrench or piece of wood to move hydraulic hoses. Do not grab hold of hydraulic hoses. Wear safety goggles for eye protection.

NOTE: The right hand joystick button performs two separate functions depending on the status of the delimber arms. With delimber arms closed the button operates

2.22

Tigercat 230/240 Loader

Controls and operation

STOPPING THE ENGINE

LOADER MOUNTING/INSTALLATION The mounting procedure will vary with the type of trailer being used. The following procedure is intended as a guide for mounting the loader on a typical I-beam or Channel beam trailer.

The procedure may not be complete or may differ from the actual method or procedure used.

CAUTION Stopping the engine immediately after it has been working under load can result in overheating and premature wear of the engine components. Follow the stopping procedure outlined below to allow the engine to cool.

1.

Ensuring grapple and booms are fully supported by lowering grapple onto the trailer or stable ground.

2.

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

3.

Ensure all controls are in neutral positions and that all accessories and functions are turned off.

4.

Do not race engine before shut-off

5.

Stop engine by turning ignition switch to the OFF position.

6.

Ensure grapple and booms are fully supported and that all functions are turned off. Remove key from ignition, lock up cab and turn battery disconnect switch to OFF prior to leaving the machine.

NOTE: It is the responsibility of the owner of the machine to ensure that the installation or mounting of the loader onto the trailer is safe and complies to all local, state, provincial and federal regulations applicable for the region.

2.23

1.

Raise the loader off the ground by extending the stabilizers to a sufficient height to allow the trailer to pass underneath. Ensure that the grapple and booms are clear of any interference are supported on a stable surface.

2.

Carefully back the trailer under the subframe of the loader. Ensure that the trailer is centered under the loader and that the loader is in the proper location. Refer to manufacturer of trailer to determine proper location and positioning of loader.

3.

Ensure that trailer is stable and will not move.

4.

Slowly and evenly lower the loader by retracting the stabilizers until the loader subframe is securely resting on the trailer frame.

Tigercat 230/240 Loader

Controls and operation

YOKE

•

• •

NUTS WASHERS

TRAILER

• • LOADER LOWER FRAME

•

WASHERS

• • • NUTS

• YOKE STUDS

YOKE 230B-02

TRAILER MOUNTING

5. Using Tigercat installation hardware (clamping bar(s) and studs) only, attach the loader to the frame of the trailer in four locations.

NOTE: When clamping to a frame that is a 'C' or 'U' channel, make use of proper length spacers placed in between the flanges to prevent any deforming of the channel when tightening the clamps. The spacers length must be a slip fit into the channel. Short or long spacers will distort or deform the channel.

6. Torque the nuts/studs to 500 lbf-ft, then secure in place with a "jam" nut.

WARNING Do not perform any unauthorized welding of the loader subframe or any other component of the loader. Doing so may cause structural failure resulting in injury, death or property damage. Any welding performed on the Loader unauthorized by Tigercat will void the associated warranty.

7. Check torque of mounting bolts as specified in maintenance schedule.

8. Ensure installation conforms to all applicable regulations.

2.24

Tigercat 230/240 Loader

Controls and operation

TRANSPORTING THE LOADER The transporting procedure given is intended only as a guide and may not be complete or may differ from actual practice due to local regulations.

NOTE: It is the responsibility of the owner of the machine to ensure that the installation, mounting and transporting of the loader is safe and complies to all local, state, provincial and federal regulations applicable for their region.

WARNING Improper loading or transportation of the loader can lead to accidents resulting in serious injury, death and property damage.

1.

Perform Loader Mounting/Installation as described in LOADER MOUNTING/ INSTALLATION in THIS SECTION.

2.

Start loader and rest or attach grapple and/ or boom to the trailer such that they are sufficiently secure and are within all height and width restrictions. Refer to trailer manufacturer for information on proper location and procedure for attaching grapple and/or booms.

3.

Raise all four stabilizers to their fully upright positions. Turn off the machine and turn the battery disconnect switch to OFF.

4.

Ensure that the setup conforms to all applicable local, state, provincial and federal regulations for mounting and transporting equipment. Check height, width and weight restrictions.

