Tigercat 230B 240B Loader OPERATOR'S MANUAL - PDF DOWNLOAD

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

ISSUE 2.0, JUNE, 2005

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

230B-OM00

230B/240B Available Literature Operator's Manual .................................................. Part No. 13040A Service Manual ....................................................... Part No. 13041A Parts Catalog .......................................................... Part No. 13042A CD - Master Parts Catalog .................................... Part No. 24995A CD - Master Operator's and Service Manual ........ Part No. 24996A 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 230B/240B 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 230B and 240B Loaders Serial numbers:- 2300501 and up.

Serial numbers:- 2400501 and up.

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.

240B-1

iii

Tigercat 230B/240B Loader

Introduction

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

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

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

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

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

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

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

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

Tigercat Industries Inc.

iv

Tigercat 230B/240B Loader

SECTION 1 - SAFETY JUNE, 2005

CONTENTS - SECTION 1 BATTERY DISCONNECT SWITCH ........................................................... 1.6, 1.8 COOLING SYSTEM ........................................................................................... 1.8 EXHAUST FUMES ............................................................................................ 1.9 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 .................................................................................................... 1.8 LOOSE CLOTHING HAZARD ............................................................................ 1.9 PROTECTIVE CLOTHING ................................................................................. 1.3 SAFE REMOVAL OF COUNTERBALANCE AND CHECK CARTRIDGE ............ 1.9 SAFETY PRECAUTIONS, OPERATING ........................................................... 1.5 SAFETY PRECAUTIONS, SERVICING ............................................................. 1.7 SAFETY SYMBOLS .......................................................................................... 1.2 SIGNAL WORDS ............................................................................................... 1.2

Tigercat 230B/240B Loader

Safety

SAFETY SYMBOLS

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

Understanding Signal Words

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

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

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

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

1.2

Tigercat 230B/240B 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 230B/240B 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

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

WARNING Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

Tigercat 230B/240B Loader

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

OPERATING SAFETY PRECAUTIONS

Ensure that the windshield guard is installed and properly secured.

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

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

During refuelling do not leave the filler nozzle unattended.

Avoid over filling and immediately clean up spilled fuel.

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

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

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

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

Make sure that all of the controls are positioned as 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.

WARNING

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

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

1.5

Use only prearranged and approved signalling practices.

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

Tigercat 230B/240B Loader

Safety Before transporting the machine:

OPERATING SAFETY PRECAUTIONS continued

• Secure the grapple to the trailer and raise the stabilizers.

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

• 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.

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

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

WARNING

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

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

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

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.

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

EARLIER MACHINES

DANGER

240B-003

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.

LATER MACHINES

Turn the battery 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.

1.6

Tigercat 230B/240B Loader

Safety SAFETY INTERLOCK SWITCH ON LEFT ARMREST:

SERVICING SAFETY PRECAUTIONS

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

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

ARMREST

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

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

1

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

LIMIT SWITCH ACTUATING LEVER ON SEAT BASE

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

• 247-25

••

PILOT SYSTEM SHUT OFF

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

Before performing maintenance or repair work on any 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.

1.7

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

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

Tigercat 230B/240B Loader

Safety

SERVICING SAFETY PRECAUTIONS continued

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.

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 pins and bearings, especially the swing bearing.

Turn the battery disconnect switch off. Also, Disconnect the engine CPU (Central Processing Unit) by unplugging the two multi-pin connectors from the left side of the engine.

•

244-045

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.

DISCONNECT THE TWO MULTI-PIN PLUGS FROM THE ENGINE CPU

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.

1.8

Tigercat 230B/240B Loader

Safety

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

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.

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.

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.

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.

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

• • •

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.

CYLINDER

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.

STABILIZER COUNTERBALANCE/CHECK VALVE CARTRIDGE REMOVAL

230-06A

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

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

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 230B/240B Loader

Safety 5.

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.

6.

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

7.

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.

8.

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

9.

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

FIRE PREVENTION

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

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

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

1.

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

2.

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

3.

Inspect the EXHAUST SYSTEM DAILY for any signs of LEAKAGE. Check for worn, cracked, broken, or damaged pipes or muffler.

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

4.

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

1.10

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

11. 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.

Tigercat 230B/240B Loader

Safety

FIRE PREVENTION continued 12. Shut down equipment immediately when a problem is suspected or smoke is detected.

•

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

•

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

•

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

•

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

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

•

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

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

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

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

16. 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.

*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.

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

WHAT TO DO IN CASE OF A MACHINE FIRE

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

•

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.

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

•

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.

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

•

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.

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

•

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.

•

If you can safely do so, turn OFF battery disconnect switch.

•

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

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

WHAT ELSE TO DO BEFORE YOU EXPERIENCE A FIRE •

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

•

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

Continued on page 12

1.11

Tigercat 230B/240B Loader

Safety

FIRE PREVENTION continued

•

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

•

Ensure that the machine and all components have cooled down sufficiently after a fire has occurred. Beware of the possibility of coolant or hydraulic hoses rupturing after a fire spraying hot oil or coolant which may result in severe burns.

Continued from page 11

•

Use the PASS method with most extinguishers.

•

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

•

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

•

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

•

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

20229A

WHAT TO DO AFTER A FIRE

TYPICAL 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.

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 230B/240B Loader

SECTION 2 - CONTROLS & OPERATION JUNE, 2005

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

CONTENTS - SECTION 2 A/C ON/OFF SWITCH .................................... 2.15 AIR CLEANER ................................................ 2.30 AIR CONDITIONER/HEATER ................ 2.5, 2.15 AM/FM STEREO CASSETTE ......................... 2.24 AUXILIARY POWER OUTLET ................ 2.4, 2.15 BATTERY DISCONNECT SWITCH ............... 2.27 BOOM CONTROLS, JOYSTICK LEVER 2.2, 2.12 BREATHER, HYDRAULIC RESERVOIR ........ 2.29 BULB TEST SWITCH ............................. 2.7, 2.17 CAB CONTROLS .................................... 2.2, 2.12 CARE OF MACHINE ....................................... 2.42 CLEANING LEXAN WINDOWS ...................... 2.42 CONTROLS, CAB ................................... 2.2, 2.12 COOLANT, LOW~ RED LIGHT ........................ 2.6 DELIMBER ARMS ................................... 2.2, 2.12 DIMMER CONTROL, GAUGE LIGHTS ............ 2.7 DISPLAY MODULE ......................................... 2.18 COMPONENT DESCRIPTION .................... 2.18 FAULTS AND WARNINGS .......................... 2.19 KEYPAD FUNCTIONS ................................ 2.19 START-UP OPERATION ............................. 2.18 ENGINE COMPARTMENT ............................. 2.27 ENGINE COOLANT LEVEL~RED LIGHT ......... 2.6 ENGINE COOLANT TEMP. ~ GAUGE ............. 2.7 ENGINE COOLANT TEMP. ~ RED LIGHT ....... 2.7 ENGINE, HOT WATER SHUT OFF VALVE ..... 2.5 ENGINE OIL PRESSURE ~ GAUGE ................ 2.7 ENGINE OIL PRESSURE ~ RED LIGHT .......... 2.7 ENGINE, STARTING ...................................... 2.36 ENGINE STOPPING ....................................... 2.39 FAN, CAB .................................... 2.11, 2.15, 2.24 FILTERS ......................................................... 2.16 A/C AND HEATER ......................................... 2.6 AIR FILTER RESTRICTION INDICATOR .... 2.31 ENGINE AIR ................................................ 2.31 HYDRAULIC PILOT ..................................... 2.30 HYDRAULIC RETURN ................................ 2.29 FIRE EXTINGUISHER .......................... 2.11, 2.24 FLUID LEAKS ................................................. 2.38 FOOT PEDAL ......................................... 2.3, 2.13 FUEL TANK AND FILLER ............................... 2.32 FUSES AND RELAYS .. 2.8, 2.9, 2.10, 2.20, 2.32 GRAPPLE CONTROLS .......................... 2.2, 2.12 HEATER/AIR CONDITIONER .......................... 2.5 HORN ...................................................... 2.3, 2.13 HOT WATER SHUT OFF VALVE ........... 2.5, 2.16 NOTE:

HYDRAULIC OIL HAND FILL PUMP ....................................... 2.28 LEVEL .......................................................... 2.17 LEVEL, LOW ~ RED LIGHT .......................... 2.6 RETURN MANIFOLD .................................. 2.29 TEMP. - GAUGE .................................. 2.7, 2.16 TEMP. - RED LIGHT ..................................... 2.7 TEMPERATURE .......................................... 2.17 JOYSTICK LH. ........................................ 2.2, 2.12 JOYSTICK RH. ....................................... 2.2, 2.12 KEY SWITCH .......................................... 2.4, 2.15 LIGHT, DOME ....................................... 2.11, 2.24 LIGHTS, SERVICE, WORK .............................. 2.4 LIMIT SWITCH ................................................ 2.14 LOADER MOUNTING/INSTALLATION .......... 2.40 LOW COOLANT - RED LIGHT ....................... 2.17 MACHINE OPERATION ................................. 2.33 MACHINE PREPARATION .......................... 2.38 PRE-START CHECKS ................................. 2.33 STARTING ENGINE .................................... 2.36 STOPPING ENGINE .................................... 2.38 MAX RPM - SWITCH ...................................... 2.13 PILOT RESET - SWITCH ....................... 2.3, 2.14 PILOT SYSTEM SHUT OFF ................... 2.4, 2.14 POWER OUTLET, AUXILIARY, 12 VOLTS ...... 2.4 POWERVIEW DISPLAY MODULE ................. 2.18 RADIO - 2 WAY .................................... 2.11, 2.24 RELAYS AND FUSE PANEL ............................ 2.8 SEAT ............................................................... 2.25 SERVICE LIGHTS .................................. 2.4, 2.15 SETTING THE MACHINE ............................... 2.37 STABILIZER OPERATION ..................... 2.3, 2.13 STARTING ENGINE ....................................... 2.36 STEREO CASSETTE AM/FM RADIO ............. 2.24 STOPPING ENGINE ....................................... 2.39 SWING .................................................... 2.3, 2.13 TACHOMETER ................................................. 2.7 TAPE DECK .......................................... 2.11, 2.24 THROTTLE CONTROL .................................... 2.4 TRANSPORTING THE LOADER .................... 2.41 VOLTMETER .................................................... 2.7 WAIT TO START - YELLOW LIGHT .............. 2.17 WATER IN FUEL - YELLOW LIGHT .............. 2.17 WINDOWS, CLEANING LEXAN ..................... 2.42 WIPER, WINDSHIELD ........ 2.3, 2.11, 2.13, 2.24

