Tigercat 230 240 Loader Service Manual - PDF DOWNLOAD

SERVICE MANUAL Tigercat 230/240 Loader TABLE OF CONTENTS

Issue 2.1, MARCH 2003

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

230-SM00

230/240 Available Literature Operator's Manual ................................. Part No. 8752A Service Manual(This Manual) ............... 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.

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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 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

Tigercat 230/240 Loader

SECTION 5 - PILOT SYSTEM DECEMBER 2000

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

Tigercat 230/240 Loader

Pilot system

PILOT SYSTEM COMPONENTS

Oil is first filtered by an in-line pressure filter before entering the pilot manifold. A pilot relief valve in the line between the filter and the pilot manifold maintains the pilot system pressure to 450 psi. The oil enters pilot manifold (inlet port) at

The pilot circuit is supplied with oil from the pilot pump. On earlier machines this pump was mounted onto the back of and driven off the main pump. On later machines the pilot pump is driven by the auxiliary drive off the left side of the engine.

RELIEF VALVE CARTRIDGE

MAIN FUNCTION PUMPS

ACCESS FROM BELOW ENGINE ENGINE BELL HOUSING

••

155-1A

••

••

PILOT PUMP

••

269-21

this reduced pressure and is then distributed by the pilot manifold to the various pilot actuated functions of the machine. Solenoid operated pilot valves, within the pilot manifold, control the flow of pilot oil to various functions. A second Stabilizer pilot manifold is fed with pilot oil from the first pilot manifold via pressure port P2. this Stabilizer pilot manifold contains four combination solenoid operated pilot valves/directional valves which are used to control the Stabilizer functions. Joysticks and foot pedals are also fed pilot oil which in turn distribute the oil to shift spools in the corresponding control valves.

PILOT PUMP (EARLIER MACHINES) LEFT SIDE OF ENGINE

•• ••

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

PILOT PUMP

249-17

PRESSURE FILTER This filter is a cartridge filter with a built-in differential pressure relief valve, if the pressure differential at the oil filter exceeds 50 psi this valve will bypass the pilot oil back to the tank. This will also result in lower pilot pressure. If a loss of controls or slow response is experienced the filter element may need to be changed.

PILOT PUMP (LATER MACHINES) HYDRAULIC TANK

BALL VALVE (SHOW OPEN)

•• •• TO PILOT PUMP

•• 287-2C

PILOT RELIEF VALVE

PILOT SHUT-OFF BALL VALVE 5.2

Tigercat 230/240 Loader

Pilot system SWING BEARING HOUSING

PILOT MANIFOLD

• FILTER ELEMENT

• PILOT MANIFOLD

266-3

• • • •

LOCATED BELOW PUMPS

The pilot shut off valve controls the flow of oil to the three outlet pressure ports (P2) and to the eight solenoid operated pilot valves. This valve is activated by pressing the pilot reset switch in cab (with the left armrest down).

The pilot manifold is located below the floor plates in the hydraulic valve compartment. Pilot oil enters the manifold at the inlet port and is then distributed to the various pilot functions of the machine.

Two outlet pressure ports ('P2') on each end of the manifold, feed the Stabilizer pilot manifold, both joysticks and a test port to connect a pressure gauge to perform pressure setting procedures. The front facing P2 port is plugged.

The manifold distributes oil to the following circuits through the ports in the manifold listed below: Joysticks (both) Swing control foot pedal Stabilizer pilot manifold Gauge test port Delimber, close Top saw, cut Stabilizers up Stabilizers down

GAUGE TEST PORT

(P2) pressure port (1) solenoid valve (2) solenoid valve (3) solenoid valve (4) solenoid valve STABILIZERS UP TOP SAW, CUT

•

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

(P2) pressure port

DELIMBER, CLOSE

•

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

SLASHER SAW, RETRACT

STABILIZERS DOWN

•

•

DELIMBER OPEN

SLASHER SAW, CUT

•

•

PILOT SHUT OFF VALVE

DELIMBER OPEN

•

•

•

•

TO JOYSTICK, FOOT PEDAL AND STABILIZER PILOT MANIFOLD

INLET

•

• •

230-01

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

Pilot oil enters the manifold through the inlet port.

PILOT MANIFOLD

• • • • • • • •

Slasher saw, retract Slasher saw, cut Delimber, open Delimber, open

•

RETURN OIL FROM ROTARY MANIFOLD

• PILOT MANIFOLD ASSEMBLY 5.3

RETURN OIL TO TANK

Tigercat 230/240 Loader

Pilot system

JOYSTICKS AND FOOT PEDALS

OPERATING DESCRIPTION

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

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

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

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

•

1

•

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

5

1

•

5

• 4

3

•

•

TANK PORT

•

•

8

•

3

•

•

WORK PORT

• AW015

PRESSURE PORT

WORK PORT

JOYSTICK PILOT VALVE (KAWASAKI)

WORK PORT

PRESSURE PORT

WORK PORT

• 2

2

•

•

8

•

•

•

4

•

•

TANK PORT

1

JOYSTICK PILOT VALVE (HUSCO)

AW009

• 1

•

5

•

5

• •

•

TANK PORT

4

•

TANK PORT

8

•

2

AW006

•

PRESSURE PORT

•

• 4

8

•

3

3

•

WORK PORT

•

• WORK PORT

WORK PORT

•

2

• PRESSURE PORT

WORK PORT

FOOT PEDAL PILOT VALVE (KAWASAKI)

FOOT PEDAL PILOT VALVE (COMMERCIAL)

AW017

5.4

Tigercat 230/240 Loader

Pilot system

PILOT SYSTEM ELECTRICAL CIRCUIT

SET PILOT PRESSURE

Refer to circuit diagram; The pilot shut off valve solenoid is not energized until the armrest is down and the pilot reset button is pushed. When this button is pushed, the coil on the pilot shut off relay is energized closing the circuit between wires 6 and 11. Wire 33 connects to the armrest switch. When this switch is closed (armrest down) the coil on the pilot shut off valve is energized shifting the valve spool to supply oil to the pilot circuit. At the same time wire 95 from the armrest switch is connected back to the function shut off relay coil through a diode and thus latches the function lock out relay in the energized position.

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

• 269-25

PILOT MANIFOLD

2. Accessing pilot relief valve from below upper frame, Loosen locknut and turn adjusting screw all the way OUT on pilot relief valve, tighten locknut on adjusting screw.

IN

•

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

GAUGE TEST PORT

OUT

BODY

RELIEF VALVE CARTRIDGE

•

LOCKNUT

• • AU026

ADJUSTING SCREW

PILOT RELIEF VALVE

3. Start engine and set throttle in FULL position.

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

5. Stop engine, and remove pressure gauge.

5.5

Tigercat 230/240 Loader

230-02

Pilot system

PILOT SYSTEM CIRCUIT DIAGRAM 5.6

Tigercat 230/240 Loader

SECTION 6 - ELECTRICAL, GAUGES & ALARMS JUNE 99

CONTENTS - SECTION 6 ELECTRICAL SCHEMATIC DIAGRAM ............................................... 6.2, 6.3 FUSE AND RELAY PANEL ........................................................................ 6.4 GAUGES AND ALARMS ............................................................................ 6.6 INSTRUMENT PANEL WIRING DIAGRAM ................................................ 6.5 RELAYS, DELIMBER ................................................................................. 6.4 SENSOR LOCATIONS (EARLIER MACHINES) ........................................ 6.7 SENSOR LOCATIONS (LATER MACHINES) ............................................ 6.8 WIRE COLOUR CODE CHART ................................................................. 6.4

Tigercat 230/240 Loader

Electrical, Gauges and Alarms

REFER TO COLOUR CODE CHART IN THIS SECTION 230-21

ELECTRICAL SCHEMATIC DIAGRAM 3960B (REV 6, SHEET 1) 6.2

Tigercat 230/240 Loader

Electrical, Gauges and Alarms

REFER TO COLOUR CODE CHART IN THIS SECTION 230-22

ELECTRICAL SCHEMATIC DIAGRAM 3960B (REV 6, SHEET 2) 6.3

Tigercat 230/240 Loader

Electrical, Gauges and Alarms

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

FUNCTION EXAMPLE Power ........................................ (fused and not fused) Ground Engine control ........................... (fuel shut-off, start aid) Propulsion Control .................... (transmission/reverser solenoids) Monitor, electrical and mechanical systems.................. (air cleaner, alternator, wheel speed, engine speed) Electrical and electromechanical control ......... (park brake, alternator excitation) (power door motor, backup alarm) Monitors .................................... (flow, pressure, temperature, level) Standard monitor system .......... (logic module to monitor) Lights Electro-hydraulic control ........... (pilot solenoids) Accessories .............................. (horn, A/C, heater)

279-15A

279-9A

19 39

9654A

41

18 90

RELAY #4 DELIMBER CLOSE

FUSE AND RELAY PANEL

91 92

RELAY #5 DELIMBER OPEN

RELAY #6 SAW CUT

7670A

6.4

DELIMBER RELAYS

15 57 GND

Tigercat 230/240 Loader

230-23 (2078D R2)

Electrical, Gauges and Alarms

INSTRUMENT PANEL WIRING DIAGRAM 6.5

Tigercat 230/240 Loader GAUGES AND ALARMS

Electrical, Gauges and Alarms

The 230/240 Loaders are monitored for proper operation by sensors located in the hydraulic system and on the engine. These sensors are connected to either gauges or warning lights.

The operator may sound the warning horn at any time.

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

GAUGE RANGE

LIGHT

INFORMATION

0 - 100 psi

YES

RED Light ON below 15psi.

STOP engine below 15 psi

Engine coolant temp.

100°F - 280°F

YES

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

Engine coolant level

NONE

YES

RED light ON when level in surge tank is LOW

0 - 9999.9

NONE

Total running hours

8v - 18v

NONE

Normal operating range 12 - 13.5 volts

Hydraulic oil temp.