2.25

Tigercat 230/240 Loader

Controls and operation

CARE OF THE MACHINE 1. Ensure that all fluid levels are always at the proper level. Refer to the LUBRICATION AND MAINTENANCE SCHEDULE provided in SECTION 3 of THIS MANUAL.

Mirror Glaze Plastic Polish. It is suggested that a test be made on a sample of LEXAN sheet with the product selected and that the product manufacturers instructions be followed.

Some important Dont’s

2. Follow proper procedure for cleaning windows described in this section.

Don’t use abrasive or highly alkaline cleaners on LEXAN sheet products

3. Lubricate all necessary points as per the maintenance schedule provided.

Never scrape LEXAN sheet with squeegees, razor blades or other sharp instruments.

4. Never apply a load to a cold engine.

Benzene, gasoline, oil, acetone, or carbon tetrachloride should never be used on LEXAN.

5. Close and secure all doors and access panel prior to operating machine.

6. Clean machine including all platforms, inside engine enclosure and around radiator of all dirt and debris on a regular basis.

Don’t clean LEXAN in direct hot sunlight or at elevated temperatures.

Compatible Cleaning Agents Aqueous solutions of soaps and detergents

7. Keep all steps, ladders and platforms clear of oil and other material or debris that can cause an unsafe condition.

• • • •

8. Ensure grapple head or boom is resting securely before shutting down the machine or servicing.

CLEANING LEXAN WINDOWS (WINDOWS AND SKYLIGHT)

Formula 409 • Top Job Freon T.F. • VM&P grade naphtha Joy • Windex with Ammonia D Palmolive Liquid

GRAFFITI REMOVAL (A) Butyl Cellosolve (for removal of paints, marking pen inks, etc.) The use of masking tape, adhesive tape or lint removal tools works well for lifting off old weathered paints.

1. Rinse with lukewarm water 2. Using a soft cloth or sponge, gently wash the sheet with a mild solution of soap or detergent and lukewarm water. DO NOT scrub or use brushes or squeegees.

(B) To remove labels, stickers, etc., the use of kerosene, VM&P Naphtha or petroleum spirits is generally effective. When the solvent will not penetrate sticker material, apply low heat to soften the adhesive and promote removal.

GASOLINE SHOULD NOT BE USED.

3. Rinse with lukewarm water.

4. Dry thoroughly with a chamois of moist cellulose sponge to prevent water spotting.

To remove wet paint, glazing compound or grease, rub lightly (not in direct sunlight) with a good grade of VM&P naphtha, isopropyl alcohol or butyl cellosolve (2-Butoxy Ethanol), then wash and rinse thoroughly. DO NOT USE GASOLINE, Gasoline or oil will cause uncoated LEXAN to become opaque.

MARGUARD coated LEXAN will start to become opaque around the edges and creep inwards.

Removing hairline Scratches.

Scratches and minor abrasions can be removed or minimized by using a mid automotive polish. Three such products that tend to polish and fill scratches are Johnson Paste Wax, Novus Plastic Polish #1 & #2 and

2.26

Tigercat 230/240 Loader

SECTION 3 - LUBRICATION & MAINTENANCE DECEMBER 2000

CONTENTS - SECTION 3 AIR CONDITIONING - SERVICE ............................................................................ 3.10 FILTERS HYDRAULIC OIL RETURN FILTERS ................................................................... 3.8 PILOT RETURN PRESSURE FILTER ................................................................ 3.9 GENERAL MAINTENANCE .................................................................................... 3.3 HYDRAULIC OIL RETURN FILTERS ...................................................................... 3.8 HYDRAULIC OILS .................................................................................................. 3.5 LUBRICATING CYLINDER PINS AND BOOM JOINTS ......................................... 3.4 LUBRICATION POINTS .......................................................................................... 3.7 NEW MACHINE MAINTENANCE ........................................................................... 3.2 FIRST 100 HOURS ............................................................................................. 3.2 FIRST 25 HOURS ............................................................................................... 3.2 PILOT RETURN PRESSURE FILTER .................................................................... 3.9 PRESSURE SETTING PROCEDURES. SEE SERVICE MANUAL PRESSURE SETTINGS ......................................................................................... 3.14 PREVENTIVE MAINTENANCE SCHEDULE .......................................................... 3.2 SCHEDULED MAINTENANCE EVERY 125 HOURS ............................................................................................ 3.4 EVERY 24 HOURS: ............................................................................................ 3.4 EVERY 250 HOURS ............................................................................................ 3.5 EVERY 500 HOURS: ........................................................................................... 3.5 EVERY 8 HOURS: .............................................................................................. 3.4 SEASONAL ......................................................................................................... 3.5 SERVICE AND LUBRICATION POINTS ................................................................. 3.7 TIGHTENING POINTS ........................................................................................... 3.2 TORQUE CHART, GENERAL ................................................................................. 3.13 TORQUE SETTINGS, RECOMMENDED ............................................................... 3.12

