Tigercat 234 LOADER SERVICE MANUAL SN 2340601-2342000 - PDF DOWNLOAD

234 LOADER

SERVICE MANUAL

SERIAL NUMBER 2340601 TO 2342000

ISSUE 2.0, JULY 2015 Tigercat Industries Inc. P.O. Box 637 Brantford, Ontario Canada N3T 5P9 Tel: (519) 753-2000 Fax: (519) 753-8272

Tigercat 234 Loader

Introduction

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Tigercat 234 Loader

Introduction

Tigercat 234 LOADER TABLE OF CONTENTS

SECTION INTRODUCTION ............................................................................................................................. v NON-APPROVED FIELD PRODUCT CHANGES.......................................................................... vi SAFETY........................................................................................................................................... 1 CONTROLS AND OPERATION ...........................................See separate OPERATOR'S MANUAL LUBRICATION AND MAINTENANCE ............................................................................................. 3 HYDRAULIC SYSTEM .................................................................................................................... 4 PILOT SYSTEM .............................................................................................................................. 5 ELECTRICAL SYSTEM AND COMPUTER .................................................................................... 6 ENGINE AND ANTI-STALL.............................................................................................................. 7 RADIATOR, OIL COOLER AND CHARGE AIR COOLER............................................................. 10 BOOM FUNCTIONS...................................................................................................................... 12 SWING .......................................................................................................................................... 15 STABILIZERS ................................................................................................................................ 16 GRAPPLE...................................................................................................................................... 17 DELIMBER/SLASHER .................................................................................................................. 18

CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.

234 Available Literature Operator's Manual (2340101 to 2340600)...........................................................................Part No. 29466A Operator's Manual (2340601 to 2342000)...........................................................................Part No. 35176A Service Manual (2340101 to 2340600) ...............................................................................Part No. 29467A Service Manual (This Manual) (2340601 to 2342000) ........................................................Part No. 35177A Parts Catalog .......................................................................................................................Part No. 29468A iii

Tigercat 234 Loader

Introduction

iv

Tigercat 234 Loader Tigercat 234 Loader

Introduction

INTRODUCTION An Operator's manual, Service manual and a Parts catalog are made available by Tigercat to assist the dealer, customer and operator in becoming familiar with the features of the 234 Loaders.

Serial numbers 2340601 to 2342000 The 234 Loader is designed for log processing, sorting, log transfering and loading.

The operator's manual will assist the operator with the techniques of proper and safe operation of the 234 Loader. There is also important information regarding the safe operation of the attachment. The service manual contains safety and servicing procedures and a preventive maintenance schedule to ensure optimum machine performance. ,,,,

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

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

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

The phrase “and up” appearing in this manual after the serial number implies that the related information is current for any machine serial number HIGHER than the serial number preceding the “and up”.

Tigercat reserves the right to make changes to the machine after this manual release date that may not immediately appear in this manual.

Every effort is made to send out updates on a regular basis. If the machine in question was built after the release date of this manual and there is a discrepancy, call Tigercat service department. The release date appears on the first page.

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

Tigercat Industries Inc.

v

Tigercat 234 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.

vi

Tigercat 234 Loader SECTION 1 – SAFETY Read and understand this safety section prior to operating any equipment.

Read and understand all manuals for any attachments or accessories.