100°F - 240°F

NONE

Stop machine above 180°F

Hydraulic oil level LOW

SIGHT GLASS

YES

Red light ON indicates 10 gallons below FULL

NONE

NONE

Switch on control panel

Engine oil pressure

Engine hours Volts

Warning Horn

6.6

Tigercat 230/240 Loader

Electrical, Gauges and Alarms

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

BATTERY DISCONNECT SWITCH BATTERY

START SOLENOID RELAY

STABILIZER PILOT MANIFOLD

PILOT MANIFOLD

• • • •

•

•

•_ TO BOOM LIGHTS +

• •

DELIMBER RELAY BOX

•

•

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

•

COOLANT LEVEL PROXIMITY SWITCH (RED LIGHT)

• WARNING HORN (SWITCH ON CONTROL PANEL) SENDER ENGINE OIL PRESSURE (GAUGE)

230-24

SENDER COOLANT TEMPERATURE (GAUGE)

SENSOR LOCATIONS (EARLIER MACHINES) 6.7

Tigercat 230/240 Loader

Electrical, Gauges and Alarms

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

BATTERY DISCONNECT SWITCH PILOT MANIFOLD

BATTERY STABILIZER PILOT MANIFOLD

START SOLENOID RELAY

• • •

•

•

• •_

•

TO BOOM LIGHTS

•

+

DELIMBER RELAY BOX SWITCH COOLANT TEMPERATURE (RED LIGHT)

•

•

••

SENDER ENGINE OIL PRESSURE (GAUGE)

••

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

COOLANT LEVEL PROXIMITY SWITCH (RED LIGHT)

• WARNING HORN (SWITCH ON CONTROL PANEL) SENDER COOLANT TEMPERATURE (GAUGE)

230-25

SENSOR LOCATIONS (LATER MACHINES) 6.8

Tigercat 230/240 Loader

SECTION 7 - ENGINE START AND STOP JUNE 99

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

Tigercat 230/240 Loader

Engine start and stop

ENGINE START CIRCUIT FUEL CONTROL VALVE SOLENOID

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

The engine normally installed on the Tigercat 230/ 240 Loaders is a Cummins Diesel 6BTA5.9C.

••

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

THROTTLE ARM

• ••

To start engine; Turn battery disconnect switch to the ON position. Turn ignition key to the START position and releasing it to the RUN position after the engine starts.

FUEL CONTROL VALVE

CIRCUIT DESCRIPTION

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

279-11A

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

When the key switch is turned to the START position, the BATTERY contact is connected to the RELAY and START contacts. Current (voltage) then flows through wire (16) to energize the coils of the fuel solenoid relay and the start solenoid relay. The fuel solenoid relay contacts close and current flows from the alternator + RED wire (1) through wire (54) to the fuel solenoid PULL IN contact. The start solenoid relay contacts also close and current flows from the alternator + RED wire (1) through wire (12) to the start solenoid coil to close the contacts and operate the start motor to start the engine. Current also flows through wire (20) to wire (13) to the fuel solenoid HOLD contact.

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

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

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

7.2

Tigercat 230/240 Loader

Engine start and stop

START CIRCUIT - AT REST

230-15

START CIRCUIT - AT REST BATTERY DISCONNECT SWITCH - ON

230-16

7.3

Tigercat 230/240 Loader

Engine start and stop

START CIRCUIT - START IGNITION KEY - START POSITION

230-17

START CIRCUIT - RUN IGNITION KEY - RUN POSITION

230-18

7.4

Tigercat 230/240 Loader

Engine start and stop

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

230-19

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

7.5

Tigercat 230/240 Loader

Engine start and stop

7.6

Tigercat 230/240 Loader

SECTION 12 - BOOM JUNE 99

CONTENTS - SECTION 12 BOOM PUMP GEAR PUMP ............................................................................................... 12.3 VANE PUMP ................................................................................................ 12.2 CIRCUIT DESCRIPTION ................................................................................ 12.4 CIRCUIT DIAGRAM ........................................................................................ 12.8 CONTROL VALVES HOIST CONTROL VALVE ............................................................................ 12.4 JOYSTICK CONTROL VALVE. SEE SERVICE MANUAL SECTION 5 STICK CONTROL VALVE ............................................................................ 12.4 HOIST VALVE RELIEF VALVE SETTINGS ...................................................... 12.6 PRESSURE SETTINGS SUMMARY ......................................................................................... 12.6, 12.7 RETURN FILTERS .......................................................................................... 12.4 STICK VALVE RELIEF VALVE SETTINGS ............................................ 12.6, 12.7

Tigercat 230/240 Loader BOOM SYSTEM COMPONENTS

Boom functions This pump requires no adjustments, system relief valves are located either in the line or on the control valve. Fluid flow is developed in each pump section by a cartridge which consists of a cam ring, a rotating rotor with vanes, side plates and support plates.

BOOM PUMP Two types of pumps have been used on the 230/ 240 loader. Earlier machines were equipped with a fixed displacement triple vane pump and later machines with a fixed displacement external triple gear pump.

The pump is bolted onto the bell housing and driven directly off the engine. To ensure optimum performance of the hydraulic system when operating the machine, the engine must always be set at FULL throttle.

PILOT PUMP

SWING PUMP

•

BOOM PUMPS

••

206-3A

CAM RING WALL

••

BELL HOUSING

• ••

••

VANE-1

TYPICAL VANE PUMP

As the rotor rotates, the vanes are forced up against the oval shaped cam ring wall transferring oil from the inlet port to the outlet port of each pump section.

VANE PUMP (EARLIER MACHINES)

Delivery of the hydraulic oil from each cartridge is governed only by the speed of the engine, therefore the values given above, e.g.; 50/45/40 will only be true when the engine is running at FULL throttle.

VANE PUMP Three vane cartridges (or sections) all connected together internally supply hydraulic oil to all of the functions on the machine except for the pilot system. The pilot pump is bolted to the end of the boom pump and driven from a thru' shaft off the end of the boom pump.

The three vane cartridges in the boom pump will each deliver (from the bell housing end):50 gpm/45 gpm/40 gpm at 2200 rpm (230 loader) 50 gpm/50 gpm/40 gpm at 2200 rpm (240 loader) Two of the three cartridges at the shaft end supply oil to the boom valves. The 230 loader uses a 50 gpm and a 45 gpm cartridge and the 240 loader uses 2-50 gpm cartridges. The last cartridge supplies oil to the swing valve and is a 40 gpm cartridge for both the 230 and 240 loaders.

12.2

Tigercat 230/240 Loader

Boom functions

BOOM PUMPS SWING PUMP

•• ••

• BELL HOUSING

••

GEAR PUMP (LATER MACHINES) 249-26 GEAR PUMP This is a triple gear pump with a similar setup to the triple vane pump in so much as three gear housing sections, all connected together internally supply hydraulic oil to all of the functions on the machine except the pilot system. Similarly, the first two gear housings at the shaft end supply oil for the boom functions and the end gear housing supplies oil for the swing circuit.

OUTLET DRIVEN (IDLER) GEAR

DRIVE GEAR

•

•

INLET GEAR1

TYPICAL GEAR PUMP

The operation of a typical external gear pump (so called because the gear teeth are on the external surface of the hub) is shown in Figure gear1.

A gear pump carries oil from the inlet to the outlet in the spaces between gear teeth. The pumping chamber is formed by the gears, the pump housing, and side plates. One of the two gears, called the drive gear, will be connected to the drive shaft. The other idler gear is driven by the drive gear.

12.3

Tigercat 230/240 Loader

Boom functions

JOYSTICK CONTROL VALVE

To protect components and hoses when the valve is closed, each work port in the valve sections have a port relief valve with an anti-cavitation function.

The hoist boom and stick boom functions are controlled by the left and right joysticks which when operated send proportional pilot signals to the two boom control valves which supply oil to the two boom cylinders.

A main relief valve is installed in the inlet section of the valve to protect the hydraulic system against overload pressures.

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

CHECK VALVE

BOOM CONTROL VALVES The hoist boom and stick boom are each controlled by two spool sections located in two separate identical control valves. Each control valve consists of three pilot operated, open center spool sections, an inlet section and an outlet section. The outlet section directs return oil back to tank. The control valves are located in the upper frame below the floor plates inside the valve compartment.

••

•• DUAL HEAD RETURN FILTER WITH 20 PSI BYPASS

CONTROL VALVE OPERATING DESCRIPTION Oil enters the inlet section and is allowed to pass through the three spool sections and back to tank via the outlet section. Each of these spool sections has a self centering 3-position spool which is open centered. A spring in the spool end cap holds the spool in the center neutral position.

The spool is shifted by pilot pressure being applied to either end of the spool. Shifting the spool directs oil to operate any one of the three functions (or all at the same time if required but with reduced flow to each).

RELIEF VALVE PORT 'A'

•

•

RETURN FILTER WITH 20 PSI BYPASS

HYDRAULIC FILTERS

281-14A

RETURN FILTERS All return oil from the main control valve tank lines is directed back to tank via one dual head return filter and one single head return filter. each filter is equipped with a 20 psi bypass. In the event that the element(s) are unable to handle the flow of oil due to cold temperatures etc., the internal bypass valves will open and bypass the oil in the filter from the IN port to the OUT port.

SEAL GROOVES

A

RELIEF VALVE PORT 'B'

B

SPOOL CENTERING SPRINGS

•

• • •

•

•

•

• •

•

• PILOT END CAP

AT047IL2

•

•

•

• SPOOL TANK PASSAGE

PARALLEL PASSAGE

LOAD CHECK VALVE

THRU' NEUTRAL PASSAGE

WORK PORT BRIDGE

CROSS SECTION OF SPOOL SECTIONS 12.4

TANK PASSAGE

PILOT END CAP

Tigercat 230/240 Loader

Boom functions

MAIN RELIEF (2600 PSI) (S/N 2400101 & UP) (2600 PSI) (S/N 2300101 TO 0126) (2500 PSI) (S/N 2300127 & UP

HOIST 'DOWN' PORT RELIEF (1500 PSI)

MAIN RELIEF (2600 PSI) (2800 PSI) (S/N 2300101 TO 0126)

STICK 'DOWN' PORT RELIEF (1500 PSI)

OUTLET SECTION

OUTLET SECTION

•

•

• •

GAUGE TEST PORT INLET SECTION

GRAPPLE ROTATE

STICK

•

•

• •

GAUGE TEST PORT INLET SECTION

HOIST 'UP' PORT RELIEF (3000 PSI) AT047IL

SLASHER CUT

• SAW RETRACT

SLASHER CUT

GRAPPLE OPEN/ CLOSE

•

HOIST

•

TOP SAW CUT

•

STICK 'UP' PORT RELIEF (3000 PSI) (3500 PSI) (S/N 2300101 TO 0126)

BOOM CONTROL VALVES

CIRCUIT DESCRIPTION The boom circuit is supplied with oil from two of the three gear housing sections on the main pump, (earlier machines a fixed displacement vane pump). Each of the two boom valves receive oil at the inlet sections and directs the oil through the three open center spool sections, to the outlet section. From there it is directed back to tank via a check valve and a dual head filter which is equipped with an internal 20 psi element bypass valve.