Tigercat 230/240 Loader

Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE FOR 230/240 LOADER NEW MACHINE MAINTENANCE THE FIRST 100 HOURS:~ AFTER THE INITIAL PRE-DELIVERY INSPECTION HAS TAKEN PLACE BY THE DEALER PROCEED WITH THE FOLLOWING:~

REPLACE OIL IN:~ ENGINE AND CHANGE OIL FILTER:

SEE ENGINE OPERATOR'S MANUAL. TIGHTENING POINTS:~ CHECK TORQUE ON SWING BEARING RETAINING BOLTS

THE FIRST 25 HOURS:~ REPLACE:~

ENGINE MOUNTING BOLTS

ENGINE FUEL FILTER

PUMP MOUNTING BOLTS

HYD. OIL PILOT PRESSURE FILTER †

PILOT PUMP MOUNTING BOLTS

HYD. OIL RETURN FILTERS † (3 ELEMENTS)

SWING GEARBOX MOUNTING BOLTS SWING MOTOR MOUNTING BOLTS CAB SECURING BOLTS BOOM PIN NUTS

TIGHTENING POINTS:~

TRAILER MOUNTING STUDS

ALL HYDRAULIC CONNECTIONS

ANY OTHER LOOSE NUT, BOLT OR FITTING

HOSE CLAMPS PIN RETAINERS TRAILER MOUNTING STUDS ANY OTHER LOOSE NUT, BOLT OR FITTING

REFER TO DIESEL ENGINE SERVICE MANUAL AND ATTACHMENT MANUAL FOR ADDITIONAL REQUIRED MAINTENANCE AT THIS SCHEDULED TIME PERIOD.

† Use only Genuine Tigercat replacement hydraulic oil filters.

3.2

Tigercat 230/240 Loader

Lubrication and Maintenance

GENERAL CAUTION ALL HANDLES, STEPS AND PLATFORMS MUST BE KEPT FREE OF GREASE, OIL, FUEL MUD, SNOW ICE AND FOREST DEBRIS þ CLEAN AROUND FILLER CAPS BEFORE CHECKING OR ADDING FLUIDS þ CLEAN AROUND HYDRAULIC FITTINGS BEFORE BREAKING CONNECTION. PLUG OR CAP IMMEDIATELY þ CLEAN UP SPILLS AS SOON AS POSSIBLE þ ALWAYS USE CLEAN OIL AND CONTAINERS þ DRAIN DIRTY OIL WHILE STILL WARM þ DO NOT EXCEED RECOMMENDED FLUID LEVELS þ SERVICE ALL HYDRAULIC FILTERS AFTER THE FAILURE OF A PUMP, MOTOR, CYLINDER OR VALVE. FAILURES OF THIS NATURE COULD CONTAMINATE THE ENTIRE HYDRAULIC SYSTEM þ TOP UP DIESEL FUEL AT EACH SHIFT TO REDUCE CONTAMINATION BY CONDENSATION þ CLEAN UP OIL SPILLS ON WALKING SURFACES IN ENGINE ENCLOSURE IMMEDIATELY þ BEFORE WELDING ON MACHINE BE SURE THE NEGATIVE BATTERY TERMINAL IS DISCONNECTED þ WHEN WELDING, SECURE GROUND CONNECTION AS CLOSE TO WORKING POSITION AS POSSIBLE TO PREVENT ARCING ACROSS MACHINED SURFACES OR THROUGH BEARINGS þ CLEAN AWAY ALL BRANCHES, BARK AND CHIPS. CLEAN UP ALL TRACES OF OIL TO AVOID FIRES þ ALWAYS HAVE A FIRE EXTINGUISHER AT HAND þ FOR SAFETY, ALWAYS LOWER BOOM ASSY. TO THE GROUND WHEN LEAVING CAB, LEAVING MACHINE UNATTENDED OR DURING SERVICE 3.3