EARLY MACHINES: S/N 2300501 TO 2300850, AND 2400501 TO 2401000 LATER MACHINES: S/N 2300851 & UP, AND 2401001 & UP POSITIVE BATTERY DISCONNECT: S/N 2301021 & UP, 2401271 & UP

Tigercat 230B/240B Loader

Controls and Operation IMPORTANT

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

CAB CONTROLS (EARLIER MACHINES) (SEE PAGES 2.12 to 2.22 for later machines - S/N 2300851 & UP, AND 2401001 & UP) NOTE All joystick and Foot Pedal controls require pilot pressure. Refer to PILOT RESET in THIS SECTION. 1

2

•• ••

240B-D02

240B-D03

1. LEFT HAND JOYSTICK LEVER Hoist Boom

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

Push the joystick lever forward to lower the Hoist Boom.

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

Pull the joystick lever back to raise the Hoist Boom.

RIGHT HAND JOYSTICK SWITCHES*

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

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

LEFT HAND JOYSTICK SWITCHES

*The right hand joystick push button switches perform two separate functions depending on the status of the delimber arms.

With the delimber arms Open: Push the left hand push button switch to extend (cut) with slasher saw.

Push the left hand push button switch to open delimber arms.

Push the right hand push button switch to retract slasher saw.

Push the right hand push button switch to close delimber arms.

OR With the delimber arms Closed: Push the left hand push button switch to extend (cut) with top saw.

2. RIGHT HAND JOYSTICK LEVER Stick (Jib) Boom Push the joystick lever forward to move the Stick in.

Push the right hand push button switch to retract top saw.

Pull the joystick lever back to move the Stick out.

2.2

Tigercat 230B/240B Loader 4

5

6

Controls and Operation 9

7

• •

8

11

• •

••

10

14

•

•

••

• ••

•

13

12

•

CONTROL PANEL

240B-D04

SWING LEFT

3

10. HORN ~ SWITCH

SWING RIGHT

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

•

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

156-8A

FOOT PEDAL

12. WIPER ~ SWITCH

3. FOOT PEDAL - SWING

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

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

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

13. WASHER ~ SWITCH

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

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

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

•

•

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

First select a direction (up or down) using the Stabilizer Direction selector switch (4).

The center position on the switch turns off all stabilizers. This switch should be left in the center position whenever stabilizers are not being moved. This will prevent accidental operation of the stabilizers.

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

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

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

Also see SETTING THE MACHINE in THIS SECTION.

2.3

Tigercat 230B/240B Loader

Controls and Operation 16

17

•

ARMREST

•

•• ••

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

19

20

18

• •

15 LIMIT SWITCH ACTUATING LEVER ON SEAT BASE

240B-D05

•

CONTROL PANEL

circuit draws current directly from the battery and is protected by a fuse located in the fuse box.

•

20. KEY SWITCH 247-25

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

PILOT SYSTEM SHUT OFF

15. PILOT SYSTEM SHUT OFF ~ LIMIT SWITCH When the L.H. arm rest is placed in the UP position, a limit switch shuts OFF the pilot system DEACTIVATING all operating functions.

When the L.H. arm rest is placed in the DOWN position, the limit switch closes and turns ON the pilot system. But the operating functions are not REACTIVATED until the PILOT RESET switch (item 14) is pressed.

16. LIGHTER Depress lighter fully into socket and wait until it pops back up. Pull lighter out of socket and use coil to light cigar(ette). CAUTION: Lighter coil reaches high temperature which can cause burns to skin and can start fire. Handle with care. DO NOT use in presence of explosive or flammable liquids or vapor. Serious injury, death and/or property damage may result.

17. AUXILIARY POWER OUTLET, 12 VOLTS A 12 volt outlet with a 20 amp. capacity for portable devices such as cell phones, service lights etc.

OFF Position - All electrical power through the Key switch is turned OFF. Electrical power is still available for the horn, lighter, tape deck, 2 way radio, cab dome light, defroster fan, work lights and service light.

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

START Position - Connects the battery to the start relay to start the engine. Turning the key to this position starts the engine. The key will return to RUN position when released.

21. THROTTLE CONTROL The throttle control should not be moved unless the Key switch is in the RUN position otherwise damage to the fuel control solenoid and linkage may result.

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

18. SERVICE LIGHTS This switch controls the service light located in the engine enclosure. The circuit draws current directly from the battery and is protected by a fuse located in the fuse box.

19. WORK LIGHTS This switch controls the work lights located on the front of the cab and on the stick boom. The

2.4

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

Tigercat 230B/240B Loader

Controls and Operation

Maintaining Correct Engine Speed

E. AIR CONDITIONING - VARIABLE

The engine RPM should checked regularly with a hand tachometer and adjusted as necessary.

This is a variable, rotary dial to adjust the temperature of cooled air for the cab.

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

Low Idle - 950 rpm (No Load) High Idle - 2400 rpm Max (No Load) The above values are taken with the hydraulic and engine oil at normal operating temperature and without any functions operating.

•

WARNING

•

••

240B-D06

209-7

A

•

HOT WATER SHUT OFF VALVE (CUMMINS ENGINE)

23. HOT WATER SHUT OFF VALVE (ENGINE)

••

•• B

C

23 SHUT-OFF VALVE

••

•

••

ENGINE

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

HOSE TO A/C HEATER UNIT

D

E

To maximize the efficiency of the air conditioning, the HEAT control knob (D) on the A/C Heater control panel must be rotated to the "OFF" position. During times when cab heating is not required the HOT WATER SHUT OFF VALVE, on the heater hose from the engine, should also be closed to prevent hot water from seeping through the A/C unit, thereby reducing the effect of the cooling.

21

A/C HEATER CONTROL PANEL

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

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

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

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

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

2.5

Tigercat 230B/240B Loader

Controls and Operation 31

30

•

27 26 28 32

• ••

•

25 29 33 28

• •

••

• 240B-D08

••

GAUGES AND WARNING LIGHTS

25. LOW COOLANT ~ RED LIGHT This light comes ON when the engine coolant drops below a safe operating level. If this light turns on, immediately turn off the engine and correct the fault. The engine coolant sensor is located in the side of the radiator surge tank.

The coolant surge tank (reservoir) can be filled through the access panel located on top of the engine compartment. Ensure that the engine has cooled down sufficiently before

•

RECIRCULATION AIR FILTER

A/C HEATER UNIT

68-7C

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

••

FILLER CAP

EXTERNAL AIR FILTER ACCESS PANEL

••

••

248-25

CHECK ENGINE COOLANT LEVEL

removing radiator cap. Prior to removing cap, relieve pressure in radiator by loosening cap slowly to first stop. Use the proper solution of coolant antifreeze when filling the surge tank.

26. LOW HYDRAULIC OIL LEVEL ~ RED LIGHT

LOWER RIGHT SIDE OF OPERATOR'S CAB 245DIG-01

This light will come on when the hydraulic oil level falls 13 gallons from the full mark.

When this light first comes on stop engine and determine cause. Repair leaks and refill the tank to FULL mark on the sight gauge.

Restart engine and inspect for leaks.

EXTERNAL AIR FILTER

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

2.6

Tigercat 230B/240B Loader

Controls and Operation

27. HYDRAULIC OIL TEMP. ~ RED LIGHT

28 34

This light will come ON when the temperature of the hydraulic oil rises above 205°F. When this light first comes on stop engine and determine cause. Do not continue to operate machine

36

37

••

•

35

••

••

28. LOW ENGINE OIL PRESSURE ~ RED LIGHT This light will come ON when the engine oil pressure falls below 15 psi. If this light comes ON stop the engine and determine cause.

29. ENGINE COOLANT TEMP. ~ RED LIGHT

240B-D07

34. HOUR METER

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

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

30. HYDRAULIC OIL TEMP. ~ GAUGE

35. ENGINE OIL PRESSURE ~ GAUGE

The gauge labelled OIL TEMPERATURE displays the current temperature of the hydraulic oil in the hydraulic reservoir.

This oil pressure gauge indicates the engine oil pressure while the engine is running.

The oil pressure must be greater than 15 psi at all times. If the oil pressure drops below 15 psi, stop the engine and determine cause.

Check engine oil pressure every time the engine is started.

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

Plugged oil cooler

•

Low hydraulic oil level

•

Malfunction in a hydraulic circuit

•

High loads on the hydraulic system

GAUGES AND HOUR METER

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

Do not continue to operate the machine if temperature remains above 180°F. Operation at high hydraulic oil temperature will shorten the life of hydraulic components.

31. TACHOMETER

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

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

This meter indicates the RPM. of the engine.

For engine RPM values, refer to THROTTLE CONTROL in THIS SECTION. 32. BULB TEST SWITCH Hold this switch in the ON position to test the bulbs in the 5 warning lights; Items 25, 26, 27, 28and 29. Replace the bulb in any light that does not come ON. If the light does not come ON after inserting a new bulb, check the fuse labelled "gauges". Bulbs should be tested at the start of each shift.