CONTENTS - SECTION 1

ISSUE 3.0, JULY, 2015

ARTICULATION LOCK............................................................................................................................. 1.33 BATTERY DISCONNECT SWITCH........................................................................................................... 1.9 BATTERY SAFETY.................................................................................................................................... 1.6 CAB EXITS.................................................................................................................................................1.7 COOLING SYSTEM................................................................................................................................. 1.14 EMERGENCY CAB EXITS......................................................................................................................... 1.7 ENGINE DOORS...................................................................................................................................... 1.15 EXHAUST FUMES................................................................................................................................... 1.15 FIRE PREVENTION................................................................................................................................. 1.21 DRY CHEMICAL CLEANUP PROCEDURES....................................................................................... 1.25 FIRE PREVENTION GUIDELINES....................................................................................................... 1.21 WHAT TO DO AFTER A MACHINE FIRE HAS OCCURRED............................................................... 1.24 WHAT TO DO TO PREPARE FOR A MACHINE FIRE......................................................................... 1.22 WHAT TO DO WHEN A MACHINE FIRE OCCURS............................................................................. 1.23 FLUID INJECTION INJURY..................................................................................................................... 1.16 FLUID LEAKS.......................................................................................................................................... 1.11 GREASE INJECTION INJURY................................................................................................................. 1.17 HYDRAULIC PRESSURE HAZARD........................................................................................................ 1.11 LIGHTNING SAFETY AWARENESS LIGHTNING SAFETY........................................................................................................................... 1.18 WHAT IS A LIGHTNING STRIKE?........................................................................................................ 1.18 LOOSE CLOTHING HAZARD.................................................................................................................. 1.15 PARKING THE MACHINE........................................................................................................................ 1.10 PROTECTIVE CLOTHING......................................................................................................................... 1.2 SAFE REMOVAL OF COUNTERBALANCE AND CHECK CARTRIDGE................................................ 1.13 SAFETY INTERLOCK SWITCH................................................................................................................. 1.8 SAFETY LABELS..................................................................................................................................... 1.26 SAFETY PRECAUTIONS, GENERAL....................................................................................................... 1.2 SAFETY PRECAUTIONS, OPERATING.................................................................................................... 1.7 SAFETY PRECAUTIONS, SERVICING................................................................................................... 1.11 SAFETY SYMBOLS................................................................................................................................... 1.2 SIGNAL WORDS........................................................................................................................................ 1.2 WELDING, PRIOR TO............................................................................................................................. 1.12 WORKING WITH OIL................................................................................................................................. 1.4

Tigercat 234 Loader

Safety

GENERAL SAFETY PRECAUTIONS

SAFETY SYMBOLS

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.

This safety alert symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Always read the operator's manual before operating the machine. Pay close attention to WARNINGS and HAZARD identifications

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

Follow all instructions from safety inspector and supervisors.

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

You must be fully trained to operate this piece of equipment. Know the capabilities and the limitations of the equipment. Learn the most efficient operating techniques.

WARNING

Do not let untrained persons operate the machine.

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

CAUTION CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

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

These safety rules highlight both general and specific measures that the operator should be familiar with and adhere to. More specific measures are illustrated with pictograms which may also be attached to the machine in locations pertinent to their respective message. Keep safety labels in good condition. Repair or replace damaged labels.

1.2

Tigercat 234 Loader

Safety Always use the handrails and steps provided when mounting and dismounting from the machine.

Do not jump off the machine at any time.

Do not try to climb onto or off of a moving machine.

Do not use the seat armrest or joystick as handle when entering or leaving the cab.

43424BUNI R0

KEEP CLEAR All personnel should be made AWARE of the HAZARD ZONE and be kept clear of this zone and it should be considered off limits to all individuals while the machine is operating.

Do not use the machine foot controls as steps.

The HAZARD ZONE is the area around the machine when the machine is being operated.

When approaching an operating machine on foot, keep a safe distance 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 the attachment resting securely on stable ground before advancing to the machine.

When mounting or dismounting the machine always use the 3 point technique; use 1 hand with 2 feet or 2 hands with 1 foot.

Always avoid the discharge path of all saws.

WARNING

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.

Avoid mounting or dismounting the machine in areas with slippery surfaces. Dry, deice, clean up or cover slippery surfaces with an anti-slip material before mounting or dismounting the machine.

1.3

Tigercat 234 Loader

Safety Check protective windows for cracks, a damaged window has reduced strength to stop flying objects. All damaged windows must be replaced with original equipment.

GENERAL SAFETY PRECAUTIONS continued

Check windows for scratching, crazing and cloudiness that could impair clear visibility all around the machine.

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

Check all fluid levels.

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

WARNING Do not walk on machine surfaces with steel cleated foot wear. Steel cleats on steel surfaces are slippery and do not provide a safe foot hold.

WARNING It is not recommended to walk on machine surfaces that are not designated walking areas.

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

No attempt should be made to walk on angled steel surfaces or surfaces that are irregular in shape.

Working with oil Direct contact with oil implies a risk of skin complaints (example: eczema). Strict hygiene should always be observed.

Walking surfaces on the machine must be covered with anti-slip materials to provide a safe foot hold and prevent slipping.