Tigercat 230/240 Loader

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 8 HOURS:~

EVERY 24 HOURS:~

• PERFORM FREQUENTLY MAINTENANCE AND IN ADDITION:~

• PERFORM 8 HOUR MAINTENANCE

• CHECK ENGINE COOLANT LEVEL

• STABILIZER ARM PINS 8-FITTINGS - PURGE

AND IN ADDITION LUBRICATE:~

• CHECK ENGINE OIL LEVEL

• STABILIZER CYLINDERS 8-FITTINGS - PURGE

• DRAIN FUEL/WATER SEPARATOR • CHECK HYDRAULIC OIL LEVEL • CHECK SWING GEARBOX OIL LEVEL FILL RESERVOIR TO HALFWAY MARK

EVERY 125 HOURS:~ • PERFORM 8 HOUR MAINTENANCE

LUBRICATE:~ • SWING BEARING; 1-FITTING - 4 SHOTS WHILE SWINGING

• PERFORM 24 HOUR MAINTENANCE

• SWING PINION; 1-FITTING - 10 SHOTS WHILE SWINGING

• RETURN FILTERS RESTRICTION INDICATOR WITH ENGINE RUNNING AT HIGH IDLE AND OIL FLOW

• •

AND IN ADDITION CHECK:~

¯

BOOM JOINTS; 4-FITTINGS - PURGE

• FLUID LEVEL IN BATTERIES UNLESS MAINTENANCE FREE

¯

CYLINDERS; BOOM, STICK & TILT; 4-FITTINGS TOTAL - PURGE

• ENGINE R.P.M.

¯ LUBRICATING CYLINDER PINS AND BOOM JOINTS:-

• ALL HYDRAULIC PRESSURES

1. ENSURE MACHINE IS ON LEVEL GROUND 2. FULLY EXTEND STICK BOOM CYLINDER

• HYDRAULIC PUMPS AND MOTOR SECURING BOLTS

3. LOWER MAIN BOOM AND REST GRAPPLE FIRMLY ON GROUND OR STABLE TRAILER

• TORQUE TIGHTENING POINTS AS PER NEW MACHINE MAINTENANCE

4. WHILE IN THIS POSITION LUBRICATE ALL CYLINDER RETAINING PINS AND BOOM JOINTS

VISUALLY CHECK FOR DAMAGE TO:~ • MAIN AND STICK BOOMS AND CYLINDERS

CLEAN:~

• LOWER FRAME, STABILIZER ARMS AND CYLINDERS

• OIL COOLER, ENGINE RADIATOR AND A/C CONDENSER

• SWING BEARING AREA

• REMOVE POTENTIALLY DAMAGING LIMBS OR STICKS AND ALL DEBRIS

• ATTACHMENT MAKE REPAIRS IMMEDIATELY

CHECK:~

VISUALLY INSPECT FOR:~

• FOR LEAKAGE AROUND HYDRAULIC COMPONENTS AND FLEXIBLE HOSES

• FRAYED ELECTRICAL WIRING AND HYDRAULIC HOSES

• FOR LOOSE NUTS, BOLTS AND FITTINGS

• WEAR IN ANY OTHER COMPONENTS

• CONDITION AND TENSION OF FAN BELTS. • CONDUCT AN OVERALL VISUAL INSPECTION.

Continued on page 5

REFER TO DIESEL ENGINE SERVICE MANUAL AND ATTACHMENT MANUAL FOR ADDITIONAL REQUIRED MAINTENANCE AT THIS SCHEDULED TIME PERIOD. 3.4

Tigercat 230/240 Loader

Lubrication and Maintenance

SCHEDULED MAINTENANCE Continued from page 4

CLEAN/REPLACE:~

• HYD. OIL RETURN FILTERS †

• AIR CONDITIONER RE-CIRCULATION FILTER

• HYD. OIL PILOT PRESSURE FILTER † • OIL IN SWING GEARBOX FILL RESERVOIR TO HALFWAY MARK

• CAB FRESH AIR FILTER REFER TO DIESEL ENGINE SERVICE MANUAL AND ATTACHMENT MANUAL FOR ADDITIONAL REQUIRED MAINTENANCE AT THIS SCHEDULED TIME PERIOD.