33. DIMMER CONTROL

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

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

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

Rotate this control to dim or brighten the back lights in the gauges except for the HOURS gauge. The gauge back lights are ON only when the work lights are ON.

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

2.7

Tigercat 230B/240B Loader

Controls and Operation

38. FUSE AND RELAY PANEL The fuse panel is located below the control panel behind a removable cover. Each circuit of the machine is protected by a fuse. If a fuse is blown it must be replaced by one of the same value. If the fuse blows again, the circuit should be inspected for possible short circuit or other malfunction.

FUSE AND RELAY PANEL - CAB SN 2300501 TO 2300580 & 2400501 TO 2400620

240B-039

RELAYS

FUSES 5A

RELAY #1 LOW ENG. OIL PRESS.

GAUGES WARNING LIGHT

15A PILOT SYSTEM 10A FUEL 15A JOYSTICK BUTTONS 15A OUTRIGGERS

RELAY #2 PILOT SHUT - OFF

15A WIPER / WASHER 15A ETHER STARTING AID

15A

RELAY #3 A/C HEATER POWER

240B-041

19

RADIO / FAN DOME LIGHT

20A LIGHTER 20A HORN

39

40 41 93

18 90

91

92

RELAY #4 DELIMBER CLOSE

RELAY #5 DELIMBER OPEN

RELAY #6 SAW CUT

SPARE RELAY

15

57 GND

25A A/C HEATER 7670A

25A WORK LIGHTS

RELAY ELECTRICAL BOX - SN 2300501 TO 2300580 AND 2400501 TO 2400620 This relay electrical box is located in the engine compartment.

RELAY #8 OUTRIGGER CONTROL

15A SERVICE LIGHTS

9654A

NOTE: These components were relocated and incorporated in the cab fuse and relay panel on later machines. See page 2.9 for later design.

2.8

Tigercat 230B/240B Loader

Controls and Operation

240B-D14

FUSE AND RELAY PANEL - CAB ~ SN 2300581 TO 2300850 & 2400621 TO 2401000

1

DIODE MODULE 1

DIODE MODULE 2

DIODE MODULE 3

RELAY 1

RELAY 2

RELAY 3

RELAY 4

LOW ENG. OIL PRESS.

PILOT LOCK-OUT

A/CHEATER

LOW HYD. OIL

2 3 4 5

DIODE MODULE 4

DIODE MODULE 5

DIODE MODULE 7

DIODE MODULE 6

RELAY 5

RELAY 6

RELAY 7

RELAY 8

WORK LIGHTS

DELIMBER CLOSE

DELIMBER OPEN

SAW CUT

6

GAUGES 5A SAFETY 15A FUEL 10A JOYSTICKS 15A STABILIZERS 15A WIPER/WASH 15A

7

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

DIODE MODULE 8

FUSE AND RELAY PANEL - CAB SN 2300581 TO 2300850 & 2400621 TO 2401000

2.9

144

Tigercat 230B/240B Loader

240B-034

Controls and Operation

FUSE AND RELAY PANEL

FUSE AND RELAY PANEL

21096B

FUSE AND RELAY PANEL - CAB ~ SN 230851 AND UP, AND 2401001 AND UP The fuse panel is located below the control panel behind a removable cover.

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

2.10

Tigercat 230B/240B Loader 39

41

42

Controls and Operation 40

•

44

••

•

•

206-13A

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

40. LIGHT - DOME 205-9A

Push the switch on the side of the dome to turn the light ON and OFF.

SLIDING WINDOWS HANDLE R.H. WINDOW AND CAB

44. WINDOWS

41. TAPE DECK/RADIO

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

Consult the operators manual for the tape deck with two front mounted speakers.

42. 2 WAY RADIO Refer to component manufacturers manual.

CUP HOLDER

45

43 ASHTRAY

•

•

• • 240B-D15

WINDSHIELD WASHER FLUID

45. WINDSHIELD WASHER FLUID

247-23

In cold climates, fill with an anti-freeze washer fluid. To avoid scratching NEVER operate the wipers on a dry windshield.

PORTABLE FIRE EXTINGUISHER

43. FIRE EXTINGUISHER A portable fire extinguisher is located in operator's cab. The extinguisher should be checked daily to ensure that it is charged.

The pointer on the charge gauge should point to the green region. If the indicator falls out of this green area, the extinguisher should be serviced immediately.

2.11

Tigercat 230B/240B Loader

Controls and Operation

CAB CONTROLS (LATER MACHINES) (SEE PAGES 2.2 to 2.9 for earlier machines - S/N 2300501 to 2300850, AND 2400501 to 2401000) NOTE All joystick and Foot Pedal controls require pilot pressure. Refer to PILOT RESET in THIS SECTION. 1

2

• •

240B-D02

240B-D03

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

1. LEFT HAND JOYSTICK LEVER Hoist Boom Push the joystick lever forward to lower the Hoist Boom.

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

Pull the joystick lever back to raise the Hoist Boom.

RIGHT HAND JOYSTICK SWITCHES*

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

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

LEFT HAND JOYSTICK SWITCHES

*The right hand joystick push button switches perform two separate functions depending on the status of the delimber arms.

With the delimber arms Open: Push the left hand push button switch to extend (cut) with slasher saw.

Push the left hand push button switch to open delimber arms.

Push the right hand push button switch to retract slasher saw.

Push the right hand push button switch to close delimber arms.

OR With the delimber arms Closed: Push the left hand push button switch to extend (cut) with top saw.

2. RIGHT HAND JOYSTICK LEVER Stick (Jib) Boom Push the joystick lever forward to move the Stick in.

Push the right hand push button switch to retract top saw.

Pull the joystick lever back to move the Stick out.

2.12

Tigercat 230B/240B Loader 5

4

6B

Controls and Operation 9

7

•• ••

••

6A

••

13

12

•

•• ••

••

•

CONTROL PANEL

240B-028

SWING LEFT

3

•

SWING RIGHT

•

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

Also see SETTING THE MACHINE in THIS SECTION.

FOOT PEDAL

3. FOOT PEDAL - SWING

10. HORN ~ SWITCH

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

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

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

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

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

12. ENGINE SPEED - SWITCH

4. MAX RPM - SWITCH

The engine speed is controlled by this three position switch. The engine speeds are as follows:

Depressing the Max RPM rocker switch (4) will incrase the engine speed to 2270 RPM. DO NOT OPERATE at MAX RPM unless hydraulic oil temperature is above 38°C 100°F.

Idle - 900 rpm (No Load) Warm-Up - 1400 rpm (No Load)

NOTE: To maximize fuel efficiency this switch should only be used on ocassion when extra power is required. See ENGINE SPEED SWITCH in this section for more details.

Run - 2000 rpm (No Load) The above values are taken with the hydraulic and engine oil at normal operating temperature with no functions operating.

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

•

10

•

••

••

156-8A

11

8

First select a direction (up or down) using the Stabilizer Direction selector switch (4).

The center position on the switch turns off all stabilizers. This switch should be left in the center position whenever stabilizers are not being moved. This will prevent accidental operation of the stabilizers.

2.13

Tigercat 230B/240B Loader

Controls and Operation

13

••

CONTROL PANEL

244-002

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

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

ARMREST

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

14 LIMIT SWITCH ACTUATING LEVER ON SEAT BASE

•

• 247-25

PILOT SYSTEM SHUT OFF

14. PILOT SYSTEM SHUT OFF - LIMIT SWITCH When the L.H. arm rest is placed in the UP position, a limit switch shuts OFF the pilot system DEACTIVATING all operating functions.

When the L.H. arm rest is placed in the DOWN position, the limit switch closes and turns ON the pilot system. But the operating functions are not REACTIVATED until the PILOT RESET switch (item 16) is pressed.

2.14

Tigercat 230B/240B Loader 15

19. SERVICE LIGHTS

16

•

Controls and Operation 18

17

•• ••

•

This switch controls the service light located in the engine enclosure. The circuit draws current directly from the battery and is protected by a fuse located in the fuse box.

19

•

240B-028

CONTROL PANEL

••

15. LIGHTER Depress lighter fully into socket and wait until it pops back up. Pull lighter out of socket and use coil to light cigar(ette). CAUTION: Lighter coil reaches high temperature which can cause burns to skin and can start fire. Handle with care. DO NOT use in presence of explosive or flammable liquids or vapor.

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

C 244-003

••

•

••

• B

A

D

E

A/C HEATER CONTROL PANEL

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

A. A/C ON/OFF SWITCH

16. AUXILIARY POWER OUTLET, 12 VOLTS

This is a push/on push/off power switch.

A 12 volt outlet with a 20 amp. capacity for portable devices such as cell phones, service lights etc.

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

17. KEY SWITCH

C. AIR SOURCE

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

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

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

D. HEAT - VARIABLE

Electrical power is still available for the horn, lighter, tape deck, 2 way radio, cab dome light, defroster fan, work lights, hydraulic tank pressurization/vacuum system, auxillary power and service light.

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

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

E. AIR CONDITIONING - VARIABLE

START Position - Connects the battery to the start relay to start the engine. Turning the key to this position starts the engine. The key will return to RUN position when released.

18. WORK LIGHTS This switch controls the work lights located on the front of the cab and on the stick boom.

The circuit draws current directly from the battery and is protected by a fuse located in the fuse panel.

2.15

This is a variable, rotary dial to adjust the temperature of cooled air for the cab.

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

Tigercat 230B/240B Loader

EXTERNAL AIR FILTER ACCESS PANEL

FILTER

••

HOSE TO A/C HEATER UNIT

•

••

ENGINE

21 SHUT-OFF VALVE

209-7

Controls and Operation

••

••

HOT WATER SHUT OFF VALVE (CUMMINS ENGINE)

21. HOT WATER SHUT OFF VALVE (ENGINE) To maximize the efficiency of the air conditioning, the HEAT control knob (D) on the A/C Heater control panel must be rotated to the "OFF" position. During times when cab heating is not required the HOT WATER SHUT OFF VALVE, on the heater hose from the engine, should also be closed to prevent hot water from seeping through the A/C unit, thereby reducing the effect of the cooling.