Some advice which should be observed:

These anti-slip surfaces should be maintained on a regular basis. If the surface shows signs of wear, the anti-slip material must be replaced immediately.

• • •

To reduce risk of fire, 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, always shut off engine before cleaning machine.

•

• •

Maintain a clean cab interior, clear away trash or debris.

•

Machine should be washed completely at every major service.

•

Inspect the machine daily for signs of damage or unusual wear, to structures.

• •

Check for fluid leaks, or faulty operation. Repair or replace malfunctioning parts and systems immediately.

Check windows and door guards for damage.

1.4

Oils used in this machine may be hot enough to cause serious burns.

Avoid contact with oil, particularly heated oil.

Oil on the skin should be washed off immediately with soap and water.

Wear protective gloves. Hands should be clean before putting on gloves. Apply protective cream to the hands to make washing easier.

Don't put oily rags in your pockets.

Oil soiled clothing should be changed as soon as possible.

Always keep an extra overall handy, but not in the machine where it can become dirty.

Cuts and abrasions must be attended to immediately. Clean them and apply first-aid.

Avoid breathing in oil fumes.

Wash hands and arms frequently (example: at each meal break or as often as possible).

Tigercat 234 Loader

Safety Approach with extreme caution any area where overhanging electrical power lines 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.

GENERAL SAFETY PRECAUTIONS continued Safety Hazards - Viton Seals O-rings and other seals manufactured of Viton material (fluorine rubber) produce a highly corrosive acid (Hydrofluoric) when subjected to temperatures above 600°F (315°C).

Maintain a distance of 10 ft. (3m) between the machine or boom and any power line carrying up to 50,000 volts or less plus 1/2 inch (10mm) for each addition 1,000 volts above the 50,000 volt level.

This contamination can have extreme consequences on human tissue since it is almost impossible to remove after contact.

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.

The following procedures are recommended when inspecting equipment that has been subjected to high temperatures such as fire: •

Visually inspect any seals or gaskets which have suffered from heat; they will appear black and sticky.

•

If these are found, Do Not Touch!!!

•

Determine the material composition of any seals or gaskets, If fluoro-elastomer seals (Viton, fluorel, or tecmoflon) have been used, the affected area must be decontaminated before undertaking further work. Natural rubber and nitrile materials are not hazardous.

•

Disposable heavy duty gloves (neoprene) must be worn and the affected area decontaminated by washing thoroughly with limewater (Calcium Hydroxide solution).

•

Any cloths, residue and gloves must be safely discarded after use.

If the machine must be transported, make sure that it is adequately secured to the transporting vehicle. Refer to tranporting instructions in SECTION 2 of the OPERATOR'S MANUAL. Stopping the engine immediately after it has been working under load can result in overheating and premature wear of the engine components.

Reduce engine speed to LOW IDLE and let run for approximately 5 minutes to allow gradual dissipation of heat and also to reduce turbo speed. This will also prevent loss of coolant by after boil and possible hot spot damage to the engine.

Be aware when performing service and maintenance tasks that surfaces and grab handles in and around the engine and cooling system may become very hot when the engine has been running. Contact with hot surfaces may cause injury.

NOTE: Burning discarded items is not recommended except in an approved incineration process where the dangerous products are treated by alkaline scrubbing.

Safety Hazards - Operating Maintain a charged fire extinguisher on the vehicle at all times and KNOW HOW TO USE IT.

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

Do not carry passengers either in the cab or anywhere else on the machine. The vehicle is provided and approved with seating for the operator only.

Read, understand and follow all general safety precautions specified by attachment manufacturer.

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.

When moving the machine, watch that enough 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.

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.

1.5

Tigercat 234 Loader

Safety

GENERAL SAFETY PRECAUTIONS continued

Avoid Injury from Backover Accidents Before moving machine, be sure all persons are clear of the area.

Always be alert for bystanders moving into the work area. Use horn to warn bystanders before moving the machine.

WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Wash hands after handling.

When using a signal person, keep the person in view at all times. Always be sure the signal person is clear before backing up.

To avoid backover accidents:

If acid is accidentally splashed into your eyes, flush immediately with clean water and get medical attention.

• •

Do not attempt to charge a frozen battery; it can explode.

Disconnect battery before working on electrical systems as follows: -

turn off master switch in cab

-

disconnect negative starter motor cable from both battery posts

-

disconnect positive master solenoid cable from both battery posts

• • •

Connect ground terminal last when reconnecting.