LUBRICATE:~ • DOOR AND COVER HINGES 8 FITTINGS - 1 SHOT CHECK:~ • TORQUE ON SWING BEARING AND SWING GEARBOX RETAINING BOLTS

EVERY 250 HOURS:~

REFER TO DIESEL ENGINE SERVICE MANUAL AND ATTACHMENT MANUAL FOR ADDITIONAL REQUIRED MAINTENANCE AT THIS SCHEDULED TIME PERIOD.

• PERFORM 8 HOUR MAINTENANCE • PERFORM 24 HOUR MAINTENANCE • PERFORM 125 HOUR MAINTENANCE AND IN ADDITION:~

SEASONAL:~

• REPLACE ENGINE OIL AND FILTER

DRAIN AND REFILL HYDRAULIC OIL TANK WITH RECOMMENDED HYDRAULIC OIL. SEE "APPROVED HYDRAULIC OILS"

• REPLACE ENGINE FUEL FILTER • REPLACE AIR INTAKE PRIMARY ELEMENT • CHECK TORQUE ON TRAILER MOUNTING STUDS

______________________________________________

EVERY 500 HOURS:~ • PERFORM 8 HOUR MAINTENANCE

APPROVED HYDRAULIC OILS

• PERFORM 24 HOUR MAINTENANCE • PERFORM 125 HOUR MAINTENANCE

USE ONLY ONE OF THE FOLLOWING OILS TO FILL OR REPLENISH THE HYDRAULIC SYSTEM.

• PERFORM 250 HOUR MAINTENANCE AND IN ADDITION REPLACE:~

CHEVRON

TRACTOR HYDRAULIC FLUID (SUMMER)

CITGO

TRACTOR HYDRAULIC FLUID (33-310) (SUMMER)

IMPERIAL

ESSO HYDRAUL 56 (SUMMER) HYDRAUL 50 (LOW VISC) (WINTER)

SHELL

DONAX TD (SUMMER) DONAX TDL (WINTER)

SUN

SUNFLEET TH FLUID (SUMMER)

• AIR INTAKE SAFETY ELEMENT

JOHN DEERE TYPE J20C (HY-GARDTM) (SUMMER) TYPE J20D (HY-GARDTM) (WINTER)

† Use only Genuine Tigercat replacement hydraulic oil filters.