Moving either of the joysticks in the cab will direct pilot oil to the ends of the hoist or stick spool sections in the boom valves to shift the spools and direct hydraulic oil from the pump to the hoist or stick hydraulic cylinders to raise or lower to booms. Return oil from the cylinders is directed back through the spool sections, to the outlet section, through the dual head return oil filter and back to tank.

12.5

Tigercat 230/240 Loader PRESSURE SETTINGS

Boom functions IMPORTANT

CAUTION

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

Use caution when in the cab as a slight touch of the controls can cause sudden rotation of the upper frame and booms or movement of the stabilizers

7. While holding the L.H. joystick in the HOIST UP position (fully extended), check gauge pressure reading. If less than set value, turn relief valve adjusting screw in until set value is obtained on gauge.

CAUTION Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

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

9. While holding the L.H. joystick in the HOIST DOWN position (fully retracted), check gauge pressure reading. If less than set value, turn relief valve adjusting screw in until set value is obtained on gauge.

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

IMPORTANT

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

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

11. Repeat steps 7 and 9 to verify settings. reset main relief valve: 12. Loosen locknut on "hoist" main relief and unscrew adjusting screw 3 full turns.

HOIST VALVE RELIEF VALVE SETTINGS Hoist main relief setting:-

13. While holding the L.H. joystick in the HOIST UP position (fully extended), check gauge pressure reading. If less than set value, turn relief valve adjusting screw in until set value is obtained on gauge.

S/N 2300101 to 2300126 ................. 2600 psi S/N 2400101 and up ........................ 2600 psi S/N 2300137 and up ........................ 2500 psi Hoist up port relief setting .................. 3000 psi Hoist down port relief setting ............. 1500 psi

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

1. Park machine on level ground with stabilizers down.

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

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

SUMMARY:

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

1. Ensure hydraulic oil is at operating temperature.

2. Connect gauge to "hoist" valve.

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

3. Turn main relief fully "in".

4. Turn both "hoist" port reliefs out.

5. Turn both port relief valve adjusting screws on the "hoist" spool section of the valve out until spring pressure is relieved then turn adjusting screws one full turn in.

5. Start engine.

6. Set HOIST UP port relief.

7. Set HOIST DOWN port relief.

6. Start the engine, and put the throttle control to the FULL position.

8. Reset main relief.

12.6

Tigercat 230/240 Loader

Boom functions

CAUTION

IMPORTANT

Use caution when in the cab as a slight touch of the controls can cause sudden rotation of the upper frame and booms or movement of the stabilizers

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

CAUTION

7. While holding the R.H. joystick in the STICK OUT position (fully extended), check gauge pressure reading. If less than set value, turn relief valve adjusting screw in until set value is obtained on gauge.

Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

WARNING

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

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

9. While holding the R.H. joystick in the STICK IN position (fully retracted), check gauge pressure reading. If less than set value, turn relief valve adjusting screw in until set value is obtained on gauge.

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

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

11. Repeat steps 7 and 9 to verify setting.

STICK VALVE RELIEF VALVE SETTINGS

reset main relief valve:

Stick main relief setting:-

12. Loosen locknut on "stick" main relief and unscrew adjusting screw 3 full turns.

S/N 2300101 to 2300126 ................. 2800 psi S/N 2400101 and up ........................ 2600 psi S/N 2300137 and up ........................ 2600 psi

13. While holding the R.H. joystick in the stick UP position (fully extended), check gauge pressure reading. If less than set value, turn relief valve adjusting screw in until set value is obtained on gauge.

Stick out port relief setting:S/N 2300101 to 2300126 ................. 3500 psi S/N 2400101 and up ........................ 3000 psi S/N 2300137 and up ........................ 3000 psi

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

Stick in port relief setting .................... 1500 psi

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

1. Park machine on level ground with stabilizers down.

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

SUMMARY: 1. Ensure hydraulic oil is at operating temperature.

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

2. Connect gauge to "stick" valve.

3. Turn main relief fully "in".

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

4. Turn both "stick" port reliefs out.

5. Start engine.

5. Turn both port relief valve adjusting screws on the "stick" spool section of the valve out until spring pressure is relieved then turn adjusting screws one full turn in.

6. Set STICK UP port relief.

7. Set STICK DOWN port relief.

8. Reset main relief.

6. Start the engine, and put the throttle control

12.7

Tigercat 230/240 Loader

230-03

Boom functions

BOOM CIRCUIT 12.8

Tigercat 230/240 Loader

SECTION 15 - SWING DECEMBER 2000

CONTENTS - SECTION 15 CIRCUIT DESCRIPTION ................................................................................ 15.6 CIRCUIT DIAGRAM ........................................................................................ 15.7 CONTROL VALVES FOOT PEDAL CONTROL VALVE. SEE SERVICE MANUAL SECTION 5 SWING CONTROL VALVE ........................................................................... 15.2 GEARBOX, SWING DRIVE ............................................................................. 15.5 PRESSURE SETTINGS SET SWING MOTOR CROSSLINE RELIEF VALVES .................................. 15.9 SET SWING RELIEF VALVES ..................................................................... 15.8 SUMMARY ................................................................................................... 15.9 RETURN FILTERS .......................................................................................... 15.6 SWING MOTOR .............................................................................................. 15.4 MOTOR CROSSLINE RELIEF VALVE ......................................................... 15.6 MOTOR REMOVAL NOTE ........................................................................... 15.4 SWING PUMP ................................................................................................. 15.2

Tigercat 230/240 Loader

Swing

SWING DRIVE COMPONENTS

FOOT PEDAL CONTROL VALVE

SWING PUMP

The swing function is controlled by the center foot pedal valve which sends proportional pilot signals to the swing valve which supplies oil to the swing motor.

Two types of pumps have been used on the 230/ 240 loader. Earlier machines were equipped with a fixed displacement triple vane pump and later machines with a fixed displacement external triple gear pump.

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

PILOT PUMP

SWING CONTROL VALVE

SWING PUMP

The swing drive is controlled by one of three spool sections in a three section control valve.

The control valve consists of three pilot operated, open center spool sections, an inlet section and an outlet section. The outlet section directs return oil back to tank. The control valve is located in the upper frame below the floor plates inside the valve compartment.

BOOM PUMPS

••

BELL HOUSING

• ••

••

206-3A

••

CONTROL VALVE OPERATING DESCRIPTION Oil enters the inlet section and is allowed to pass through the three spool sections and back to tank via the outlet section. Each of these spool sections has a self centering 3-position spool which is open centered. A spring in the spool end cap holds the spool in the center neutral position.

The spool is shifted by pilot pressure being applied to either end of the spool. Shifting the spool directs oil to operate any one of the three functions (or all at the same time if required but with reduced flow to each).

VANE PUMP (EARLIER MACHINES)

BOOM PUMPS SWING PUMP

To protect components and hoses when the valve is closed, each work port in the valve sections have a port relief valve with an anti-cavitation function.

•• •

• BELL HOUSING

A main relief valve is installed in the inlet section of the valve to protect the hydraulic system against overload pressures.

••

249-26

GEAR PUMP (LATER MACHINES)

The swing drive system utilizes the third vane pump cartridge or gear housing from the shaft end of the pump to supply hydraulic oil to the swing valve.

For a more detailed description of both the triple vane pump and the triple gear pump, refer to SECTION 12 in THIS SERVICE MANUAL.

15.2

Tigercat 230/240 Loader

Swing SWING 'CW' PORT RELIEF (3000 PSI)

•

MAIN RELIEF (2500 PSI)

•

SWING

STABILIZER

DELIMBER

GAUGE TEST PORT

•

•

•

INLET SECTION

OUTLET SECTION

•

SWING 'CCW' PORT RELIEF (3000 PSI)

SWING CONTROL VALVE

AT041ZIL

RELIEF VALVE PORT 'A'

SEAL GROOVES

RELIEF VALVE PORT 'B'

A

B SPOOL CENTERING SPRINGS

•

• • •

•

•

•

• • • PILOT END CAP

AT041YIL

•

•

• •

• SPOOL TANK PASSAGE

PARALLEL PASSAGE

LOAD CHECK VALVE

THRU' NEUTRAL PASSAGE

WORK PORT BRIDGE

CROSS SECTION OF SPOOL SECTIONS 15.3

TANK PASSAGE

PILOT END CAP

Tigercat 230/240 Loader

Swing

SWING MOTOR

coupling, and the other is an idler gear. Not shown in the illustration are the side plates, which create a sealing wear surface on the sides of the gear set.

The swing motor is a gear motor with two, 2-stage crossline relief valves mounted on the port end cover. The crossline relief valves provide a

Gear motors operate because of a pressure differential, between the motor inlet and outlet.

This pressure differential acts across the gear teeth, creating a force that tries to rotate the gear.

As the diagram shows, there are two paths around the periphery of the gears, and one path through the intersection of the two gears. In each path, the pressure works against the area of one tooth so that there are two tooth forces working in one direction, and one tooth force working in the opposite direction. The net result is the force of one tooth working around the periphery to rotate the output shaft.

CROSS LINE RELIEF VALVES

••

•• ••

•

PRESSURE PORTS

••

••

SYSTEM PRESSURE LINES

CASE DRAIN LINE

••

SWING DRIVE MOTOR

SWING MOTOR

266-7

cushion to the high forces that occur during start and stop of the boom swing. The 2-stage relief involves increasing the relief setting by 1000 psi during swing acceleration. When coasting to a stop, the relief valve opens at a lower pressure resulting in a soft stop.

•• CONNECTING HOSE FROM OIL RESERVOIR

4. THESE TWO TEETH HAVE ONLY TANK LINE PRESSURE OPPOSING THEM. 3. PRESSURE BETWEEN TEETH IN THIS SEGMENT PUSHES BOTH WAYS AND DOES NOT AFFECT TORQUE AS OIL IS CARRIED AROUND TO OUTLET.

•

••

3. PRESSURE BETWEEN TEETH IN THIS SEGMENT PUSHES BOTH WAYS AND DOES NOT AFFECT TORQUE AS OIL IS CARRIED AROUND TO OUTLET.