•

Do not short out battery terminals for any reason.

Serious burns or an explosion can result.

CAUTION Lead-acid batteries contain sulfuric acid which can severly damage eyes or skin on contact. Always wear a safety face shield, rubber gloves and protective clothing to reduce risk of accidents.

Lead-acid batteries produce flammable and explosive gasses. Keep arcs, sparks, open flames and lighted tobacco a safe distance from the batteries.

1.6

Always look around before you back up. Be sure that everyone is clear.

Keep motion warning alarm in working condition. The motion warning alarm must sound when the machine is moving in forward or reverse.

Use a signal person when backing up if view is obstructed. Always keep the signal person in view.

Learn the meaning of all flags, signs and markings on the job site and who is responsible for signaling.

Keep windows, mirrors and lights in good condition.

Dust, heavy rain, fog, snow etc. can reduce visibility. As visibility decreases, reduce speed and use proper lighting.

Tigercat 234 Loader

Safety Before moving the machine to the work site, check to ensure that all doors, panels, and access covers are installed properly and secured.

CAB EXITS There are two ways to exit the cab in case of an emergency.

1. Side Door, this is the main point of entry used under normal operating conditions to enter or leave the cab. This door is not equipped with a safety interlock switch and therefore when left open will not deactivate the pilot controls in the cab. The left armrest is equipped with a safety interlock switch that prevents machine operation when the armrest is raised. See SAFETY INTERLOCK SWITCH ON LEFT ARMREST later in this section for more details. ALWAYS shut OFF engine before using the side door exit.

2. Side Window, this is a second cab exit for use if the side door exit becomes blocked.

This window is not equipped with a safety interlock switch and therefore when left open will not deactivate the pilot controls in the cab.

ALWAYS shut OFF engine before using the side window as an escape hatch exit.

It is important that the operator of the machine be familiar with these emergency exits and how to use them.

All operators should practice using all the cab exits to become familiar with escape procedures should they need to perform them in the dark, when the machine is in a rolled position, or other possible adverse condition.

The exits should be checked to make sure that they are operational and will function in an emergency.

For additional information, refer to EMERGENCY EXITS in SECTION 3 of the OPERATOR'S MANUAL.

OPERATING SAFETY PRECAUTIONS

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

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

Sound the machine horn before starting the machine.

The operator’s seat is equipped with a lap belt.

Use the lap belt at all times when operating the machine.

Start the engine according to the instructions in this manual. Refer to OPERATING THE MACHINE in SECTION 2 of the OPERATOR'S MANUAL.

WARNING

Never use a liquid staring aid to start an engine.

THIS MACHINE IS EQUIPPED WITH A COMPUTER CONTROLLED HEATING ELEMENT IN THE ENGINE INTAKE SYSTEM. STARTING FLUIDS WILL EXPLODE ON CONTACT WITH THE HEATING ELEMENT.

1.7

Tigercat 234 Loader

Safety

OPERATING SAFETY PRECAUTIONS continued

WARNING

SAFETY INTERLOCK SWITCH ON LEFT ARMREST: 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).

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

Sound the machine horn before starting the machine.

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

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.

ARMREST

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

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

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

1 LIMIT SWITCH ACTUATING LEVER ON SEAT BASE

247-25

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

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

PILOT SYSTEM SHUT OFF

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

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

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.

WARNING

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.

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

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.

Use only prearranged and approved signalling practices.

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

1.8

Tigercat 234 Loader

Safety

OPERATING SAFETY PRECAUTIONS continued

WARNING DO NOT operate this machine to lift or move any objects other than what it is designed to lift or move.

• Do not use the boom to service other equipment.

• Do not use the boom to lift items such as tires, engines, cylinders, boom components, etc.

• Do not modify the boom system.

• Do not add hooks or lugs to the boom for the purpose of attaching lifting rigging.

• Do not use the attachment for any purpose other than the intended function.

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

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

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

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

Maintain a safe operating distance between the machine and workers and all other personnel. It is the duty of the operator to ensure that no person approach the machine while in use.

Failure to follow the above instructions could result in serious injury or death.

220D-002

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

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

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

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

1.9

Tigercat 234 Loader

Safety

OPERATING SAFETY PRECAUTIONS continued When parking a machine with self-propelled option: •

Park on level ground.