3.5

Tigercat 230/240 Loader

Lubrication and Maintenance

SWING BEARING

*

13

1 FTG /8

DOOR HINGES

5

1

2 FTG / 500

4 SHOTS WHILE SWINGING

•

SWING PINION

1 FTG /8

• •

• •

10 SHOTS WHILE SWINGING

2

• •

• •

3 4

•

DOOR HINGES

•

•

2 FTG / 500

•

• • ••

6 7 9

8

9

STICK JOINT

•

2 FTG / 8

•

2 FTG IN BOOM

GRAPPLE CYLINDERS

2 FTG / 8

4 FTG / 8

11

DOOR HINGES

4 FTG / 500 BOOM AND STICK CYLINDERS

• •

4 FTG / 8

• •

GRAPPLE YOKE

2 FTG / 8

•

•

•

•

1 FTG / 8 GRAPPLE ROTATE BEARING

•

•

•

2 SHOTS Tigercat

•

•

GRAPPLE ROTATE PINION/GEAR

•

•

•

•

• • •

1 FTG / 50

•

1 SHOT

12 GRAPPLE ARMS

6 FTG / 8

•

•

4 FTG / 24

4 FTG / 24

STABILIZER ARM JOINTS AND CYLINDERS

STABILIZER ARM JOINTS AND CYLINDERS

9813B

3.6

10

Tigercat 230/240 Loader

Lubrication and Maintenance

Tigercat 230/240 Loader TM

SERVICE AND LUBRICATION POINTS

2 3 4

*

5 6 7 8

COOLING SYSTEM

CHK

REP

10

PRESSURE FILTER PILOT †

11 12

SWING GEARBOX GRAPPLE ATTACHMENT FIRE EXTINGUISHER

8

REP REP

CHK

SEE ENGINE MANUFACTURER'S SERVICE MANUAL 1 1 1

CHK

CHK

MIXTURE 50% DISTILLED WATER 50% ANTIFREEZE (GM 6038M SPEC.)**

16.4 4.3

AIR INTAKE PRIMARY CHK REP FILTER ELEMENT AIR INTAKE SAFETY REP FILTER ELEMENT HYDRAULIC RESERVOIR CHK RETURN FILTERS † (3 ELEMENTS)

30

DESCRIPTION

QTY.

2000

1000

500

250

CHANGE COOLANT EVERY 2 YEARS

ENGINE OIL AND FILTER CHK CUMMINS 'B' FUEL FILTER (ENGINE) FUEL/WATER SEPARATOR DRN INTANK FUEL STRAINER

9

13

125

8

ITEM

CAPACITY US GAL

1

SERVICE EVERY

LITER

SERVICE POINT NO.

REFER TO THIS Tigercat OPERATOR’S MANUAL FOR ADDITIONAL INFORMATION

DRAIN TANK, CLEAN OR REPLACE AS NECESSARY

1 1 D/R 350 92

1 DRAIN AND REFILL AS REQ'D BY SEASONAL OIL CHANGE. SEE APPROVED HYD. OILS

REP

3

REP

1

D/R

+

CHK

CHECK FILTER RESTRICTION INDICATOR AT FULL ENGINE RPM

CHECK FILTER RESTRICTION INDICATOR ON FILTER HEADS WITH ENGINE RUNNING AT HIGH IDLE AND WITH OIL FLOW

+ 1 + HALF FILL RESERVOIR WITH SAE 75W90 EP OIL SEE MANUFACTURERS MAINTENANCE SCHEDULE 1 TURN TO MIX CONTENTS

† Use only Genuine Tigercat replacement hydraulic oil filters.

LEGEND

* 2 FTG/125

**

MACHINE SERIAL NUMBERS:

2300181 AND UP 2400161 AND UP

LUBRICATION POINT WITH A DESIGNATED NUMBER OF FITTINGS (2 FTG) AND HOURS BETWEEN SERVICING (125 ).

EXCEPT WHERE SPECIFIED, PURGED WITH LITHIUM BASED EP2 GREASE CONTAINING MOLYBDENUM DISULFIDE (MOLY).

ANTIFREEZE MUST MEET GM 6038M SPECIFICATIONS SEE ENGINE MANUFACTURERS MAINTENANCE MANUAL.

3.7

.......

CHK ....

REP .....

DRN ....

D/R ......

HOURS CHECK REPLACE DRAIN DRAIN AND REFILL LUBE ... LUBRICATE

Tigercat 230/240 Loader

Lubrication and Maintenance

HYDRAULIC OIL RETURN FILTERS

•

There are three identical full flow filters mounted on filter heads with built-in bypasses. One is in the swing/stabilizer/delimber return line and two are in the boom return line, on a dual head. For service and replacement intervals see SERVICE AND LUBRICATION CHART in THIS SECTION.

FILTER HEAD

• GASKET

•

FILTER ELEMENT

SQUARE SECTION GASKET INSTALLATION

Changing the filters:

FILTR_SEALS 2

1. Ensure Loader is on level ground with stabilizers down. Lower grapple to ground, stop engine, put parking brake ON. 2. Wipe clean the area around the filter and head.

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

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

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

Apply clean oil to new gasket surfaces.

Install new gasket into groove in filter head.

Screw on new filter until gasket makes contact.

Tighten filter an additional 3/4 turn.

FILTER HEAD

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

• • GASKET

• FILTR_SEALS 2

FILTER ELEMENT

'O' RING GASKET INSTALLATION

l 'O' Ring Gasket Remove used gasket and clean gasket seat in head.

Apply clean oil to new gasket surfaces.

Install new gasket on inside lip of filter.

Screw on new filter until gasket makes contact.