•

••

• • OIL FILL TUBE

• •

•

SWING DRIVE GEARBOX 206-15A

1. THESE TWO TEETH ARE SUBJECT TO HIGH PRESSURE AND TEND TO ROTATE GEARS IN DIRECTION OF ARROWS.

••

2. SEGMENTS OF TWO MESHING TEETH TEND TO OPPOSE ROTATION MAKING NET TORQUE AVAILABLE A FUNCTION OF ONE TOOTH.

SWING DRIVE GEARBOX

MOTOR REMOVAL NOTE: Before removing the drive motor, drain the oil from the reservoir bottle by disconnecting the hose at the oil fill tube. Replace the oil fill tube.

GEAR3 TYPICAL GEAR MOTOR A cross sectional view of an external gear hydraulic motor is shown in Figure Gear3 This design is referred to as “external gear” design because the gear teeth are machined on the outside of the gears. One of the gears is connected to an output shaft which in turn is connected to the swing drive gearbox input

IMPORTANT: Do not allow dirt to enter the gearbox during and after the motor has been removed.

After the motor has been replaced, partly fill the reservoir with correct oil. Bleed swing gearbox by loosening air bleed plug. Add oil to reservoir until half full.

15.4

Tigercat 230/240 Loader

Swing

SWING DRIVE GEARBOX Power is transmitted from the motor to a double reduction planetary gearbox. The swing gearbox upper gearing is lubricated by oil stored in a reservoir attached to the side of the gearbox cover.

The reservoir must remain half full of oil* at all times. The lower bearing area is lubricated by grease where the cavity is filled with grease at assembly, a grease fitting is not provided since additional greasing is not necessary.

RESERVOIR

• CONNECTING HOSE TO GEARBOX

•

SWING DRIVE LUBRICATION To drain the gearbox unscrew the drain plug and allow oil to drain into a suitable container. To facilitate draining, the oil should be warm.

206-16A

To fill the gearbox with oil, unscrew the air bleed plug located on the motor flange, remove the cap on the reservoir and add oil to the reservoir. When oil begins to come out of the air bleed hole replace the plug and continue to add oil until the reservoir is half full. Replace the cap on the reservoir.

*For correct oil specification and maintenance schedule, refer to SECTION 3 in THIS MANUAL.

TO OIL RESERVOIR

•

MOTOR MOUNTING FLANGE

• •

AIR BLEED PLUG

MOTOR DRIVE SHAFT COUPLING

UPPER GEARING AREA LUBRICATED WITH OIL

• • TWO STAGE PLANETARY GEARING

GEARBOX MOUNTING FLANGE

• •

OIL DRAIN PLUG

•

•

LOWER BEARING AREA FILLED WITH GREASE

DRIVE PINION

•

BK0011-5

SWING DRIVE GEARBOX 15.5

Tigercat 230/240 Loader

Swing SWING CIRCUIT DESCRIPTION

CHECK VALVE

The swing circuit is supplied with hydraulic oil by a fixed displacement gear pump, (earlier machines a fixed displacement vane pump). The swing valve receives oil at the inlet section and directs it through the three open center spool sections, to the outlet section. From there it is directed back to tank via the oil cooler, a single element filter and a check valve. A 50 psi. relief valve is installed in the oil cooler line to bypass the oil around the oil cooler, usually on cold start ups when the oil is cold and thicker.

•

•

••

DUAL HEAD RETURN FILTER WITH 20 PSI BYPASS 281-14A

•

RETURN FILTER WITH 20 PSI BYPASS

Pressing the foot pedal in the cab directs pilot oil to either end of the swing spool section on the swing valve to shift the spool and direct hydraulic oil to the swing motor causing it to rotate either clockwise or counterclockwise.

HYDRAULIC FILTERS

RETURN FILTERS All return oil from the main control valve tank lines is directed back to tank via one dual head return filter and one single head return filter. Each filter is equipped with a 20 psi bypass. In the event that the element(s) are unable to handle the flow of oil due to cold temperatures etc., the internal bypass valves will open and bypass the oil in the filter from the IN port to the OUT port.

RELIEF VALVE HIGH ADJUSTER PRESSURE HOSE CONNECTION

•

LOCKNUT ADJUSTING SHIMS FOR SECOND STAGE ADDITIONAL 1000 PSI RELIEF SETTING (FACTORY SET)

•

• MOTOR CROSSLINE RELIEF VALVE Crossline relief valves on the motor provide a cushion to the high forces that occur during start and stop of the boom swing. The crossline relief valves used on this motor are 2-stage which means that when the foot pedal is pressed and the control valve spool shifts to swing the upper frame, inertia caused by the mass of the upper frame creates a pressure increase at the inlet section of the control valve. This pressure increase is transmitted through a hose line connected to the ends of the crossline relief valves. A piston in the end of each relief valve moves to increase the relief setting by an additional 1000 psi** to provide a faster swing acceleration time. During deceleration the relief valve opens at a lower pressure resulting in a softer stop. Internal leakage in the swing motor is returned to tank via the case drain port on the motor, through the dual element return filter.

AQ014-2

**NOTE: The additional 1000 psi second stage value is controlled by the use of shims, this is factory set and requires no adjustment.

15.6

Tigercat 230/240 Loader

230-04

Swing

SWING DRIVE CIRCUIT 15.7

Tigercat 230/240 Loader

Swing

PRESSURE SETTINGS

8.

Lower boom assembly to the ground and restrict boom swing movement in both directions.

9.

With the aid of an assistant, Press and hold the swing foot pedal in the SWING LEFT position, check gauge pressure reading. If less than set value, turn swing left relief valve adjusting screw in until set value is obtained on gauge.

CAUTION Use caution when in the cab as a slight touch of the controls can cause sudden rotation of the upper frame and booms or movement of the stabilizers

CAUTION Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

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

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

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

11. Press and hold the swing foot pedal in the SWING RIGHT position, check gauge pressure reading. If less than set value, turn swing right relief valve adjusting screw in until set value is obtained on gauge.

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

SET SWING RELIEF VALVES

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

Swing main relief valve setting ........... 2500 psi

13. Repeat steps 9 and 11 to verify settings.

Swing left port relief setting ................ 3000 psi

reset main relief valve:

Swing right down port relief setting ... 3000 psi

14. Loosen locknut on swing main relief and unscrew adjusting screw 3 full turns.

Motor crossline relief valves (low setting) 230 ................................................... 1650 psi 240 ................................................... 2000 psi 1.

Park machine on level ground with stabilizers down.

2.

Ensure that the hydraulic oil is at operating temperature.

3.

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

4.

Turn both port relief valve adjusting screws on the swing spool section of the valve out until spring pressure is relieved then turn adjusting screws one full turn in.

5.

Loosen locknut on motor crossline relief valves and turn relief valve adjusters all the way in, tighten locknut.

6.

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

7.

Start engine and place throttle control in FULL.

15. While holding the foot pedal in the SWING LEFT position, check gauge pressure reading. If less than set value, turn swing main relief valve adjusting screw in until set value is obtained on gauge.

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

15.8

Tigercat 230/240 Loader

Swing

SET SWING MOTOR CROSSLINE RELIEF VALVES 17. Set engine throttle control to IDLE. 18. Disconnect each hose from the ends of the crossline relief valves and install steel plugs in hose ends. Install caps on crossline relief valves.

19. While holding the foot pedal in the SWING LEFT position, check gauge pressure reading. If less than set value, turn swing left crossline relief valve adjuster in until set value is obtained on gauge.

20. Tighten locknut on adjuster taking care not to turn the adjuster.

21. While holding the foot pedal in the SWING RIGHT position, check gauge pressure reading. If less than set value, turn swing right crossline relief valve adjuster in until set value is obtained on gauge.

22. Tighten locknut on adjuster taking care not to turn the adjuster.

23. Repeat steps 18 and 21 to verify settings.

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

25. Reconnect two hoses to ends of crossline relief valves.

SUMMARY: 1.

Ensure hydraulic oil is at operating temperature.

2.

Turn main relief on "swing" valve fully in.

3.

Turn both "swing" port reliefs out.

4.

Turn motor crossline relief full in.

5.

Connect gauge to "swing" valve.

6.

Start engine.

7.

Set SWING LEFT port relief.

8.

Set SWING RIGHT port relief.

9.

Reset main relief.

Set swing motor crossline reliefs:10. Disconnect hoses from both crossline reliefs and plug hoses and fittings.

11. Set SWING LEFT crossline relief.

12. Set SWING RIGHT crossline relief.

13. Reconnect hoses to crossline reliefs.

15.9

Tigercat 230/240 Loader

Swing

15.10

Tigercat 230/240 Loader

SECTION 16 - STABILIZERS JUNE 99

CONTENTS - SECTION 16 CIRCUIT DIAGRAM ........................................................................................ 16.6 PILOT MANIFOLD .......................................................................................... 16.2 PRESSURE SETTINGS .................................................................................. 16.7 SUMMARY ................................................................................................... 16.8 SAFE REMOVAL OF COUNTERBALANCE AND CHECK CARTRIDGE ....... 16.4 STABILIZER CIRCUIT DESCRIPTION ........................................................... 16.5 LOWERING STABILIZER(S) ........................................................................ 16.5 RAISING STABILIZER(S) ............................................................................ 16.5 STABILIZER CONTROL VALVE ...................................................................... 16.2 STABILIZER CYLINDERS AND COUNTERBALANCE VALVES ..................... 16.4 STABILIZER PILOT MANIFOLD ..................................................................... 16.2 STABILIZER PUMP ......................................................................................... 16.2

Tigercat 230/240 Loader

Stabilizers

STABILIZER CIRCUIT COMPONENTS

PILOT MANIFOLD

PUMP

Two solenoid operated pilot valves (positions 3 and 4) on the pilot manifold control the UP and DOWN movement of the stabilizers.

SWING/ STABILIZER PUMP

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

PILOT PUMP

STABILIZERS UP

BOOM PUMPS

•

••

BELL HOUSING

• ••

••

•

•

•• PILOT MANIFOLD

230-01

206-3A

PILOT SHUTOFF VALVE

STABILIZERS DOWN

STABILIZER CONTROL VALVE

VANE PUMP (EARLIER MACHINES)

The stabilizer UP/DOWN/OFF functions are controlled by one of three spool sections in the three section "swing" control valve.

For a detailed description of the swing/stabilizer control valve, refer to SECTION 15 in THIS MANUAL.