•

Do not park on a hillside or incline.

•

Take the machine out of DRIVE MODE. This will automatically engage the park brake.

•

Lower the stabilizers to the ground.

•

Park the grapple in it's proper location on the carrier or rest on the ground.

•

Stop the engine.

•

NOTE: As a safety precaution before working on or around the machine, release brake system pressure by fully applying the brake foot pedal 40 times or more.

The pedal should have a "soft" feeling when the pressure has been released Pressure may remain in the system after completing the above. Use caution when loosening hydraulic connections.

•

Turn the machine battery disconnect switch off if the vehicle is to be parked for an extended period of time (Example overnight).

NOTE: Wait for 30 seconds after turning key

220D-002

switch off before turning the battery disconnect switch off. The engine ECM requires time after the engine is turned off to record the engine data and log the information for the current operating session. If the battery disconnect is turned off too soon, the data will not be recorded and an error message will be displayed when the battery power is turned back on and the key switch is turned on.

When travelling on public roads, use accessory lights (when installed) and other cautionary devices to provide operators of other vehicles warning of your approach. Ensure your machine meets all regulatory requirements.

1.10

Tigercat 234 Loader

Safety

SERVICING SAFETY PRECAUTIONS

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

Conduct maintenance inspections at least as frequently as recommended in section 3 of the THIS MANUAL. 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.

220D-002

When servicing or repairing equipment, shut the engine down. Turn Battery Disconnect switch OFF and lock out the switch in accordance with local regulations. This machine is equipped with a remotely operated battery disconnect relay.

Some wiring on the machine is live even when the battery disconnect switch is off. When servicing the electrical system, remove the battery cables from the batteries disconnecting the negative cables first.

Pressure can be maintained in a hydraulic system long after the power source and pump have been shut down. Lower the attachment to the ground, stop engine and relieve trapped pressure from pilot system and brake accumulator (if equipped) before performing work on components, or disconnecting any hoses. For the procedure on how to RELIEVE PRESSURE, refer to PARKING THE MACHINE in THIS SECTION.

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

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

1.11

Tigercat 234 Loader

Safety This machine is equipped with sensitive electronic control equipment, prior to welding:-

SERVICING SAFETY PRECAUTIONS continued The radiator and the engine cooling system should be cleaned and serviced daily to maintain moderate engine temperatures.

CONTROL MODULE

WARNING

250CT-002

Disconnect the computer controler connector in the cab behind the upper instrument panel.

WARNING, HOT FLUIDS AND HOT MACHINE SURFACES CAN CAUSE SERIOUS BURNS! •

Before servicing the machine, allow the engine cooling system, fuel system, exhaust system, hydraulic system and machine surfaces to cool down.

•

Use a thermometer to check surface and system temperatures to ensure it is safe to begin service work.

•

DO NOT begin service work until the surface or system temperature has cooled down to below 38°C (100°F)!

COMPUTER CONNECTOR IN CAB

234E-231

COMPUTER CONTROL MODULE IN CAB BEHIND SEAT

Disconnect the control module connector in the cab behind the seat.

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

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

234E-230

COMPUTER CONTROL MODULE IN UPPER FRAME

Disconnect the control module connector in the upper frame under the platform.

220D-002

Turn the battery disconnect switch off and disconnect the battery negative terminal. Also, disconnect the engine ground connection from the frame.

1.12

Tigercat 234 Loader

Safety

SERVICING SAFETY PRECAUTIONS continued

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.

On machines with Tier 3 engine 1

SAFE REMOVAL OF STABILIZER COUNTERBALANCE AND CHECK CARTRIDGES

2

250C-001

If it becomes necessary to remove either the stabilizer counterbalance or check cartridge from the housing, or cylinder base end; 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.

ENGINE CONTROL MODULE

Disconnect the engine CPU (Central Processing Unit) by unplugging the two multi-pin connectors from the left side of the engine.

LOWER FRAME

On machines with Tier 4 engine

VERTICAL CENTERLINE COUNTERBALANCE VALVE

STABILIZER UP IN VERTICAL POSITION

CYLINDER DISCONNECT THE TWO MULTI-PIN PLUGS FROM THE ENGINE CPU

STABILIZER COUNTERBALANCE/CHECK VALVE CARTRIDGE REMOVAL

250B-025

230-06A

Disconnect the engine ECM (Engine Control Module) by unplugging the engine power connector (1) and multipin connector (2).