Tighten filter until top edge makes metal to metal contact with filter head. (approximately 1 1/2 additional turns after gasket contact) 10. Start the engine and check for leaks.

3.8

Tigercat 230/240 Loader

Lubrication and Maintenance

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

For service and replacement intervals see SERVICE AND LUBRICATION CHART in THIS SECTION. Changing the filter: 1. Ensure Loader is on level ground with stabilizers down. Lower grapple to ground, stop engine, put parking brake ON. 2. Wipe clean the area around the filter and head.

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

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

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

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

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

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

9. Start the engine and check for leaks.

IMPORTANT Filters that are an integral part of the engine (fuel and lubricating oil) should be serviced and replaced according to the engine manufacturer's operation and maintenance manual.

IMPORTANT Contaminated hydraulic fluid can lead to premature failure of hydraulic components and costly repairs. Filters must be replaced at the recommended time intervals, Refer to SCHEDULED MAINTENANCE in THIS SECTION. Only Tigercat replacement filters must be used.

Do not substitute with other cheaper inferior brands. Tests have shown that Tigercat filters can have up to twice the filtering capacity as that of other name brands.

3.9

Tigercat 230/240 Loader

Lubrication and Maintenance

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

R134a REFRIGERANT 2 LBS. 12 OZ.

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

PAG OIL (polyalkylene glycol)

A/C CONDENSER CORE

2 OZ.

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

At least 2 oz. of PAG (polyalkylene glycol) oil should be present in the system and must be used on 'O' rings and fittings during assembly.

•

• RADIATOR

A/C COMPRESSOR

• 206-6A CHECK A/C CONDENSER CORE Use the following checklist to maintain system between service intervals. The compressor and charge valves are located on the left side of the engine and accessible through the engine compartment door. The receiver dryer is located in the lower engine compartment beside the front left engine mount and accessible from either underneath the engine compartment or through the engine compartment door.

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

A/C COMPRESSOR

249-17B

b. Check fresh air filter and re-circulating air filter. Clean or replace as required.

LEFT FRONT ENGINE MOUNT

c. Check to see that compressor clutch will engage.

•

d. Check blower operation and air vents. e. Check the condenser core for dirt and debris.

RECEIVER DRYER

••

CAUTION If using water or compressed air for cleaning, always use personal protective equipment to guard against flying debris.

LOWER FRAME

•• 155-2A

A/C RECEIVER DRYER 3.10

Tigercat 230/240 Loader

Lubrication and Maintenance

3.11

Tigercat 230/240 Loader

Lubrication and Maintenance

TORQUE CHART LOCATION

Cylinders Piston nut, stabilizer cylinders Piston nut, main boom cylinder Piston nut, stick cylinder Main boom cylinder end cap bolts Stick boom cylinder end cap bolts Pin retaining bolts

THREAD DIAMETER

TORQUE (LUBRICATED) lbf-ft Nm

1 3/4"-12 UN 2" - 12 UN 2" - 12 UN 7/8" - 14 UNF 3/4" - 16 UNF 3/4" UNC

1750 2500 2250 240-270 240-270 282-310

2355 3365 3030 323-363 323-363 393-420

Main boom pin

2" - 12 UNF-2A

400

540

Stick boom pin

1 3/4" - 12 UNF-2A

400

540

7/8" - 9 UNC 1 1/4" - 7 UNC

450-500 500

610-680 680

7/8" - 9 UNC (G8) 7/8" - 9 UNC (Cat bolts) 5/8" UNC M14

400-450 450-500 160-175 130

540-610 610-680 215-235 175

7/8" UNC M12

450-500 80 63

610-680 110 83

3/8" UNC M10

33-36 25

45-49 34

Cab securing bolts Trailer mounting studs Swing bearing bolts Swing bearing bolts, Track machine Swing gearbox mounting bolts Swing motor mounting bolts Engine mounting Bolts, bracket/mount to chassis Bolts, bracket to engine Flex drive coupling hub setscrew Pump drive Drive plate to flywheel Bell housing to engine

Torque values for the engine and attachment are provided in the appropriate manuals.