LOWER RIGHT SIDE OF OPERATOR'S CAB

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

245DIG-01

23

24

•

25

26

• •

240B-033

27

28

••

29

••

••

••

GAUGES AND WARNING LIGHTS

23. HYDRAULIC OIL TEMP. - GAUGE

RECIRCULATION AIR FILTER 68-7C

The gauge labelled HYDRAULIC OIL TEMPERATURE displays the hydraulic oil temperature in the hydraulic reservoir.

If the hydraulic oil temperature rises beyond 82°C - 180°F, check the following: • Plugged oil cooler • Oil cooler bypass valve position • Low hydraulic oil level • Malfunction in a hydraulic circuit • High loads on the hydraulic system Do not continue to operate the machine if temperature remains above 82°C - 180°F. Operation at high hydraulic oil temperature will shorten the life of hydraulic components.

••

A/C HEATER UNIT

22. FILTERS Two filters are provided with the heating & A/C unit. One is for filtering re-circulated air from the cab. This is located at the bottom of the heater unit and should be inspected and cleaned on a regular basis.

2.16

Tigercat 230B/240B Loader

Controls and Operation 29. LOW COOLANT - RED LIGHT

23

24

•

25

26

•• ••

27

28

•

29

••

This light comes ON when the engine coolant drops below a safe operating level. If this light turns on, immediately turn off the engine and correct the fault. The engine coolant sensor is located in the side of the radiator surge tank.

••

••

FILLER CAP

240B-033

GAUGES AND WARNING LIGHTS

24. LOW HYDRAULIC OIL LEVEL - RED LIGHT

•

This light will come on when the hydraulic oil level falls 13 gallons from the full mark. When this light first comes on stop engine and determine cause.

Repair leaks and refill the tank to FULL mark on the sight gauge. Pressuerize the hydraulic tank and inspect for leaks.

25. HYDRAULIC OIL TEMP. - RED LIGHT

381-18A

This light will come ON when the temperature of the hydraulic oil rises above an acceptable level. When this light first comes on stop engine and determine cause. Do not continue to operate machine 26. BULB TEST SWITCH Hold this switch in the ON position to test the bulbs in the 6 warning lights; Items 28, 29, 31, 32, 33 and 34. Replace the bulb in any light that does not come ON. If the light does not come ON after inserting a new bulb, check the fuse labelled "gauges". Bulbs should be tested at the start of each shift.

27. WAIT TO START - YELLOW LIGHT This YELLOW warning light will be ON during the "key ON" engine pre-heat time. Heating elements (grid heater elements) located in the engine air intake manifold are turned ON to heat the intake air when starting the engine.

The engine must not be started until this light turns OFF automatically.

28. WATER IN FUEL - YELLOW LIGHT When this YELLOW warning light comes ON it indicates that the engine fuel/water separator needs to be drained. This task must be performed as soon as possible whenever this warning light is ON.

2.17

CHECK ENGINE COOLANT LEVEL

The coolant surge tank (reservoir) can be filled through the access panel located on top of the engine compartment. Ensure that the engine has cooled down sufficiently before removing radiator cap. Prior to removing cap, relieve pressure in radiator by loosening cap slowly to first stop. Use the proper solution of coolant antifreeze when filling the surge tank.

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

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

Tigercat 230B/240B Loader

Controls and Operation

30. POWERVIEW DISPLAY MODULE 1

S/N 2300851 & UP, AND 2401001 & UP

••

2

••

3

•• 4 244-007

7

••

••

•

5

•• 6

POWERVIEW DISPLAY MODULE

COMPONENT DESCRIPTION 1. Amber Warning LED 2. Display 244-046

3. Menu Key

POWERVIEW DISPLAY MODULE

4. Left Arrow Key

The PowerView Display Module is the operator interface with the electronic engine controls.The PowerView is a multifunction tool that enables the operator to view various engine parameters and service codes. The PowerView includes a graphical backlit LCD screen controlled via menu selection. The display can show either a single parameter or a quadrant display showing 4 parameters simultaneously. Diagnostic capabilities include fault codes with text translation for the most common fault conditions.

5. Right Arrow Key 6. Enter Key 7. Red Shutdown LED KEYPAD FUNCTIONS MENU KEY - This key is pressed to enter or exit menu screens.

LEFT ARROW KEY - This key is pressed to scroll through the screen either moving the parameter selection toward the left or down.

The PowerView has four buttons used to navigate the display with ease.

DISPLAY PARAMETERS

RIGHT ARROW KEY- This key is pressed to scroll through the screen either moving the parameter selection toward the right or up.

The following are some of the functions displayed by the PowerView Display Module:

ENTER KEY - This key is pressed to select the parameter that is highlighted on the screen.

Engine RPM Engine Hours Machine Hours System Voltage % Engine Load at the current RPM Coolant Temperature Oil Pressure Fuel Economy Throttle Position Engine Manifold Air Temperature Current Fuel Consumption Active Service Codes Stored Service Codes from the engine Set Units for display (English or Metric) Engine Configuration Parameters

Refer to manufactures Operations Manual (supplied with the machine) for detailed information.

START-UP OPERATION When power is first applied to the PowerView, the “Logo Screen” will be displayed, the “Wait to Start” message will be displayed. Once the “Wait to Start” message is no longer displayed the operator may start the engine. When the engine has started the display will show the single engine parameter display.

2.18

Tigercat 230B/240B Loader

Controls and Operation Some of the display and warning functions are: LOW ENGINE OIL PRESSURE - RED LED This light will come ON when the engine oil pressure falls below 15 psi. If this light comes ON stop the engine and determine cause.

ENGINE COOLANT TEMP. - RED LED

SINGLE PARAMETER DISPLAY MAIN MENU NAVIGATION 244-007

1. Starting at the single or four engine parameter display, depress the “Menu Button”.

This light will come ON when the engine coolant temperature rises above 215°F If this light comes ON stop engine and determine cause. Do not continue to operate machine.

TACHOMETER This display indicates the RPM. of the engine.

HOUR METER There are two options available for displaying hours:

244-047

2. The first seven items of the “Main Menu” will be displayed.

3. Depressing the “Arrow Buttons” will scroll through the menu selections.

4. Pressing the right arrow button will scroll down to reveal the last items of “Main Menu” screen highlighting the next item down.

5. Use the arrow buttons to scroll to the desired menu item or press the “Menu Button” to exit the Main menu and return to the engine parameter display.

FAULTS AND WARNINGS During normal operation the single or four parameter screen will be displayed. When the PowerView receives a fault code from an engine control unit the single or four parameter screen will be replaced with the “Active Fault Codes” message.

To acknowledge and “Hide” the fault and return to the single or four parameter display press the “Enter Button”. The display will return to the single or four parameter screen. Indicates Auxiliary Gage Fault. Indicates Fault Warning Indicates Derate or Shutdown Condition Fault Pressing the “Enter Button” will redisplay the hidden fault. Pressing the “Enter Button” once again will hide the fault and return the screen to the single or four parameter display.

NOTE: The fault can only be cleared by correcting the cause of the fault condition.

TOTAL ENGINE HOURS - displays total hours the engine has run as provided by the engine computer.

MACHINE HOURS - displays the total hours the engine has run as calculated by the display module.

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

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

NOTE: At low idle rpm the oil pressure will be low.

This is not an abnormal condition, however it must be closely monitored.

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

VOLTAGE DISPLAY Normal operating range is between 12-13.5 volts.

A reading in excess of 15 volts indicates a possible faulty voltage regulator. A reading of less than 12 Volts indicates a possible faulty battery or alternator.

Refer to manufactures Operations Manual (supplied with the machine) for detailed information.

2.19

Tigercat 230B/240B Loader

240B-034

Controls and Operation

FUSE AND RELAY PANEL - CAB

FUSE AND RELAY PANEL - CAB 31A. FUSE AND RELAY PANEL - CAB S/N 2300851 AND UP, AND 2401001 AND UP The fuse panel is located below the control panel behind a removable cover.

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

2.20

Tigercat 230B/240B Loader

240B-040

Controls and Operation

MAIN FUSE AND RELAY ELECTRICAL BOX

FUSES AND RELAYS - ELECTRICAL BOX - SN 2300851 TO 2300871 AND 2401001 TO 2401071 This Main Fuse and Relay electrical box is located in the engine compartment.

2.21

Tigercat 230B/240B Loader

Controls and Operation

244-060 244-060

MAIN FUSE AND RELAY ELECTRICAL BOX

244-043

GRID HEATER #1 FUSE

125A

GRID HEATER #1 RELAY

GRID HEATER #2 FUSE

125A MAIN FUSE

GRID HEATER #2 RELAY

125A 1

SPARE

RELAY 2 KEY SWITCH INPUT 5A 3 BATTERY (+) 7.5A 4 BATTERY (+) 7.5A 5 BATTERY (+) 7.5A 6 FUEL PUMP 10A 7 FUEL PUMP 10A

FUEL HEATER (OPTIONAL)

START SOLENOID RELAY DIODE MODULE 8

RELAY KEY SWITCH INPUT

21234B R0

FUSES AND RELAYS - ELECTRICAL BOX - SN 2300872 TO 2301020 AND 2401072 TO 2401270 This Main Fuse and Relay electrical box is located in the engine compartment.

2.22

Tigercat 230B/240B Loader

Controls and Operation

240B-036

240B-035

MAIN FUSE AND RELAY ELECTRICAL BOX

FUSES AND RELAYS - ELECTRICAL BOX - S/N 2301021 AND UP, AND 2401271 AND UP This Main Fuse and Relay electrical box is located in the engine compartment.