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.

1.13

Tigercat 234 Loader

Safety

SERVICING SAFETY PRECAUTIONS continued

WARNING DO NOT operate this machine to lift or move any objects other than what it is designed to lift or move.

• Do not use the boom to service other equipment.

• Do not use the boom to lift items such as tires, engines, cylinders, boom components, etc.

• Do not modify the boom system.

• Do not add hooks or lugs to the boom for the purpose of attaching lifting rigging.

• Do not use the attachment for any purpose other than the intended function.

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

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

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

Maintain a safe operating distance between the machine and workers and all other personnel. It is the duty of the operator to ensure that no person approach the machine while in use.

Failure to follow the above instructions could result in serious injury or death.

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

1.14

Tigercat 234 Loader

Safety

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

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.

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

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

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.

FRONT CHASSIS

RETAINING PIN

Dispose of fluids properly. Do not pour fluids into the ground, stream, pond or lake. Before draining any fluids, know the proper way to dispose of them.

REAR CHASSIS

LYNCH PIN SPAC-002

Read, understand and follow all operating safety precautions specified by the attachment manufacturer.

LOCK BAR

LOCK BAR IN LOCKED POSITION

WARNING

To prevent accidental articulation of a selfpropelled machine and to avoid injury when working in the center joint area, install the frame articulation lock bar between the frames and hold in place with the lynch pins provided.

Always follow attachment manufacturer's instructions and safety warnings before approaching attachment head to make adjustments.

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

WARNING DO NOT work below or behind a machine that is parked on a grade.

Before performing work under the boom system ensure it is firmly supported.

When opening or closing power operated engine door, watch for personnel in door areas.

WARNING Failure to follow all of the above instructions could result in serious injury or death from crushing.

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

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Safety

SERVICING SAFETY PRECAUTIONS continued

WARNING Diesel fuel or hydraulic fluid under pressure can penetrate the skin and could result in death or serious injury. If any fluid is injected under the skin, a medical doctor familiar with the treatment of this type of injury must surgically remove it within a few hours.

FLUID INJECTION INJURY Hydraulic and diesel fuel systems on forestry machines operate at very high pressures, often 207 bar (3000 psi) and above. If a loose connection or a defect in a hose should occur, a fine, high velocity stream of fluid will result. Even for systems pressurized to as little as 7 bar (100 psi), this fluid stream can penetrate human skin as if it were a hypodermic needle.

In the event of any suspected fluid injection injury • Report the injury to your supervisor immediately.

• Seek professional medical attention immediately.

As always the best defence against suffering the effects of fluid injection is to prevent the accident from occurring in the first place.

When searching for possible fluid leaks • Never search for leaks with your bare hands.

Always wear thick protective gloves.

• Be sure to wear safety goggles for eye protection.

• Keep all body parts well away from the area being investigated for leaks.

• Use the end of a long piece of wood to move hoses or other obstacles.

Initially, an accidental fluid injection beneath the skin may only produce a slight stinging sensation.

There is a danger that you will tend to ignore this, thinking that it will get better with time. Most often, it does not! Within a very short time the wound may begin to throb painfully, indicating that tissue damage has already begun.

Similarly fluid injected directly into a blood vessel can spread rapidly through your circulatory system. The human body has little ability to purge injected fluid.

Diesel fuel or hydraulic fluid under pressure can penetrate the skin and could result in death or serious injury. If any fluid is injected under the skin, a medical doctor familiar with the treatment of this type of injury must surgically remove it within a few hours.

•

Place the end of a long piece of wood in the suspected path of any fluid stream. Never use any part of your body.

• Recognize that the source of the leak and the fluid streaming from it may be very small and not easily visible. You may only be able to see the fluid that accumulates as a result of the fluid stream.

When performing any service work • Stop the engine and relieve all diesel fuel or hydraulic pressure before disconnecting any lines or otherwise working on the system.

• Never grab any hydraulic or diesel fuel connectors or hoses when they are subjected to pressure.

• Always ensure that hoses are rated for the pressures to which they will be subjected.

• Never use any hoses that you suspect could be defective.