BOOM PUMPS SWING/ STABILIZER PUMP

STABILIZER PILOT MANIFOLD This stabilizer pilot manifold consists of an aluminum housing containing four solenoid operated pilot valves and four pilot operated

•• ••

• BELL HOUSING

•• 'E' FRONT RIGHT

•• 'D' REAR RIGHT 249-26

GEAR PUMP (LATER MACHINES)

•

Two types of pumps have been used on the 230/ 240 loader. Earlier machines were equipped with a fixed displacement triple vane pump and later machines with a fixed displacement external triple gear pump.

The stabilizer system utilizes the third vane pump cartridge or gear housing from the shaft end of the pump to supply hydraulic oil to the stabilizer spool section of the swing valve.

For a more detailed description of both the triple vane pump and the triple gear pump, refer to SECTION 12 in THIS SERVICE MANUAL.

'C' FRONT LEFT

• 'B' REAR LEFT

••

•

•

4-SOLENOID OPERATED PILOT VALVES

4- PILOT OPERATED DIRECTIONAL VALVES

'T' TANK PORT

'P' PILOT SUPPLY

•

•

•

'A' SYSTEM PRESSURE SUPPLY

STABILIZER PILOT MANIFOLD 269-22

16.2

VIEWED FROM BELOW

Tigercat 230/240 Loader

Stabilizers

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

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

OPERATING DESCRIPTION When any (or ALL) of the four solenoid operated

STABILIZER "UP" PORT RELIEF (2000 PSI)

GAUGE TEST PORT

SWING

STABILIZER

DELIMBER

MAIN RELIEF (2500 PSI)

•

•

• •

•

INLET SECTION

OUTLET SECTION

• STABILIZER "DOWN" PORT RELIEF (3000 PSI)

STABILIZER CONTROL VALVE

AT041ZIL

RELIEF VALVE PORT 'A'

SEAL GROOVES

RELIEF VALVE PORT 'B'

A

B SPOOL CENTERING SPRINGS

•

• • •

•

•

•

• • • PILOT END CAP

AT041YIL

•

•

• •

• SPOOL TANK PASSAGE

PARALLEL PASSAGE

LOAD CHECK VALVE

THRU' NEUTRAL PASSAGE

WORK PORT BRIDGE

CROSS SECTION OF SPOOL SECTIONS 16.3

TANK PASSAGE

PILOT END CAP

Tigercat 230/240 Loader

Stabilizers

STABILIZER CYLINDERS AND COUNTERBALANCE VALVES

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

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

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

CHECK CARTRIDGE

COUNTERBALANCE CARTRIDGE

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

275-15

STABILIZER CYLINDER COUNTERBALANCE VALVE

VERTICAL CENTERLINE

LOWER FRAME

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

•

COUNTERBALANCE VALVE

•

STABILIZER UP IN VERTICAL POSITION

• • •

The purpose of the counterbalance valve assembly is to; (a) Ensure that the stabilizers remain firmly placed on the ground during the loading/unloading operation by preventing oil from leaving either end of the cylinders. (b) To prevent the raised stabilizers from falling down when transporting the loader. (c) To prevent the buildup of pressure caused by thermal expansion.

CYLINDER

230-06A

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

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

COUNTERBALANCE/CHECK CARTRIDGE REMOVAL

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

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

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.

When lowering the stabilizers, oil enters the 'VC' port and opens the counterbalance valve via an internal pilot port, oil then opens the check valve to allow oil to flow to the base end of the cylinder.

Return oil from the rod end of the cylinder flows to the 'CB' port and through the open 16.4

Tigercat 230/240 Loader

Stabilizers

STABILIZER CIRCUIT DESCRIPTION Refer to STABILIZER CIRCUIT DIAGRAM The stabilizer circuit is supplied with hydraulic oil by a fixed displacement gear pump, (earlier machines a fixed displacement vane pump). The stabilizer/swing valve receives oil at the inlet section and directs it through the three open center spool sections, to the outlet section. From there it is directed back to tank via the oil cooler, a single element filter and a check valve. A 50 psi. relief valve is installed in the oil cooler line to bypass the oil around the oil cooler, usually on cold start ups when the oil is cold and thicker.

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

CAUTION When loading/unloading, the Operator must always ensure that all four stabilizers are firmly placed on the ground. Soft ground conditions can cause instability.

RAISING STABILIZER(S) Place direction switch in UP position. Press and hold one of the stabilizer control switches.

Electrical current will flow along wire RED 3, through a series of diodes and energize the stabilizer control relay. This will allow current to flow through the relay and energize the UP solenoid operated pilot valve on the pilot manifold.

Pilot oil will then be directed to the stabilizer control valve spool UP pilot end cap to shift the spool.

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

In this condition, hydraulic oil will flow from the UP side of stabilizer control valve, through the stabilizer pilot manifold, to the rotary manifold and on to the cylinder counterbalance valve where it will be directed to the rod end of the selected 16.5

cylinder. Return oil from the base end of the cylinder will be directed back to tank via the counterbalance valve, through the rotary manifold to the stabilizer control valve and the oil cooler.

LOWERING STABILIZER(S) Place direction switch in DOWN position. Press and hold one of the stabilizer control switches.

Electrical current will flow along wire RED 3, through a series of diodes and energize the stabilizer control relay. This will allow current to flow through the relay and energize the DOWN solenoid operated pilot valve on the pilot manifold.

Pilot oil will then be directed to the stabilizer control valve spool DOWN pilot end cap to shift the spool.

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

In this condition, hydraulic oil will flow from the DOWN side of stabilizer control valve, through the to the rotary manifold and on to the cylinder counterbalance valve where it will be directed to the BASE end of the selected cylinder. Return oil from the ROD end of the cylinder will be directed back to tank via the counterbalance valve, through the rotary manifold to the stabilizer pilot manifold, the stabilizer control valve and the oil cooler.

To raise or lower all of the stabilizers at the same time; Press direction switch, Press and hold the center 'ALL' switch, Electrical current will flow through all of the diodes to supply electrical current to all four solenoid operated pilot valves on the stabilizer pilot manifold and also to the stabilizer control relay and energize the solenoid operated pilot valve on the pilot manifold.

Hydraulic oil will then flow as described above for either UP or DOWN except that all cylinders will operate at the same time.

Tigercat 230/240 Loader

230-05

Stabilizers

STABILIZER CIRCUIT 16.6

Tigercat 230/240 Loader

Stabilizers

PRESSURE SETTINGS CAUTION Use caution when in the cab as a slight touch of the controls can cause sudden rotation of the upper frame and booms or movement of the stabilizers

6.

Start engine and place throttle control in FULL.

7.

Place stabilizer control switch in UP position.

8.

With the aid of an assistant, Press ONE of the stabilizer switches to RAISE stabilizer. While holding stabilizer switch in UP position, check gauge pressure reading. If less than set value, turn stabilizer UP relief valve adjusting screw in until set value is obtained on gauge.

CAUTION

IMPORTANT

Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

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

IMPORTANT

9.

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

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

10. Place stabilizer control switch in DOWN position.

11. With the aid of an assistant, Press ONE of the stabilizer switches to LOWER stabilizer. While holding stabilizer switch in DOWN position, check gauge pressure reading. If less than set value, turn stabilizer DOWN relief valve adjusting screw in until set value is obtained on gauge.

SET STABILIZER RELIEF VALVES Stabilizer/"Swing" main relief valve setting ....

2500 psi Stabilizer up port relief setting ........... 2000 psi Stabilizer down port relief setting ...... 3000 psi Counterbalance relief valves* ............. 1000 psi *NOTE: The counterbalance valve cartridge is factory set to 1000 psi, it cannot be set in the field without removing it from the cylinder and using special test equipment. If this valve is suspect, example; stabilizers will not stay in UP position, it should be replaced with a new one.

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

1.

Park machine on level ground with stabilizers down.

2.

Ensure that the hydraulic oil is at operating temperature.

3.

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

4.

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

5.

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

16.7

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

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

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

15. With the aid of an assistant, While holding stabilizer switch in DOWN position, check gauge pressure reading. If less than set value, turn stabilizer MAIN relief valve adjusting screw in until set value is obtained on gauge.

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

17. Remove pressure gauge and wipe up any spills from around gauge test port.

Tigercat 230/240 Loader

Stabilizers

SUMMARY: 1.

Ensure hydraulic oil is at operating temperature.

2.

Turn main relief on "swing" valve fully in.

3.

Turn both "stabilizer" port reliefs out.

4.

Connect gauge to "swing" valve.

5.

Start engine.

6.

Set STABILIZER UP port relief.

7.

Set STABILIZER DOWN port relief.

8.

Reset main relief.

16.8

Tigercat 230/240 Loader

SECTION 17 - GRAPPLE JUNE 99

CONTENTS - SECTION 17 CIRCUIT DESCRIPTION ................................................................................ 17.4 CIRCUIT DIAGRAM ........................................................................................ 17.5 GRAPPLE CONNECTIONS TO BOOM .......................................................... 17.2 GRAPPLE CONTROL VALVES ....................................................................... 17.2 GRAPPLE PUMP ............................................................................................ 17.2 JOYSTICK CONTROL VALVE ......................................................................... 17.2 PRESSURE SETTINGS GRAPPLE OPEN/CLOSE ............................................................................ 17.6 GRAPPLE ROTATE ..................................................................................... 17.7 SUMMARY ................................................................................................... 17.8

Tigercat 230/240 Loader GRAPPLE SYSTEM COMPONENTS

Grapple JOYSTICK CONTROL VALVE

PUMP

The grapple open/close and grapple rotate functions are controlled by the left and right joysticks which when operated send proportional pilot signals to the "hoist" and "stick" control valves to shift a spool(s) and supply system oil to the grapple open/close cylinders and the grapple rotate motor.

Two types of pumps have been used on the 230/ 240 loader. Earlier machines were equipped with a fixed displacement triple vane pump and later machines with a fixed displacement external triple gear pump.

The grapple circuit utilizes two of the three vane pump cartridges or gear housings of these pumps to supply hydraulic oil to the grapple open/close control valve spool section and the grapple rotate control valve spool section in of the "hoist" valve and the "stick" valve.

GRAPPLE ROTATE PUMP

For a detailed description of the joystick control valve refer to SECTION 5 in THIS MANUAL. GRAPPLE CONTROL VALVES The grapple open/close function is controlled by one of three spool sections in the "hoist" valve and the grapple rotate motor is controlled by one of three spool section in the "stick" valve. The control valves are located in the upper frame below the floor plates inside the valve compartment.

SWING PUMP PILOT PUMP

GRAPPLE CYLINDERS PUMP

•

BELL HOUSING

••

••

206-3A

•

For a detailed description of the "hoist" and "stick" control valves, refer to SECTION 15 in THIS MANUAL.