3.12

Tigercat 230/240 Loader

Lubrication and Maintenance

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

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

IMPERIAL

GRADE 5 BOLTS

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

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

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

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

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

METRIC

SIZE

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

M6 M8 M10

4.8 12 23

3.5 8.5 17

6 15 29

4.5 11 21

9 22 43

6.5 16 32

11 28 55

8.5 20 40

13 32 63

9.5 24 47

17 40 80

12 30 60

15 37 75

11.5 28 55

19 47 95

14.5 35 70

M12 M14 M16

40 63 100

29 47 73

50 80 125

37 60 92

75 120 190

55 88 140

95 150 240

70 110 175

110 175 275

80 130 200

140 225 350

105 165 225

130 205 320

95 150 240

165 260 400

120 190 300

M18 M20 M22

135 190 260

100 140 190

175 240 330

125 180 250

260 375 510

195 275 375

330 475 650

250 350 475

375 530 725

275 400 540

475 675 925

350 500 675

440 625 850

325 460 625

560 800 1075

410 580 800

M24 M27 M30

330 490 675

250 360 490

425 625 850

310 450 625

650 950 1300

475 700 950

825 1200 1650

600 875 1200

925 1350 1850

675 100 1350

1150 1700 2300

850 1250 1700

1075 1600 2150

800 1150 1600

1350 2000 2700

1000 1500 2000

675 850

1150 1450

850 1075

1750 2250

1300 1650

2200 2850

1650 2100

2500 3200

1850 2350

3150 4050

2350 3000

2900 3750

2150 2750

3700 4750

2750 3500

M33 900 M36 1150 ISSUE 2 395

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

3.13

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

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

Tigercat 230/240 Loader

Lubrication and Maintenance

PRESSURE SETTINGS SERIAL NUMBER

Pilot relief valve

EFFECTIVELY 2300101 to 2300137 to 2300272 2400101 to 2400243 2300126 2300271 and up 2400242 and up 450

450

450

450

450

Port relief grapple rotate ccw Port relief grapple rotate cw

2800* 1750 1750

2600* 1750 1750

2600* 1750 1750

2600* 1750 1750

2600* 1750 1750

Port relief stick out Port relief stick in

3500 1500

3000*** 1500

3000*** 1500

3000*** 1500

3000*** 1500

Port relief saw retract Port relief slasher cut

1500 2300

1500 2300

3000*** 3000***

1500 2300

3000*** 3000***

Main relief hoist valve Port relief grapple open Port relief grapple close

2600* 3000*** 3000***

2500* 3000*** 3000***

2500* 3000*** 3000***

2600* 3000*** 3000***

2600* 3000*** 3000***

Port relief hoist up Port relief hoist down

3000*** 1500

3000*** 1500

3000*** 1500

3000*** 1500

3000*** 1500

Port relief slasher cut Port relief top saw cut

2300 2300

2300 2300

3000*** 3000***

2300 2300

3000*** 3000***

Main relief swing valve Port relief swing ccw Port relief swing cw

2500** 3000*** 3000***

2500** 3000*** 3000***

2500** 3000*** 3000***

2500** 3000*** 3000***

2500** 3000*** 3000***

Port relief stabilizers down Port relief stabilizers up

3000*** 2000

3000*** 2000

3000*** 2000

3000*** 2000

3000*** 2000

Port relief delimber open Port relief spare

3000*** 3000***

3000*** 3000***

3000*** 3000***

3000*** 3000***

3000*** 3000***

Crossline reliefs swing motor

1650

1650

1650

2000

2000

Main relief stick valve

* Do not adjust pressure over 3000 psi or pump may be damaged. ** Do not adjust pressure over 2500 psi or valve may be damaged. *** Factory set at 10 gpm.

IMPORTANT 1. System to be at operating temperature when setting pressures.

2. All pressures measured in psi.

3. All main and port relief valves to be set at full engine rpm.

4. Swing motor crossline relief valves to be set at engine idle and; Using the following procedure: a. Install swing locking device or secure boom to keep the machine from swinging. b. Disconnect and cap the pilot hose running to the swing motor crossline relief valves. c. At idle adjust both swing motor crossline relief valves to the value given on the chart. d. Reconnect the pilot hose and purge the air out of the lines.

NOTE: The above values are for reference purposes only, SEE SERVICE MANUAL FOR SETTING PROCEDURE

3.14