Time becomes critical as tissue damage progresses rapidly. The longer you delay getting professional medical attention, the more damage can occur.

Although fluid injection accidents are rare, the resulting injury has on occasion required the amputation of a finger, a hand or in some cases the entire limb. The longer the delay in getting professional medical aid, the further up the limb the tissue damage can spread. An injury of this type can become very serious or even fatal if not dealt with promptly and properly.

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Safety

SERVICING SAFETY PRECAUTIONS continued GREASE INJECTION INJURY WHEN USING PNEUMATIC GREASE GUNS Pneumatic grease guns can deliver grease at pressures from 17 - 400 Bar (246 - 5801 psi).

It takes less than 7 Bar (100 psi) to inject a substance through human skin.

ALWAYS get professional medical treatment immediately after any type of injection injury.

Provide the physician with information on the type of grease, the pressure setting of the gun, and similar details.

The amount of fluid injected, type of fluid (or material), pressure at which it was injected, and the elapsed time between injection and surgery all influence the chances of successful treatment for this type of serious injury.

Prior to using a high pressure pneumatic grease gun perform the following: •

All operators of high pressure pneumatic grease guns MUST be trained in the hazards of its operations and the treatment for such injuries.

•

DO NOT OPERATE a high pressure pneumatic grease gun unless you have been trained in the proper operation and are aware of all safety precautions of such a tool.

•

Wear protective clothing such as gloves, safety hat and safety glasses.

•

Inspect all parts of the grease gun for wear and tear and replace all worn or damaged parts.

•

Ensure that protective shrouds are installed on all grease gun nozzles as safety devices.

•

Remove dirt and grease from grease fittings prior to greasing.

•

Replace any defective grease fittings on equipment with new fittings immediately.

•

When badly positioned fittings are identified, replace them with angled or swivel fittings for easier access.

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Tigercat 234 Loader

Safety LIGHTNING SAFETY

LIGHTNING SAFETY AWARENESS

In spite of the popular myth that being struck by lightning is an unlikely event, the facts show that lightning strikes occur frequently. As a result loggers are at high risk because their work is outdoors and close to known strike points such as tall trees and heavy equipment.

Loggers can increase their chances of avoiding a lightning strike by following a few simple safety practices.

1.

WHAT IS A LIGHTNING STRIKE? Lightning is a discharge of the electricity produced by a thunderstorm. As the thunderstorm develops, many small particles of ice within the storm clouds bump together. These collisions create a positive charge at the top of a cloud and a negative charge at the bottom. As this continues a second positive charge builds up on the ground beneath the cloud, concentrated around high objects such as hills, trees, buildings, equipment and even people.

Designate a member of your crew to

•

Monitor daily weather forecasts

•

Observe local weather conditions

•

Alert all other members of the crew when a possible lightning threat develops.

2.

Don’t start or continue any work that cannot be stopped immediately, when a storm moves nearby.

3.

Anticipate a high-risk situation and take action early by moving to a low-risk location.

Do not hesitate. If there is lightning, you are in danger.

4.

The electrical potential in a lightning strike can be as much as 100 million volts. Lightning strikes can occur over very large distances, even as much as 60 km (37 miles). Lightning travels both in front of and behind a thunderstorm and so strikes happen even when rain has not started or has stopped.

Lightning can hit in the same place, many times and often spreads out over 18 m (60 feet) within the soil around the strike point.

Obey the rule - If you see lightning, Flee. If you hear thunder, Clear.

5.

Do not follow the now obsolete guideline to take shelter when the time between seeing lightning and hearing thunder is 30 seconds or less. This does not provide sufficient time to ensure safety. Always follow step 4.

6.

Remain in your safe location for 30 minutes after the last sight of lightning or the last sound of thunder.

Thunder always accompanies lightning. When lightning occurs, the air through which it travels is instantaneously heated to a temperature more than 28,000°C (50,000°F). The air expands rapidly due to this heating, then quickly contracts as it cools. It is this contracting shock wave that we hear as thunder.

The safest location during lightning activity is inside a fully enclosed, substantially constructed building, a house, office, school, shopping area, etc. These are the safest because of the electrical wiring and plumbing that they contain. Should lightning strike, the electrical current will travel through the wiring or plumbing into the ground.

When such a building is nearby, always seek shelter there first.