••

GRAPPLE CONNECTIONS TO BOOM When a factory installed grapple is not specified, hydraulic lines are provided up to the end of the boom and sealed off with steel plugs.

VANE PUMP (EARLIER MACHINES)

SWING PUMP GRAPPLE PUMPS

•• •• • 277-8

•• BELL HOUSING 278-3A

GEAR PUMP (LATER MACHINES)

For a more detailed description of both the triple vane pump and the triple gear pump, refer to SECTION 12 in THIS SERVICE MANUAL.

17.2

GRAPPLE CONNECTIONS

Tigercat 230/240 Loader

Grapple MAIN RELIEF (2600 PSI) (S/N 2400101 & UP) (2600 PSI) (S/N 2300101 TO 0126) (2500 PSI) (S/N 2300127 & UP

GRAPPLE 'CLOSE' PORT RELIEF (3000 PSI)

GRAPPLE ROTATE 'CLOCKWISE' PORT RELIEF (1750 PSI)

MAIN RELIEF (2600 PSI) (2800 PSI) (S/N 2300101 TO 0126)

OUTLET SECTION

OUTLET SECTION

•

•

GRAPPLE ROTATE

SLASHER CUT

• SAW RETRACT

SLASHER CUT

•

STICK

GRAPPLE OPEN/ CLOSE

•

HOIST

•

TOP SAW CUT

•

• •

•

• •

GAUGE TEST PORT

GAUGE TEST PORT INLET SECTION

INLET SECTION

GRAPPLE 'OPEN' PORT RELIEF (3000 PSI)

GRAPPLE ROTATE 'COUNTERCLOCKWISE' PORT RELIEF (1750 PSI)

GRAPPLE CONTROL VALVES

AT047IL

RELIEF VALVE PORT 'A'

SEAL GROOVES

A

RELIEF VALVE PORT 'B'

B

SPOOL CENTERING SPRINGS

•

• • •

•

•

•

• •

•

• PILOT END CAP

AT047IL2

•

•

•

• SPOOL TANK PASSAGE

PARALLEL PASSAGE

LOAD CHECK VALVE

THRU' NEUTRAL PASSAGE

WORK PORT BRIDGE

CROSS SECTION OF SPOOL SECTIONS 17.3

TANK PASSAGE

PILOT END CAP

Tigercat 230/240 Loader

Grapple

CIRCUIT DESCRIPTION The grapple circuit is supplied with oil from two of the three gear housing sections on the main pump, (earlier machines a fixed displacement vane pump). The "hoist" and "stick" valves receive oil at their inlet sections and direct the oil through the three open center spool sections, to the outlet section. From there it is directed back to tank via a check valve and a dual head filter which is equipped with an internal 20 psi element bypass valve.

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

Return oil from the cylinders is directed back through the spool sections, to the outlet section, through the dual head return oil filter and back to tank.

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

17.4

Tigercat 230/240 Loader

230-14

Grapple

GRAPPLE CIRCUIT 17.5

Tigercat 230/240 Loader

Grapple 7. While holding the L.H. joystick in the GRAPPLE OPEN position (cylinders fully retracted), check gauge pressure reading. If less than set value, turn relief valve adjusting screw in until set value is obtained on gauge.

CAUTION Use caution when in the cab as a slight touch of the controls can cause sudden rotation of the upper frame and booms or movement of the stabilizers

IMPORTANT

CAUTION

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

Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

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

WARNING

9. While holding the L.H. joystick in the GRAPPLE CLOSE position (cylinders fully extended), check gauge pressure reading. If less than set value, turn relief valve adjusting screw in until set value is obtained on gauge.

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

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

10. Tighten locknut on adjusting screw taking care not to turn the adjusting screw. reset main relief valve:

PRESSURE SETTINGS

11. Loosen locknut on "hoist" main relief and unscrew adjusting screw 3 full turns.

GRAPPLE OPEN/CLOSE RELIEF VALVE SETTINGS

12. While holding the L.H. joystick in the GRAPPLE CLOSE position (cylinders fully extended), check gauge pressure reading. If less than set value, turn relief valve adjusting screw in until set value is obtained on gauge.

Grapple open/close "Hoist" main relief setting:S/N 2300101 to 2300126 ................. 2600 psi S/N 2400101 and up ........................ 2600 psi S/N 2300137 and up ........................ 2500 psi

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

Grapple open port relief setting .......... 3000 psi

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

Grapple close port relief setting ......... 3000 psi 1. Park machine on level ground with stabilizers down.

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

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

4. Loosen the locknuts on both port relief valve adjusting screws for the GRAPPLE OPEN AND GRAPPLE CLOSE spool section of the "hoist" valve and turn the adjusting screws out until spring pressure is relieved then turn adjusting screws one full turn in.

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

6. Start the engine, and put the throttle control to the FULL position.

17.6

Tigercat 230/240 Loader

Grapple 8. While holding the R.H. joystick in the ROTATE CLOCKWISE position, check gauge pressure reading. If less than set value, turn relief valve adjusting screw in until set value is obtained on gauge.

CAUTION Use caution when in the cab as a slight touch of the controls can cause sudden rotation of the upper frame and booms or movement of the stabilizers

IMPORTANT

CAUTION

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

Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

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

IMPORTANT

10. While holding the R.H. joystick in the ROTATE COUNTERCLOCKWISE position, check gauge pressure reading. If less than set value, turn relief valve adjusting screw in until set value is obtained on gauge.

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

GRAPPLE ROTATE RELIEF VALVE SETTINGS

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

Grapple rotate/"Stick" main relief setting:S/N 2300101 to 2300126 ................. 2800 psi S/N 2400101 and up ........................ 2600 psi S/N 2300137 and up ........................ 2600 psi

12. Release grapple from it's secured position. reset main relief valve:

Rotate clockwise port relief setting .... 1750 psi

13. Loosen locknut on "stick" main relief and unscrew adjusting screw 3 full turns.

Rotate counterclockwise port relief setting .................................. 1750 psi

14. While holding the R.H. joystick in the STICK OUT position (fully extended), check gauge pressure reading. If less than set value, turn relief valve adjusting screw in until set value is obtained on gauge.

1. Park machine on level ground with stabilizers down.

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

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

WARNING

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

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

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

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

5. Loosen the locknuts on both port relief valve adjusting screws for the GRAPPLE ROTATE spool section of the "stick" valve and turn the adjusting screws out until spring pressure is relieved then turn adjusting screws one full turn in.

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

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

17.7

Tigercat 230/240 Loader SUMMARY:

Grapple

1. Ensure that hydraulic oil is at operating temperature.

2. Turn main relief on "hoist" valve fully in.

3. Turn GRAPPLE OPEN and CLOSE port reliefs on "hoist" valve out.

4. Connect gauge to "hoist" valve.

5. Start engine.

6. Set GRAPPLE OPEN port relief on "hoist" valve.

7. Set GRAPPLE CLOSE port relief on "hoist" valve.

8. Reset main relief.

Grapple rotate/"stick" valve:1. Secure grapple to prevent from rotating.

2. Ensure that hydraulic oil is at operating temperature.

3. Turn main relief on "stick" valve fully in.

4. Turn GRAPPLE ROTATE C/W and CC/W port reliefs on "stick" valve out.

2. Connect gauge to "stick" valve.

5. Set GRAPPLE ROTATE C/W port relief on "stick" valve.

6. Set GRAPPLE ROTATE CC/W port relief on "stick" valve.

7. Reset main relief.

17.8

Tigercat 230/240 Loader

SECTION 18 - DELIMBER/SLASHER JUNE 99

CONTENTS - SECTION 18 CIRCUIT DESCRIPTION ................................................................................ 18.6 CIRCUIT DIAGRAM ...................................................................................... 18.12 CONTROL VALVE, DELIMBER (SWING VALVE) ............................................ 18.2 CONTROL VALVE, SAWS RETRACT SLASHER CUT (STICK VAL ............... 18.2 CONTROL VALVE, TOP/SLASHER SAW CUT (HOIST VALVE) ..................... 18.2 DELIMBER/SLASHER CIRCUIT DESCRIPTION ........................................... 18.6 DELIMBER/SLASHER CONNECTIONS ......................................................... 18.5 DELIMBER/SLASHER PUMP ......................................................................... 18.2 DIVERTER VALVE ........................................................................................... 18.4 ELECTRICAL CIRCUIT ................................................................................... 18.9 PILOT MANIFOLD .......................................................................................... 18.2 PRESSURE SETTINGS ................................................................................ 18.13 PRESSURE SETTINGS, SUMMARY ............................................................ 18.15 RELAYS, DELIMBER ...................................................................................... 18.8 TROUBLESHOOTING DELIMBER RELAY CIRCUIT ..................................... 18.8

Tigercat 230/240 Loader

Delimber/Slasher PILOT MANIFOLD

DELIMBER/SLASHER CIRCUIT COMPONENTS

Five solenoid operated pilot valves (positions 2, 5, 6, 7 and 8) on the pilot manifold control the flow of pilot oil to operate the delimber and top saw functions.

DELIMBER PUMP PILOT PUMP SLASHER CUT AND SAWS RETRACT PUMP

SLASHER CUT DELIMBER TOP/SLASHER OPEN SAWS RETRACT TOP SAW

TOP SAW AND SLASHER CUT PUMP

•• •• •

•

PILOT SHUTOFF VALVE

•

•

•

•

•

•

•

BELL HOUSING 230-01 206-3A

VANE PUMP (EARLIER MACHINES)

TOP SAW AND SLASHER CUT PUMP

DELIMBER PUMP

SLASHER CUT AND SAWS RETRACT PUMP

DELIMBER CONTROL VALVE (SWING VALVE) The delimber arms OPEN/CLOSE functions are controlled by one of three spool sections in the three section "swing" control valve.

TOP/SLASHER SAW CUT CONTROL VALVE (HOIST VALVE)

• •• ••

The Top saw cutting function is controlled by one of three spool sections in the "hoist" control valve.

The Slasher saw cutting function utilizes the same spool section as the top saw but is combined with a spool section in the "stick" control valve to provide the additional flow of hydraulic oil required by the slasher saw.

•• BELL HOUSING 278-3A

PILOT MANIFOLD

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

GEAR PUMP (LATER MACHINES)

SLASHER SAW CUT AND SAWS RETRACT CONTROL VALVE (STICK VALVE)

PUMP Two types of pumps have been used on the 230/ 240 loader. Earlier machines were equipped with a fixed displacement triple vane pump and later machines with a fixed displacement external triple gear pump.