2.23

Tigercat 230B/240B Loader 33

32

34

•

Controls and Operation

37

•

•• •• 244-020 247-23

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

PORTABLE FIRE EXTINGUISHER

37. FIRE EXTINGUISHER A portable fire extinguisher is located in operator's cab. The extinguisher should be checked daily to ensure that it is charged.

The pointer on the charge gauge should point to the green region. If the indicator falls out of this green area, the extinguisher should be serviced immediately.

33. 2 WAY RADIO Refer to component manufacturers manual.

34. LIGHT - DOME Push the switch on the side of the dome to turn the light ON and OFF. 35

••

36

•• 244-019

SLIDING WINDOWS HANDLE

244-060

38. WINDOWS 35. AM/FM STEREO RADIO/CD

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

Consult the operators manual for the tape deck with two rear mounted speakers.

36. WINDSHIELD WIPER/WASHER The wiper/washer rotary switch controls the windshield wiper. Turning the dial one setting clockwise, operates wiper on low speed.

CUP HOLDER

39

ASHTRAY

Turning the dial a setting further clockwise sets the wiper to high speed. To slow or turn off the wiper, turn the dial counterclockwise until the desired setting is reached.

•

•

•

To operate the washer function, press the dial. This function sprays washer fluid on the windshield.

240B-D15

WINDSHIELD WASHER FLUID

39. WINDSHIELD WASHER FLUID In cold climates, fill with an anti-freeze washer fluid. To avoid scratching NEVER operate the wipers on a dry windshield.

2.24

Tigercat 230B/240B Loader

Controls and Operation RIDE ADJUSTMENT After adjusting height, the ride adjustment should be made by turning the RIDE ADJUSTMENT KNOB counter-clockwise until the seat cushion is level.

4-WAY LUMBAR VERTICAL ADJUSTMENT 4-WAY LUMBAR HORIZONTAL ADJUSTMENT

4-WAY ADJUSTABLE LUMBAR To position lumbar mechanism vertically, move VERTICAL ADJUSTMENT KNOB up or down. For fore-and-aft displacement, rotate HORIZONTAL ADJUSTMENT KNOB.

••

RIDE ADJUSTMENT KNOB

BACK ANGLE ADJUSTMENT Rotate BACK ANGLE ADJUSTMENT KNOB to place seat at the desired angle.

• ••

FORE/AFT SLIDE Move and hold FORE/AFT SLIDE LEVER. Roll seat forward or backward to the desired position relative to the foot pedal controls.

• • FORE/AFT SLIDE LEVER 332-1X

•

SEAT ADJUSTMENTS

ARMREST ADJUSTMENT Each armrest has 2 adjustments to place it in the required position. Loosen adjustment locking wingbolts to reposition armrest height and fore/aft position.

BACK ANGLE ADJUSTMENT KNOB HEIGHT ADJUSTMENT LEVER

OPERATOR’S SEAT ADJUSTMENTS HEIGHT ADJUSTMENT The spring-assisted height adjustment is controlled by the HEIGHT ADJUSTMENT LEVER located on the front left side of the seat chassis.

The four height settings: top, bottom and two in between, provide a total height adjustment of 3”.

To Raise Firmly lift up on the HEIGHT ADJUSTMENT LEVER. When the lever releases, hold it up while partially lifting the operator’s body weight from the seat. When the seat is at the desired height, firmly push down on the lever until the seat locks (a click should be heard).

To Lower Firmly lift up on the HEIGHT ADJUSTMENT LEVER. When the lever releases, partially apply operator body weight to the seat until the seat is at the desired height, firmly push down on the lever. Hold lever down until the seat locks into position (a click should be heard).

2.25

Tigercat 230B/240B Loader

Controls and Operation RIDES TOO SOFT OR BOTTOMS OUT AND PINCHES OPERATOR The seat RIDE ADJUSTMENT KNOB has not been tightened (turned counter-clockwise) enough. Insufficient ride adjustment exaggerates the knee-action movement of the seat. This usually happens because the operator is trying to lower the seat by decreasing the amount of ride adjustment instead of using the HEIGHT ADJUSTMENT LEVER. Refer to HEIGHT ADJUSTMENT.

4-WAY LUMBAR HORIZONTAL ADJUSTMENT

• • • • 332-6

RIGHT SIDE OF SEAT

SEAT TOO HIGH/SEAT TOO LOW There are several things which can cause improper seat height. Refer to the HEIGHT ADJUSTMENT and adjust seat to the desired position. If the proper height cannot be reached using one of the four height adjustment settings, it may be necessary to install the seat on a higher base.

ARMREST ADJUSTMENT

PROBLEMS AND CORRECTIVE ACTION RIDES TOO STIFF/SEAT TENDS TO PUSH OR THROW OPERATOR FORWARD The RIDE ADJUSTMENT KNOB has been tightened (turned counter-clockwise) too much.

This typically happens because the operator is trying to use additional RIDE ADJUSTMENT KNOB rather than the HEIGHT ADJUSTMENT LEVER to raise the seat. Operator is riding the seat in the low height position setting. Refer to HEIGHT ADJUSTMENT.

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

2.26

Tigercat 230B/240B Loader

Controls and Operation

ENGINE COMPARTMENT

ENGINE COMPARTMENT ACCESS FRONT ENGINE COMPARTMENT ACCESS 240B-D17

There are 3 hinged doors and one removable panel provided to allow access to the engine compartment from all four sides. The doors are secured by a retaining knob on each door, unscrew this knob to release the door. The access panel is removed by lifting the latches outwards, tuning them 90° and then lifting the panel up and out.

240B-D16

ENGINE COMPARTMENT ACCESS LEFT SIDE RADIATOR

HINGE OUT A/C CONDENSER

•• •

OIL COOLER

206-6A

EARLIER MACHINES

•

ENGINE COMPARTMENT ACCESS RIGHT SIDE

240B-003

LATER MACHINES

BATTERY DISCONNECT SWITCH Located behind the front access panel, this switch completely disconnects all electrical circuits on the machine from the battery. Turn this switch to OFF whenever the machine is left unattended for an extended period of time (overnight etc.).

153-0A

ENGINE COMPARTMENT ACCESS REAR

2.27

Tigercat 230B/240B Loader

Controls and Operation HYDRAULIC OIL RESERVOIR

HYDRAULIC OIL FILTERS

•

••

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

HYDRAULIC OIL SIGHT GAUGE/ SENDER

•

•• ••

SUCTION TUBES

••

••

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

• •• ••

••

PILOT PUMP SUCTION LINE SHUT-OFF VALVE 240B-D18

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

•

RESERVOIR

HYDRAULIC PUMPS

•

SENDER HYD. OIL TEMP.

OIL FILL SHUT-OFF VALVE

HYDRAULIC OIL RESERVOIR

• HAND FILL PUMP

•• ••

SIGHT GAUGE

SUCTION HOSE IN STORED POSITION

•• 206-17A

LOW LEVEL SENDING UNIT

248-16

HYDRAULIC HAND FILL PUMP

HYDRAULIC HAND FILL PUMP The hydraulic hand fill pump is used to add oil to the hydraulic reservoir. It is located inside the engine compartment near the front left corner and is made accessible by removing the front access panel.

•

HYDRAULIC OIL SIGHT GAUGE/SENDER

2.28

Tigercat 230B/240B Loader

Controls and Operation

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

Remove hose clamp from end of suction hose, remove hose from stored position, thoroughly clean outside surface of suction hose and insert end into supply drum. Operate the pump by moving the handle back and forth at medium speed and a steady motion. The oil passes through the filters on the return lines of the hydraulic system. When the sight gauge reads between LOW and HIGH cease pumping and return handle to upright position. Close the oil fill shut off valve.

onto the manifold. To check the condition of the filter elements; With the hydraulic oil at normal operating temperature, place engine throttle control to FULL and with no machine functions operating, the filter restriction indicator should be in the GREEN zone. If the pointer is in the RED zone replace all four filter elements.

DOUBLE FILTER HEADS

RETURN MANIFOLD

••

••

••

AIR VENT

TOP RIGHT SIDE OF RESERVOIR

•

•

1-WATER ABSORBING RETURN FILTER (COLOUR BLUE)

FROM OIL COOLER "OUT"

3-HYDRAULIC RETURN FILTERS

•• ••

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

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

OIL COOLER BYPASS CHECK VALVE (50 PSI)

••

••

FROM HAND FILL PUMP

HYDRAULIC RETURN FILTERS

OIL SAMPLING CONNECTOR

FILTER RESTRICTION INDICATOR

•

AIR BREATHER VENT, HYDRAULIC RESERVOIR

•

HYDRAULIC RETURN FILTERS

358-17

358-24

•

••

•

CHECK VALVES

RETURN MANIFOLD

•

•

TO OIL COOLER "IN"

The majority of return oil entering the hydraulic tank passes through 4 spin-on hydraulic oil filters. One of the filters is a water absorbing filter (color blue) which is in place to assist with the removal of unwanted moisture from the hydraulic oil (the filters are rated 10m abs).

••

Each filter head has a bypass valve with a 25 psi cracking pressure so that oil can bypass the filters if they become restricted. The "in" side of the filter heads are connected to a return manifold. A filter restriction indicator and an oil sampling connector are mounted

CHECK VALVE

• FROM SWING VALVE

362-15

2.29

FROM STICK VALVE

FROM HOIST VALVE

HYDRAULIC OIL RETURN MANIFOLD

Tigercat 230B/240B Loader

Controls and Operation

LOCATED LOWER LEFT SIDE OF ENGINE COMPARTMENT

•• 205-23A

PILOT FILTER ELEMENT

HYDRAULIC PILOT FILTER

HYDRAULIC PILOT FILTER A single element filter head filters all pilot oil prior to entering the pilot system. The filter head has a built-in bypass valve with a 50 psi cracking pressure so that oil can bypass the filter if the element becomes restricted.

The return filters and the pilot filter should be checked and replaced as per the maintenance schedule in SECTION 3 of THIS 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, See SECTION 3 in THIS MANUAL. Use of hydraulic oil filters other than the Tigercat brand could lead to severe wear and rapid failure of hydraulic system components.

2.30

Tigercat 230B/240B Loader

Controls and Operation

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

• SAFETY ELEMENT

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

AIR INTAKE GRILL

INDICATOR

AIR INTAKE TUBE AIR FILTER

••

•

• 1/4" HOSE CONNECTION

•• 283-7A

••

•

PRIMARY ELEMENT

FILTER RESTRICTION INDICATOR AIR CLEANER .PLT

AIR FILTER ELEMENTS

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

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

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

AIR CLEANER UNLOADER VALVE 205-18A

AIR CLEANER UNLOADER VALVE

•• AIR CLEANER

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

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

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

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

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

Refer to SECTION 3 of THIS MANUAL for service intervals and additional AIR CLEANER MAINTENANCE instructions.

2.31

Tigercat 230B/240B Loader

Controls and Operation

FUEL TANK AND FILLER - EARLIER MACHINES

FUEL TANK AND FILLER - LATER MACHINES

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

The tank is located underneath the cab and has a capacity of 100 US gallons. The fuel filler is located on the front of the machine below the cab.

FILLER TUBE

•• FUEL SIGHT GAUGE

• FILLER TUBE

• FUEL SIGHT GAUGE

244-26

••

FUEL TANK AND FILLER

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

248-18

FUEL TANK AND FILLER

NOTE: EARLIER MACHINES: S/N 2300101 TO 2301015, AND 2400101 TO 2401245

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

LATER MACHINES: S/N 2301016, AND 2401246 & UP

AIR VENT PASSAGE

••

INNER FILL TUBE

•

248-20

FUEL FILL TUBE

2.32

Tigercat 230B/240B Loader

Controls and Operation

MACHINE OPERATION Prior to operating the machine, ensure that the proper lubrication and maintenance schedule has been performed as outlined in SECTION 3 of THIS MANUAL.

••

For the Diesel Engine supplied with the machine, Refer to the engine manufacturers operator’s manual .

FUEL SIGHT GAUGE

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

Read and understand this entire manual prior to operating machine.

248-20

CHECK FUEL LEVEL (later machines)

3. Check fuel level.

PRE-START CHECKS

SIGHT GAUGE

••

KEY SWITCH - OFF

240B-D05

1. Ensure Key switch is in the OFF position.

CHECK FIRE EXTINGUISHER

LOW LEVEL SENDING UNIT

• 247-23

PORTABLE FIRE EXTINGUISHER

•

2. Check fire extinguisher is sufficiently charged.

248-16

CHECK HYDRAULIC OIL LEVEL

4. Check that the hydraulic oil level is between the HIGH and LOW marks on the level gauge.

2.33

Tigercat 230B/240B Loader

Controls and Operation ENGINE OIL LEVEL DIPSTICK

ENGINE OIL LEVEL DIPSTICK

•• • 205-17A

CHECK ENGINE OIL LEVEL EARLIER MACHINES CHECK ENGINE OIL LEVEL

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

AIR FILTER RESTRICTION INDICATOR

240B-035

S/N 2300851 & UP, AND 2401001 & UP

AIR CLEANER

••

•

CHECK AIR FILTER

283-7AA

6. Check air filter restriction indicator.

SERPENTINE FAN BELT

•

• • FAN BELT

A/C COMPRESSOR BELT

• A/C COMPRESSOR BELT 230B-01

CHECK ENGINE BELT(S)

244-001

S/N 2300501 TO 2300850, AND 2400501 TO 2401000

CHECK ENGINE BELTS S/N 2300851 & UP, AND 2401001 & UP

7. Check tension and condition of all engine belts.

2.34

Tigercat 230B/240B Loader

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

FILLER CAP

•

••

CONNECTING HOSE TO GEARBOX

•

206-16A

SWING DRIVE GEARBOX OIL RESERVOIR

248-25 CHECK ENGINE COOLANT LEVEL 8. Check engine coolant level.

CONNECTING HOSE FROM OIL RESERVOIR

RADIATOR

••

HINGE OUT A/C CONDENSER

•

••

SWING DRIVE MOTOR

• ••

•• OIL FILL TUBE

OIL COOLER 206-6A

SWING DRIVE GEARBOX

CLEAN RADIATOR AND OIL COOLER

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

206-15A

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

• SWING DRIVE GEARBOX

12. Check swing drive gearbox oil level.

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

RESERVOIR

••

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

CHECK WINDSHIELD WASHER LEVEL 11. Check windshield washer fluid level.

240B-D15

2.35

Tigercat 230B/240B Loader

Controls and Operation

STARTING THE ENGINE

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

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

2. Sound horn to warn personnel of machine start-up.

2. Ensure key is turn to OFF.

3. Move the throttle control to LOW IDLE position

4. Remove engine fuel filter and fill with clean fuel.

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

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

3. Refill fuel tank completely.

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

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

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

Serious injury or property damage may result.

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

If engine fails to start, refer to engine manufacturers maintenance manual.

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

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

2.36

Tigercat 230B/240B Loader

Controls and Operation

SETTING THE MACHINE

WARNING

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

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

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

VERTICAL CENTERLINE

LOWER FRAME

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

Ensure loader is sufficiently stable to perform all log loading operations.

•

COUNTERBALANCE VALVE

•

(c) Stabilizers should be lowered so that the weight is just taken off the trailer tires and the loader is level. The machine should not be operated with the stabilizer cylinders fully extended; they should have at least 1/2" of unused stroke so that the counterbalance valves may relieve pressure build up caused by an increase in temperature.

STABILIZER UP IN VERTICAL POSITION

• • •

CYLINDER

STABILIZER COUNTERBALANCE/CHECK CARTRIDGE REMOVAL

230-06A

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

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

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

2.37

Tigercat 230B/240B Loader

Controls and Operation

MACHINE PREPARATION

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

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

Warm up the hydraulic system.

•

Test all systems for proper operation.

•

Inspect for hydraulic oil leaks.

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

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

(n) Lower the grapple onto the trailer or stable ground ensuring grapple and booms are fully supported. (o) Lower the throttle control to LOW IDLE.

(a) Perform PRE-START CHECKS, STARTING THE ENGINE and SETTING THE MACHINE procedures as outlined in THIS SECTION.

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

(b) Sound horn to warn personnel of machine operation. (c) Ensure gauges and warning lights are indicating normal operating conditions. (d) Check that all personnel are safe and clear of the machine.

WARNING

(e) Ensure both armrests are in the lowered position and press the PILOT RESET button. (f) Raise the throttle control to MID position. (g) Ensure all stabilizers are firmly set on level, stable ground.

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

(h) Ensure grapple and booms are not attached, chained or clamped around trailer or any other stationary object. (i) Slowly raise and lower the hoist boom and stick boom and check for proper operation. (j) With the grapple raised slightly off the ground, test the grapple rotate in both directions and test the open and close functions. (k) Operate the swing in both direction to ensure proper operation. (l) Test all accessory equipment including delimber, top saw, slasher saw etc.

2.38

Tigercat 230B/240B Loader

Controls and Operation

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

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

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

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

4. Do not race engine before shut-off 5. Stop engine by turning Key switch to the OFF position.

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

2.39

Tigercat 230B/240B Loader

Controls and Operation

LOADER MOUNTING/INSTALLATION

YOKE

The mounting procedure will vary with the type of trailer being used. The following procedure is intended as a guide for mounting the loader on a typical I-beam or Channel beam trailer. The procedure may not be complete or may differ from the actual method or procedure used.

•

• •

NUTS WASHERS

TRAILER

•

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

• LOADER LOWER FRAME

•

WASHERS

• • •

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

NUTS

• YOKE STUDS

YOKE 230B-02

TRAILER MOUNTING

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

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

3. Ensure that trailer is stable and will not move.

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

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

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

8. Ensure installation conforms to all applicable regulations.

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

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

2.40

Tigercat 230B/240B Loader

Controls and Operation

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

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

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

1. Perform Loader Mounting/Installation as described in LOADER MOUNTING/ INSTALLATION in THIS SECTION. 2. Start loader and rest or attach grapple and/or boom to the trailer such that they are sufficiently secure and are within all height and width restrictions. Refer to trailer manufacturer for information on proper location and procedure for attaching grapple and/or booms.

3. Raise all four stabilizers to their fully upright positions. Turn off the machine and turn the battery disconnect switch to OFF. 4. Ensure that the setup conforms to all applicable local, state, provincial and federal regulations for mounting and transporting equipment. Check height, width and weight restrictions.

2.41

Tigercat 230B/240B Loader

Controls and Operation

CARE OF THE MACHINE

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

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

Some important Dont’s

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

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

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

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

4. Never apply a load to a cold engine.

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

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

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

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

Compatible Cleaning Agents Aqueous solutions of soaps and detergents

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

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

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

CLEANING LEXAN WINDOWS (Windshield and Skylight)

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

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

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

GASOLINE SHOULD NOT BE USED.

3. Rinse with lukewarm water.

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

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

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

Removing hairline Scratches.