The delimber and slasher circuits utilize all three vane pump cartridges or gear housings of these pumps to supply hydraulic oil to the three main control valve spool sections of the swing valve, hoist valve and stick valve.

The slasher saw cutting function and the retraction of both the slasher saw and the top saw are controlled by one of three spool sections in the "stick" control valve. Additional oil flow from the "hoist" control valve maybe provided for operating the slasher saw when the 100 gpm slasher option is used.

For a detailed description of the "swing", "hoist" and "stick" control valves, refer to SECTION 15 in THIS MANUAL.

For a more detailed description of both the triple vane pump and the triple gear pump, refer to SECTION 12 in THIS SERVICE MANUAL.

18.2

Tigercat 230/240 Loader

Delimber/Slasher MAIN RELIEF (2600 PSI) (S/N 2400101 & UP) (2600 PSI) (S/N 2300101 TO 0126) (2500 PSI) (S/N 2300127 & UP

MAIN RELIEF (2500 PSI) 'SPARE' PORT RELIEF (3000 PSI)

TOP SAW 'CUT' PORT RELIEF (3000 PSI) (2300 PSI) (S/N 2300101 TO 0271) (2300 PSI) (S/N 2400101 TO 0242)

SLASHER 'CUT' PORT RELIEF (3000 PSI) (2300 PSI) (S/N 2300101 TO 0271) (2300 PSI) (S/N 2400101 TO 0242)

•

•

• •

•

GRAPPLE ROTATE

SLASHER CUT SAW RETRACT

GRAPPLE OPEN/ CLOSE

HOIST

TOP SAW CUT

•

•

SLASHER CUT

SWING

OUTRIGGERS

•

STICK

•

•

• DELIMBER

•

•

•

•

MAIN RELIEF (2600 PSI) (2800 PSI) (S/N 2300101 TO 0126)

•

•

•

AT047IL AT041ZIL

AT047IL

OUTLET SECTION OUTLET SECTION

OUTLET SECTION INLET SECTION

INLET SECTION SLASHER 'CUT' PORT RELIEF (3000 PSI) (2300 PSI) (S/N 2300101 TO 0271) (2300 PSI) (S/N 2400101 TO 0242)

GAUGE TEST PORT

DELIMBER 'OPEN' PORT RELIEF (3000 PSI)

GAUGE TEST PORT

GAUGE TEST PORT INLET SECTION SAWS 'RETRACT' PORT RELIEF (3000 PSI) (1500 PSI) (S/N 2300101 TO 0271) (1500 PSI) (S/N 2400101 TO 0242)

"SWING", "HOIST" AND "STICK" CONTROL VALVES

RELIEF VALVE PORT 'A'

SEAL GROOVES

RELIEF VALVE PORT 'B'

A

B SPOOL CENTERING SPRINGS

•

• • •

•

•

•

• • • PILOT END CAP

AT041YIL

•

•

• •

• SPOOL TANK PASSAGE

PARALLEL PASSAGE

LOAD CHECK VALVE

THRU' NEUTRAL PASSAGE

WORK PORT BRIDGE

CROSS SECTION OF SPOOL SECTIONS 18.3

TANK PASSAGE

PILOT END CAP

Tigercat 230/240 Loader

Delimber/Slasher

DIVERTER VALVE

When pilot oil is applied to port '1', the valve shifts to connect ports '3' and '4' while blocking port '2'.

The diverter valve is a pilot operated three way directional valve consisting of a screw-in spool type valve cartridge housed in an aluminum block.

CARTRIDGE

The purpose of the valve in the circuit is to divert hydraulic oil either to or from the the base end of the delimbing arms cylinder to open or close the delimbing arms.

'V' VENT

•

DIVERTER VALVE-DELIMBER

269-15

In the neutral position with no pilot oil supply, oil flows from port '3' to port '2', while flow is blocked at '4'. 'V' is a spring chamber vent-to-atmosphere, which is internally 'O' ring sealed from the cartridge flow paths.

'V'

CARTRIDGE

ALUMINUM BLOCK

•

• PORT '4'

PORT '3'

PORT '2'

PORT '1' AW112

DIVERTER VALVE 18.4

Tigercat 230/240 Loader

Delimber/Slasher

DELIMBER/SLASHER CONNECTIONS Hydraulic connections for the delimber and the slasher are located on the lower frame. The delimber connections, located at the front of the lower frame and accessed from below, consist of three No.12 JIC elbows and one No. 8 JIC elbow.

The slasher connections, located at the rear of the lower frame consist of two No. 16 JIC fittings and one No. 12 JIC fitting. All fittings are capped when not in use with special steel caps to prevent leakage. Always ensure caps are tightly in place when not operating a delimber or slasher. When making the hydraulic connection to either the delimber or the slasher, it is very important to clean around the fittings before disconnecting them to prevent dirt from entering the system.

IMPORTANT Alway check hydraulic oil level after connecting and running the delimber and/or slasher.

DELIMBER OPEN

TANK

•

••

TOP SAW CUT

•

TOP SAW RETRACT

•

DELIMBER CONNECTIONS

277-3

SLASHER RETRACT

TANK

SLASHER CUT

•• •

•

275-16 SLASHER CONNECTIONS For information on the DELIMBER or SLASHER, please refer to the MANUFACTURERS MANUAL.

18.5

Tigercat 230/240 Loader

Delimber/Slasher

DELIMBER/SLASHER CIRCUIT DESCRIPTION

rod end of the cylinders from the DELIMBER ACCUMULATOR to close the arms.

REFER TO CIRCUIT DIAGRAMS

Cut with delimber top saw; Push and hold RIGHT side of L.H. Joystick switch, Push LEFT side of R.H. joystick switch, Current flows through wire 92, through contacts on SAW CUT RELAY (6), wire 41 and energizes TOP SAW SOLENOID valve on pilot manifold.

The delimber/slasher circuit is supplied with hydraulic oil by a fixed displacement gear pump, (earlier machines a fixed displacement vane pump). One spool section in each of the three main control valves hydraulically control all of the delimber or slasher functions. The three main control valves each receive oil at their inlet sections where it is directed through the three open center spool sections, to the outlet sections.

From there it is directed back to tank via a check valve and dual head filter which is equipped with an internal 20 psi element bypass valve.

Pilot oil flows through the TOP SAW solenoid pilot valve to shift the spool in the TOPSAW/SLASHER CUT VALVE (hoist valve) to allow system oil to flow through the ROTARY MANIFOLD to the TOP SAW MOTOR and the rod end of the TOP SAW CYLINDER to run the saw motor and cut with the saw bar.

Two 3-position joystick switches and three relays (numbers 4, 5 and 6) electrically control the delimber and slasher functions:-

Cut with slasher saw; Push and hold LEFT side of L.H. Joystick switch, Push LEFT side of R.H. joystick switch, Current flows from L.H. joystick switch through wire 90 and 19, to energize SAW CUT RELAY (6). Current also flows from R.H. joystick switch through wire 92, the SAW CUT RELAY CONTACTS (6) and wire 39, to energize SLASHER CUT solenoid valve on pilot manifold.

Open delimber arms; Push LEFT side of L.H. Joystick switch, Current flows through wires 90 and energizes DELIMBER OPEN RELAY (5) to energize a DELIMBER OPEN SOLENOID valve on the pilot manifold. Current also flows through wire 18 to energize a second DELIMBER OPEN SOLENOID valve on the pilot manifold.

Pilot oil flows through the SLASHER CUT solenoid pilot valve on the pilot manifold to shift the spools in both the TOPSAW/SLASHER CUT VALVE (hoist valve) and the SAW RETRACT/ SLASHER CUT (stick valve) to allow an increased volume of system oil to flow through the ROTARY MANIFOLD to the SLASHER SAW MOTOR and the rod end of the BAR CYLINDER to run the saw motor and cut with the saw bar.

Current also flows via the contacts of DELIMBER CLOSE RELAY (4) through wire 94 and jumper wire 19 to "latch" RELAY (5) in the energized position so that the joystick switch may be released to the spring return center position while the delimber arms remain in the OPEN position.

Pilot oil flows through the two DELIMBER OPEN solenoid pilot valves to shift the spool in the DIVERTER VALVE and also the spool in the DELIMBER VALVE (swing valve) to allow system oil to flow through the ROTARY MANIFOLD to the base end of the DELIMBER ARM CYLINDERS to open the arms.

Retract delimber top saw and/or slasher saw; Push RIGHT side of R.H. joystick switch, Current flows through wire 93 and energizes TOP SAW/ SLASHER SAW solenoid valve on pilot manifold.

Pilot oil flows through the TOP SAW/SLASHER SAW RETRACT solenoid pilot valve to shift the spool in the SAW RETRACT VALVE (stick valve) to allow system oil to flow through the ROTARY MANIFOLD to the base end of the TOP SAW BAR CYLINDER and the SLASHER SAW CYLINDER base end to retract the saw bar(s).

The pilot line connected to the SPARE spool section end cap is a "vent" to allow the spool to shift when pilot pressure is applied to the DELIMBER pilot end cap.

Close delimber arms; Push RIGHT side of L.H. Joystick switch, Current flows through wire 91 and energizes DELIMBER CLOSE RELAY (4).

In this condition system oil to the delimber arms cylinders is shut off at the DELIMBER VALVE (swing valve) and oil from the base end of the DELIMBER ARMS CYLINDER is returned to tank via the DIVERTER VALVE, due to oil entering the

18.6

Tigercat 230/240 Loader

Delimber/Slasher

18.7

Tigercat 230/240 Loader

Delimber/Slasher

TROUBLESHOOTING DELIMBER RELAY CIRCUIT If an electrical problem is suspected, the operation of the joystick switches and the delimber relays can be verified with the following procedure.

1.

2.

With the delimber arms switch in OPEN position, voltage should be present at wires 90, 18 and 19; if so, go to step 2. If voltage is not present in wire 90, operate the joystick switch in the other direction (ARMS CLOSE) and check wire 91. If voltage is present at wire 91, there may be problem in the joystick switch or in wire 90 from the joystick switch to the relay box. If voltage is not present in wire 91, check for voltage at wire 15 in the instrument panel. If voltage is not present at wire 15, check 15 amp fuse; if voltage is present at wire 15, check joystick switch and wiring to switch.