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

2.42

Tigercat 230B/240B Loader

SECTION 3 - LUBRICATION & MAINTENANCE JUNE, 2005

CONTENTS - SECTION 3 AIR CLEANER ............................................................................................. 3.10 AIR CLEANER MAINTENANCE .................................................................. 3.11 AIR CONDITIONING - SERVICE ................................................................. 3.12 EMERGENCY EXITS, CHECK MONTHLY .................................................... 3.3 FILTERS ENGINE AIR FILTER ................................................................................ 3.10 HYDRAULIC RETURN ............................................................................... 3.8 PILOT RETURN PRESSURE FILTER ....................................................... 3.9 FIRE PREVENTION ....................................................................................... 3.3 GENERAL ...................................................................................................... 3.3 HYDRAULIC OILS ......................................................................................... 3.5 LUBRICATING CYLINDER PINS AND BOOM JOINTS ............................... 3.4 LUBRICATION POINTS ................................................................................. 3.6 NEW MACHINE MAINTENANCE .................................................................. 3.2 FIRST 50-100 HOUR INSPECTION AND SERVICE REPORT .................. 3.2 INITIAL PRE-DELIVERY INSPECTION ...................................................... 3.2 TIGHTENING POINTS ............................................................................... 3.2 OIL LOST FROM LEAKAGE CHART ............................................................ 3.2 PILOT RETURN PRESSURE FILTER ........................................................... 3.9 PRESSURE SETTING PROCEDURES. SEE SERVICE MANUAL PRESSURE SETTINGS .............................................................................. 3.15 PREVENTIVE MAINTENANCE SCHEDULE ................................................. 3.2 SCHEDULED MAINTENANCE EVERY 8 HOURS: ...................................................................................... 3.4 EVERY 24 HOURS: .................................................................................... 3.4 EVERY 125 HOURS ................................................................................... 3.4 EVERY 250 HOURS ................................................................................... 3.5 EVERY 500 HOURS: .................................................................................. 3.5 EVERY 1000 HOURS ................................................................................. 3.5 EVERY 2000 HOURS ................................................................................. 3.5 SERVICE AND LUBRICATION POINTS ....................................................... 3.7 TIGHTENING POINTS................................................................................... 3.2 TORQUE CHART, GENERAL ..................................................................... 3.14 TORQUE SETTINGS, RECOMMENDED .................................................... 3.13 NOTE:

EARLY MACHINES: S/N 2300501 TO 2300850, AND 2400501 TO 2401000 LATER MACHINES: S/N 2300851 & UP, AND 2401001 & UP POSITIVE BATTERY DISCONNECT: S/N 2301021 & UP, 2401271 & UP

Tigercat 230B/240B Loader

Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE FOR 230B/240B LOADER NEW MACHINE MAINTENANCE

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

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

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

Tightening points:~

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

All hydraulic connections Hose clamps Pin retainers Check torque on swing bearing retaining bolts Engine mounting bolts

OIL LOST FROM LEAKAGE

Pump mounting bolts

LOST 0IL (GALLONS) PER PER PER DAY MONTH YEAR LEAKAGE RATE ONE DROP IN 10 SECONDS 0.112 3.36 40.0 ONE DROP IN 5 SECONDS 0.225 6.75 81.0 ONE DROP SECOND 1.125 33.75 405.0 THREE DROP PER SECOND 3.75 112.5 1,350.0 DROPS BREAK INTO STREAM 24.00 720.0 8,640.0

Pilot pump mounting bolts Swing gearbox mounting bolts Swing motor mounting bolts Cab securing bolts Boom pin nuts Trailer mounting studs Any other loose nut, bolt or fitting

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

3.2

Tigercat 230B/240B Loader

Lubrication and Maintenance

GENERAL Clean around filler caps before checking or adding fluids.

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

CHECK EMERGENCY EXITS, MONTHLY:~ An alternate exit route is provided: skylight/ emergency exit. This exit is only to be used if the side door cannot be opened.

It is therefore essential that this emergency exit be checked at least once per month to ensure it is fully operational.

Clean up spills as soon as possible.

Always use clean oil and containers.

Drain dirty oil while still warm.

Do not exceed recommended fluid levels.

Service all hydraulic filters after the failure of a pump, motor, cylinder or valve. Failures of this nature could contaminate the entire hydraulic system.

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

Refer to EMERGENCY EXIT MAINTENANCE GUIDE in SECTION 2 of the OPERATOR'S MANUAL for checking procedure.

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

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

Clean up oil spills in engine enclosure immediately.

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

CAUTION

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

Clean away all branches, bark and chips.

Clean up all traces of oil to avoid fires.

Inspect the EXHAUST SYSTEM DAILY for any signs of LEAKAGE. Check for worn, cracked, broken, or damaged pipes or muffler.

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

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

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

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

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

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

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

Always have a fire extinguisher at hand.

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

3.3

Also refer to FIRE PREVENTION in SECTION 1 of THIS MANUAL for additional information.

Tigercat 230B/240B Loader

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 8 HOURS:~

• Condition and tension of fan belts.

• Check engine coolant level

• Conduct an overall visual inspection.

• Check engine oil level

• Exhaust system for leaks.

• Drain fuel/water separator

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

• Check swing gearbox oil level. Fill reservoir to half way mark.

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

EVERY 24 HOURS:~ • Perform 8 hour maintenance

• Check hydraulic oil level

And in addition:~ • Lubricate stabilizer arm pins; 8-fittings - purge

Lubricate:~ • Swing bearing; 1-fitting - 4 shots while swinging • Swing pinion; 1-fitting - 10 shots while swinging

• Lubricate stabilizer cylinders; 8-fittings - purge

• * Boom joint; 2-fittings - purge

• Lubricate grapple rotate bearing; 1-fitting - 4 shots, rotate 90° after each shot

• * Stick joint; 2-fittings - purge

EVERY 125 HOURS:~

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

• Perform 8 hour maintenance • Perform 24 hour maintenance

*Lubricating cylinder pins and boom joints:-

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

1. Ensure machine is on level ground 2. Fully extend stick boom cylinder

• Check hydraulic oil return filter restriction indicator on filter return manifold with engine running at high idle and oil flow

3. Lower main boom and rest grapple firmly on ground or stable trailer 4. While in this position lubricate all cylinder retaining pins and boom joints

Check:~ • Fluid level in batteries unless maintenance free

• Yoke pins; 2-fittings - purge

• Engine RPM

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

• All hydraulic pressures • Hydraulic pumps and motor securing bolts

• Grapple arm pins; 6-fittings - purge

• Torque tightening points as per new machine maintenance

• Grapple cylinder pins; 4-fittings - purge

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

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

• Lower frame, stabilizer arms and cylinders

• Remove potentially damaging limbs or sticks and all debris

• Swing bearing area

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

Make repairs immediately

• Attachment

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

• For loose nuts, bolts and fittings

• Wear in any other components 3.4

Tigercat 230B/240B Loader

Lubrication and Maintenance

SCHEDULED MAINTENANCE Clean/replace:~ • Air conditioner re-circulation filter

EVERY 1000 HOURS:~

• Cab fresh air filter

• Perform 8 hour maintenance

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

• Perform 24 hour maintenance • Perform 125 hour maintenance • Perform 250 hour maintenance • Perform 500 hour maintenance

EVERY 250 HOURS:~

And in addition:~ • Check intank fuel strainer. Drain tank, clean or replace as necessary.

• Perform 8 hour maintenance • Perform 24 hour maintenance

• Replace air cleaner unloader valve.

• Perform 125 hour maintenance And in addition:~ • Replace engine oil and filter

EVERY 2000 HOURS:~

• Replace engine fuel filter

• Perform 8 hour maintenance

• Replace fuel/water separator filter

• Perform 24 hour maintenance

• Replace air cleaner primary element

• Perform 125 hour maintenance

• Check fire extinguisher and turn it to mix contents

• Perform 250 hour maintenance

• Check torque on trailer mounting studs.

• Perform 1000 hour maintenance

• Perform 500 hour maintenance

• Perform 24 hour maintenance

And in addition:~ • Drain and refill hydraulic oil tank with recommended hydraulic oil. Refer to APPROVED HYDRAULIC OILS in THIS SECTION.

• Perform 125 hour maintenance

______________________________________________

EVERY 500 HOURS:~ • Perform 8 hour maintenance

• Perform 250 hour maintenance

APPROVED HYDRAULIC OILS

And in addition:~ • Replace air cleaner safety element • Replace hydraulic oil return filters †

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

• Replace hydraulic oil pilot pressure filter † • Replace oil in swing gearbox. Fill reservoir to half way mark

Chevron

Mechanism LPS 68 (summer)

Citgo

Mystik HVI-68 (summer)

• Lubricate door and cover hinges; 8 fittings - 1 shot

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

Check:~ • Torque on swing bearing and swing gearbox retaining bolts

Shell

Tellus T68 (summer) Tellus T22 (winter)

Texaco

Rando HDZ 68 (summer)

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

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

3.5

Tigercat 230B/240B Loader

Lubrication and Maintenance

DOOR HINGES 2 FTG/500

SWING BEARING 1 FTG/8 13 12

4 SHOTS WHILE SWINGING

5 1

SWING PINION 1 FTG/8

4

10 SHOTS WHILE SWINGING

2 3 6 7

DOOR HINGES 2 FTG/500 8

9

STICK JOINT 2 FTG/8

9

BOOM JOINT 2 FTG/8

YOKE PINS 2 FTG/8

DOOR HINGES 4 FTG/500

11

10

•

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

11 12

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

GRAPPLE ARM PINS 6 FTG/8

STABILIZER ARM JOINTS AND CYLINDERS 16 FTG/24

CYLINDER PINS 4 FTG/8

230B240B LUBCHART R1.EPS

3.6

SERVICE AND LUBRICATION POINTS

Tigercat 230B/240B Loader

Lubrication and Maintenance

Tigercat® 230B/240B Loader SERVICE AND LUBRICATION POINTS REFER TO Tigercat OPERATOR’S MANUAL FOR ADDITIONAL INFORMATION

34

9

24

6.3

60/40 ANTIFREEZE/DISTILLEDWATER **

1

COOLING SYSTEM

CHK

2

ENGINE OIL AND FILTER CUMMINS 'C'

CHK

REP

3

FUEL FILTER (ENGINE)

REP

1

4

FUEL/WATER SEPARATOR

DRN

REP

1

5

INTANK FUEL STRAINER

CHK

AIR CLEANER PRIMARY ELEMENT

SEE ENGINE MANUFACTURER'S SERVICE MANUAL

1

CHK REP

1

6 AIR CLEANER SAFETY ELEMENT

REP

7

AIR CLEANER UNLOADER VALVE

CHK

8

HYDRAULIC RESERVOIR

CHK

1 REP

D/R 350

92

DESCRIPTION

QTY

US GAL

CHANGE COOLANT EVERY 2 YEARS

LITER

2000

CAPACITY

1000

500

250

ITEM

125

SERVICE EVERY 8

SERVICE POINT NO.