279-9A

19 39

With the delimber arms switch RELEASED to center position, voltage should still be present at wire 19 but not at wires 90 & 18. If this is the case go to step 3. If voltage is present at wires 90 & 18, check diode no. 12.

If voltage is not present at wire 19, check relays 4 & 5.

3.

With the delimber arms switch in CLOSE position, voltage should be present at wire 91 and voltage at wire 19 will drop to zero. If voltage on wire 19 does not drop to zero, check relay 4 for operation.

4.

With the delimber arms switch RELEASED to center position, voltage will drop to zero on wire 91 and will remain at zero on wire 19. If this does not happen suspect the joystick switch.

5.

With the delimber arms switch in CLOSED postion and the saw switch in the CUT (SAW EXTEND) position, voltage should be present at wire 41. If this is not the case, recheck voltage in wire 19 and, if it is not present, check relay 6 for proper operation.

6.

With the delimber arms switch in OPEN position and the saw switch in the CUT position, voltage should be present in wire 39. If voltage is not present in wire 39, check wire 19 which should have voltage, if this is the case check relay 6 for proper operation.

7.

When the saw switch is in the RETRACT position, voltage should be present in wire 93 regardless of the arm position.

41

18 90

RELAY #4 DELIMBER CLOSE

91 92

RELAY #5 DELIMBER OPEN

RELAY #6 SAW CUT

7670A

18.8

DELIMBER RELAYS

15 57 GND

Tigercat 230/240 Loader

Delimber/Slasher

DELIMBER/SLASHER CIRCUIT AT REST 230-08

OPEN DELIMBER ARMS 230-09

18.9

Tigercat 230/240 Loader

Delimber/Slasher

CLOSE DELIMBER ARMS 230-10

CUT WITH DELIMBER TOP SAW 230-11

18.10

Tigercat 230/240 Loader

Delimber/Slasher

CUT WITH SLASHER SAW 230-13

RETRACT DELIMBER TOP SAW AND SLASHER SAW 230-12

18.11

Tigercat 230/240 Loader

230-07

Delimber/Slasher

DELIMBER/SLASHER CIRCUIT 18.12

Tigercat 230/240 Loader

Delimber/Slasher

PRESSURE SETTINGS

RELIEF VALVE SETTINGS SLASHER CUT, SAW RETRACT (STICK VALVE)

CAUTION

Slasher cut and saw retract/"Stick" main relief setting:-

Use caution when in the cab as a slight touch of the controls can cause sudden rotation of the upper frame and booms or movement of the stabilizers

S/N 2300101 to 2300126 ................. 2600 psi S/N 2400101 and up ........................ 2600 psi S/N 2300137 and up ........................ 2500 psi Slasher cut port relief setting:-

CAUTION

S/N 2300101 to 2300271 ................. 2300 psi S/N 2300272 and up ........................ 3000 psi S/N 2400101 to2400242 .................. 2300 psi S/N 2400243 and up ........................ 3000 psi

Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

Saw retract port relief setting:S/N 2300101 to 2300271 ................. 1500 psi S/N 2300272 and up ........................ 3000 psi S/N 2400101 to2400242 .................. 1500 psi S/N 2400243 and up ........................ 3000 psi

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

NOTE:

IMPORTANT

The Delimber and/or Slasher hydraulic hoses must be disconnected at the loader bulkhead connections before carrying out the following procedure. Cap the hoses to keep clean and use the appropriate steel caps on the bulkhead fittings to prevent leakage during the pressure setting procedure.

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

NOTE: The procedure to set the main and port relief valves for the TOP SAW and SLASHER SAW involve setting both the "hoist" valve and the "stick" valve at the same time. This is due to the SLASHER CUT function receiving oil simultaneousely from the two valves.

NOTE: "Hoist" and "stick" valves being set at same time.

1.

Position machine on level ground with stabilizers down.

RELIEF VALVE SETTINGS TOP SAW CUT, SLASHER CUT (HOIST VALVE)

2.

Ensure that the hydraulic oil is at operating temperature.

Top and Slasher cut/"Hoist" main relief setting:-

3.

Loosen the locknut on the "hoist" main relief valve and the "stick" main relief valve and turn the relief adjusting screws all the way in, tighten locknuts.

4.

Loosen the locknut on the SLASHER CUT port relief valve on the "stick"valve and turn the relief adjusting screw all the way in, tighten locknuts.

5.

Loosen the locknuts on both port relief valve adjusting screws for the TOP SAW AND SLASHER CUT spool section of the "hoist" valve and the SAW RETRACT port relief valve on the "stick" valve and turn the adjusting screws out until spring pressure is relieved then turn adjusting screws one full turn in.

6.

Connect two 0 - 5000 p.s.i. pressure gauges to the "hoist" and the "stick" control valve test ports on the inlet sections of the valves.

S/N 2300101 to 2300126 ................. 2600 psi S/N 2400101 and up ........................ 2600 psi S/N 2300137 and up ........................ 2500 psi Slasher cut port relief setting:S/N 2300101 to 2300271 ................. 2300 psi S/N 2300272 and up ........................ 3000 psi S/N 2400101 to2400242 .................. 2300 psi S/N 2400243 and up ........................ 3000 psi Top saw cut port relief setting:S/N 2300101 to 2300271 ................. 2300 psi S/N 2300272 and up ........................ 3000 psi S/N 2400101 to2400242 .................. 2300 psi S/N 2400243 and up ........................ 3000 psi

Continued on page 14

18.13

Tigercat 230/240 Loader

Delimber/Slasher

Continued from page 13

7.

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

8.

While holding the L.H. joystick switch in the DELIMBER OPEN position and the R.H. joystick switch in the SAW EXTEND position, check gauge pressure reading at "hoist" valve test connection. If less than set value, turn SLASHER CUT port relief valve adjusting screw in until set value is obtained on gauge.

9.

Tighten locknut on adjusting screw taking care not to turn the adjusting screw. SLASHER CUT port relief on "hoist" valve is now set.

10. Loosen the locknut on the SLASHER CUT port relief valve on the "stick"valve and turn the relief adjusting screw out until spring pressure is relieved then turn adjusting screws one full turn in. tighten locknuts.

11. While holding the L.H. joystick switch in the DELIMBER CLOSE position and the R.H. joystick switch in the SAW EXTEND position, check gauge pressure reading at "stick" valve test connection. If less than set value, turn relief valve adjusting screw in until set value is obtained on gauge.

12. Tighten locknut on adjusting screw taking care not to turn the adjusting screw. SLASHER CUT port relief on "stick" valve is now set.

13. While holding the L.H. joystick switch in the DELIMBER CLOSE position and the R.H. joystick switch in the SAW EXTEND position, check gauge pressure reading at "hoist" valve test connection. If less than set value, turn TOP SAW CUT port relief valve adjusting screw in until set value is obtained on gauge.

14. Tighten locknut on adjusting screw taking care not to turn the adjusting screw. TOP SAW CUT port relief on "hoist" valve is now set.

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

15. While holding the R.H. joystick switch in the SAW RETRACT position, check gauge pressure reading at "stick" valve test connection. If less than set value, turn SAW RETRACT port relief valve adjusting screw in until set value is obtained on gauge.

16. Tighten locknut on adjusting screw taking care not to turn the adjusting screw. SAW RETRACT port relief on "stick" valve is now set. reset main relief valves: 17. Loosen locknut on "hoist" main relief and unscrew adjusting screw 3 full turns.

18. While holding the L.H. joystick in the HOIST UP position (fully extended), check HOIST gauge pressure reading. If less than set value, turn "hoist"main relief valve adjusting screw in until set value is obtained on gauge.

19. While holding the R.H. joystick in the STICK OUT position (fully extended), check STICK gauge pressure reading. If less than set value, turn "stick" main relief valve adjusting screw in until set value is obtained on gauge.

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

RELIEF VALVE SETTINGS DELIMBER ARMS (SWING VALVE) Delimber/"Swing" main relief setting:- .. 2500 psi Delimber open port relief setting:- ...... 3000 psi Spare port relief setting:- ..................... 3000 psi 1.

Position machine on level ground with stabilizers down.

2.

Ensure that the hydraulic oil is at operating temperature.

3.

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

4.

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

5.

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

6.

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

7.

While holding the L.H. joystick switch in the DELIMBER OPEN position, check gauge pressure reading at "swing" valve test connection. If less than set value, turn DELIMBER port relief valve adjusting screw in until set value is obtained on gauge.

8.

Tighten locknut on adjusting screw taking care not to turn the adjusting screw. DELIMBER port relief on "swing" valve is now set.

18.14

Tigercat 230/240 Loader

Delimber/Slasher

NOTE: The SPARE port relief is not used, it is factory set to 3000 psi and serves only as a plug. The pilot line connected to the spool section pilot end cap is a "vent" to allow the spool to shift when pilot pressure is applied to the opposite end.

SUMMARY:

reset main relief valves: Loosen locknut on "swing" main relief and unscrew adjusting screw 3 full turns.

1.

Disconnect Delimber and Slasher hoses from Loader.

2.

Ensure huydraulic oil is at operating temperature.

3.

Turn both main reliefs fully in.

4.

Turn SLASHER CUT port relief on "stick" valve fully in.

5.

Turn SLASHER CUT and TOP SAW CUT port reliefs on "hoist" valve out.

6.

Turn SAW RETRACT port relief on"stick" valve out.

7.

Connect gauges to "hoist" and "stick" valves.

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

8.

Start engine.

9.

Set SLASHER CUT port relief on "hoist" valve.

12. Remove pressure gauges and wipe up any excess oil from test port area.

10. Turn SLASHER CUT port relief on "stick" valve fully out.

13. Re-connect delimber and slasher hoses to bulkhead fittings on loader.

11. Set SLASHER CUT port relief on "stick" valve.

9.

10. While holding the L.H. joystick switch in the DELIMBER OPEN position, check gauge pressure reading. If less than set value, turn "swing" main relief valve adjusting screw in until set value is obtained on gauge.

12. Set TOP SAW CUT port relief on "hoist" valve.

13. Set SAW RETRACT port relief on "stick" valve.

14. Re-set both main reliefs.

Delimber/"swing" valve:-

18.15

1.

Connect gauge to "swing" valve.

2.

Turn main relief fully in.

3.

Turn DELIMBER port relief out.

4.

Set DELIMBER port relief.

5.

Re-set "swing" main relief.

6.

Remove all gauges.

7.

Re-connect Delimber and Slasher units to Loader.

Tigercat 230/240 Loader

Delimber/Slasher

18.16