®

DRAIN TANK, CLEAN OR REPLACE AS NECESSARY CHECK AIR CLEANER FILTER RESTRICTION INDICATOR AT FULL ENGINE RPM

1

REFER TO OPERATOR'S MANUAL SECTION 2 FOR DETAILS

1

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

4

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

RETURN FILTERS † 9

3-STANDARD FILTERS 1-WATER ABSORBING FILTER COLOUR BLUE

10

PRESSURE FILTER, PILOT †

11

SWING GEARBOX

12

CHK

REP

REP CHK

GRAPPLE, Tigercat

FIRE EXTINGUISHER

†

†

1

† HALF FILL RESERVOIR WITH SAE 75W90 EP OIL

SEE LUBRICATION POINTS DIAGRAM SEE MANUFACTURER'S MAINTENANCE SCHEDULE

GRAPPLE, OTHER MANUFACTURERS 13

1

D/R

CHK

1

TURN TO MIX CONTENTS

LEGEND LUBRICATION POINT WITH A DESIGNATED NUMBER OF FITTINGS ** ANTIFREEZE MUST MEET GM 6038M SPECIFICATIONS - SEE ENGINE MANUFACTURER'S MAINTENANCE MANUAL.

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

230B/240B LUBCHART R1.XLS

3.7

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

Tigercat 230B/240B Loader

Lubrication and Maintenance DOUBLE FILTER HEADS

RETURN MANIFOLD

•

•

•

FILTER HEAD

• GASKET

•

•

FILTER ELEMENT

SQUARE SECTION GASKET INSTALLATION FILTR_SEALS 2

••

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

••

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.

•• 3-HYDRAULIC RETURN FILTERS

HYDRAULIC RETURN FILTERS

HYDRAULIC RETURN FILTERS

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

The majority of return oil entering the hydraulic tank passes through 4 spin-on hydraulic oil filters. One of the filters is a water absorbing filter (color blue) which is in place to assist with the removal of unwanted moisture from the hydraulic oil (the filters are rated 10m abs).

FILTER HEAD

•

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

• GASKET

• FILTR_SEALS 2

FILTER ELEMENT

'O' RING GASKET INSTALLATION

z 'O' Ring Gasket

Changing the filters: 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.

Remove used gasket and clean gasket seat in head.

Apply clean oil to new gasket surfaces.

Install new gasket on inside lip of filter.

Screw on new filter until gasket makes contact.

Tighten filter until top edge makes metal to metal contact with filter head. (approximately 1 1/2 additional turns after gasket contact) DO NOT use bottom nut for filter installation or damage/leakage may result. Bottom nut is to assist in filter removal only.

4. Wearing face protection (in case of an oil squirt), unscrew the old filter. Dispose of old filter and 10. Start the engine and check for leaks. any oil properly.

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

3.8

Tigercat 230B/240B Loader

Lubrication and Maintenance 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.

LOCATED LOWER LEFT SIDE OF ENGINE COMPARTMENT

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

9. Start the engine and check for leaks.

•• PILOT FILTER ELEMENT

205-23A

HYDRAULIC PILOT FILTER

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

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

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

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

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.

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. Use of hydraulic oil filters other than the Tigercat brand could lead to severe wear and rapid failure of hydraulic system components.

3.9

Tigercat 230B/240B Loader

Lubrication and Maintenance

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

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

AIR INTAKE GRILL

INDICATOR

AIR CLEANER UNLOADER VALVE

AIR INTAKE TUBE AIR FILTER

••

••

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

205-18A

•• 1/4" HOSE CONNECTION

•• 283-7A

•

••

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

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

FILTER RESTRICTION INDICATOR

FILTER RESTRICTION INDICATOR A filter restriction indicator is located in the engine enclosure beside the air intake grill. The indicator is remote mounted and is connected to the outlet side of the air filter with a 1/4" diameter hose. Service to the filter is required when the indicator shows RED. This indicator provides a continuous reading whether the engine is running or is shut down. After servicing the filter, reset the indicator by pressing down on the reset button.

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

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

3.10

Tigercat 230B/240B Loader

Lubrication and Maintenance

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

•

AIR CLEANER MAINTENANCE The most common and most damaging air intake servicing problems are:

SAFETY ELEMENT

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

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

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

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

•

IMPROPER SERVICING Engine exposure to dust during servicing is the largest single factor contributing to engine damage due to dust. Abrasive dust can easily enter the intake system once the air cleaner element has been removed for replacement.

The safety element reduces the risk, however it must also be replaced at every third primary element change.

AIR CLEANER .PLT

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

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

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

4. Always clean the inside of the outlet tube.

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

6. Inspect the new filter for damage.

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

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

3.11

PRIMARY ELEMENT

AIR FILTER ELEMENTS

Tigercat 230B/240B Loader AIR CONDITIONING - SERVICE

Lubrication and Maintenance CAUTION

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

R134a REFRIGERANT 2 LBS. 12 OZ.

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

•

A/C COMPRESSOR EARLIER MACHINES

249-17B

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

A/C COMPRESSOR 240B-037

S/N 2300851, AND 2401001 & UP

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 3.12

Tigercat 230B/240B Loader

Lubrication and Maintenance

TORQUE CHART LOCATION

THREAD DIAMETER

TORQUE (LUBRICATED) lbf-ft Nm

Cylinders Piston nut, stabilizer cylinders 2 1/4"-12 UNF (GC) Piston nut, main boom cylinder 2 1/2"-12 UNF (GC) Piston nut, stick cylinder 2 1/2"-12 UNF (GC) Piston nut, heel cylinder 2 1/4"-12 UNF (GC) Piston nut, grapple cylinder 1 3/4"-12 UNF (GC) Gland, grapple cylinder 4 1/2" I/D CYLINDER Gland, stabilizer cylinder 6" I/D CYLINDER Keeper plate bolts, heel cylinder 3/4"-10 UNC (G8) Keeper plate bolts, Main boom cylinder 7/8"-14 UNF (G8) Keeper plate bolts, Stick boom cylinder 3/4"-16 UNF (G8)

2100 3200 3200 2100 1750 450 450 275-325 300-325 240-270

2835 4320 4320 2835 2355 607 607 370-440 405-440 323-363

Boom joint and cylinder pin retaining bolts

3/4"-10 UNC (G8)

282-310

393-420

Main and Stick boom pin retaining nut

2"-12 UNF (G8)

400

540

Grapple to Stick boom pin retaining nut

1 3/4"-12 UNF (G8)

400

540

Cab securing bolts Trailer mounting studs

7/8"-9 UNC (G8) 1 1/4"-7 UNC (G5)

450-500 500

610-680 680

7/8"-9 UNC (G8) 7/8"-9 UNC (Cat bolts) 5/8"-11 UNC (G8) M14-2 (10.9)

400-450 450-500 160-175 130

540-610 610-680 215-235 175

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

7/8"-9 UNC (G8) M12-1.75 (10.9) M10-1.5 (12.9)

450-500 75 63 40

610-680 100 83 54

Pump drive Drive plate to flywheel Bell housing to engine

3/8"-16 UNC (G8) M10-1.5 (10.5)

40 45

54 60

*

Swing bearing bolts Swing bearing bolts, Track machine Swing gearbox mounting bolts Swing motor mounting bolts

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

*Refer to LOADER MOUNTING/INSTALLATION in SECTION 2 of the OPERATOR'S MANUAL for additional precautionary information.

3.13

Tigercat 230B/240B 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 1000 1350

1150 1700 2300

850 1250 1700

1075 1600 2150

800 1150 1600

1350 2000 2700

1000 1500 2000

M33 M36

900 1150

675 850

1150 1450

850 1075

1750 2250

1300 1650

2200 2850

1650 2100

2500 3200

1850 2350

3150 4050

2350 3000

2900 3750

2150 2750

3700 4750

2750 3500

ISSUE 3 800

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

3.14

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

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

Tigercat 230B/240B Loader

Lubrication and Maintenance

PRESSURE SETTINGS SERIAL NUMBER

Pilot relief valve

2300501 and up

2400501 and up

450

450

Port relief grapple rotate ccw Port relief grapple rotate cw

2500* 1750 1750

2600* 1750 1750

Port relief stick out Port relief stick in

3000*** 1500

3000*** 1500

Port relief saw retract Port relief slasher cut

1500 3000***

1500 3000***

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

2500* 3000*** 3000***

2600* 3000*** 3000***

Port relief hoist up Port relief hoist down

3000*** 1500

3000*** 1500

Port relief spare Port relief top saw cut

3000*** 3000***

3000*** 3000***

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

2500* 3000*** 3000***

2500* 3000*** 3000***

Port relief stabilizers down Port relief stabilizers up

3000*** 2000***

3000*** 2000***

Port relief delimber open Port relief spare

3000*** 3000***

3000*** 3000***

Crossline reliefs swing motor

1650

2000

Main relief stick valve

* Do not adjust pressure over 3000 psi or pump 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

3.15

Tigercat 230B/240B Loader

Lubrication and Maintenance

3.16