When the difference between the electrical charge in the cloud and on the ground becomes great enough to overcome the resistance of the insulating air between them, an electrical current flows instantly. This is a lightning strike.

In many areas of the world, lightning strikes are second only to flooding as the greatest cause of storm related deaths and injuries. Although only 10% of lightning strike victims are killed, virtually all from cardiac or respiratory arrest, over 70% of those that survive suffer severe, life-long injury and disability. The symptoms of a lightning strike include memory loss, fatigue, chronic pain, dizziness, sleeping difficulty and the inability to complete several tasks at one time.

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Safety WHAT TO DO IF YOU ARE OUTSIDE AND SEE LIGHTNING OR HEAR THUNDER. If you can, get inside.

1.

Run to the nearest building, motor vehicle or fully enclosed ROPS equipment cab immediately. Being anywhere outside is not safe.

2.

If inside a building:

Unfortunately loggers do not often work close to buildings and therefore other alternatives need to be considered.

Sheds, weather shelters, hunting blinds, tents and other partially open or small structures are not safe against lightning strikes as they lack the electrically grounded components of larger buildings. They are intended for sun or rain protection only. Do not seek shelter from lightning strikes inside these structures.

•

Don’t watch the lightning storm from open windows or doorways. Stay in inner rooms.

•

Stay well away from corded telephones, electrical appliances, lighting fixtures, radio microphones, electrical sockets and plumbing pipes and fixtures.

3.

If inside a motor vehicle or fully enclosed ROPS equipment cab: •

The second safest location during lightning activity is inside a fully enclosed car, van, truck or bus with a metal roof and metal sides. The electrical energy of a lightning strike to these vehicles is carried to ground by the conducting outer metal surfaces. This is called the skin effect.

Under no circumstances whatsoever step outside of the vehicle or off the equipment to move to another shelter. Very dangerous electrical pathways to ground may go through you.

•

Shut down all operation, turn off the engine, close all doors and raise all windows.

Do not seek safety from lightning strikes in vehicles with fiberglass or plastic body shells or in convertible top vehicles. None of these are safe, as they do not offer skin effect lightning protection.

•

Sit squarely in the seat with your hands in your lap and your feet flat on the floor mat.

•

Do not touch any metallic objects referenced to the outside of the vehicle.

Do not touch any door and window handles, control levers, foot pedals, steering wheels, cab interior walls and any other inside to outside metal objects.

•

Do not touch any radio or telephone connected to an outside antenna.

Heavy forestry equipment such as a skidder, loader, feller buncher, forwarder, etc. with a fully enclosed rollover protective structure (ROPS) cab take advantage of the skin effect and are therefore safe in electrical storms.

However machines with a rollover canopy only are not safe against lightning strikes as they are open to electrically conductive rainwater and do not benefit from the skin effect. Operators of this equipment must abandon their machines and get to a safer location before lightning strikes.

Note that the rubber tires on motor vehicles and heavy equipment do not increase safety from lightning strikes. Lightning has already travelled a great distance through the air to strike the vehicle.

In comparison a few inches of rubber in a tire offers absolutely no additional insulation.

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Tigercat 234 Loader

Safety What to do if you feel your skin tingling, your hair stands on end, light metal objects vibrate or you hear a crackling sound.

If you are caught outside and have no where else to go.

1.

Lightning is probably about to strike. You only have a few seconds to act.

2.

Put your feet together. Crouch down like in a baseball catcher’s position. Hold your head down. Cover your ears to protect them against the noise of the thunder.

3.

Do not lie flat on the ground. By touching as little of the ground as possible, the lightning may not move across the ground to you.

1.

Avoid wide-open areas where you project above the surrounding landscape.

2.

Seek shelter in a low place, such as a ditch, ravine, valley, canyon or cave.

What to do if a co-worker has been struck by lightning.

3.

Get away from open water such as ponds or streams.

1.

4.

Do not take shelter under any isolated tall trees or small groups of trees.

The victim does not carry any electrical charge. There is no danger to anyone helping this person. You can touch him or her immediately.

5.

Seek shelter amongst the dense, thick growth of the shortest trees.

2.

Call your local emergency response telephone number immediately.

6.

Avoid entering any small enclosures or shelters.

3.

7.

Do not seek shelter under any motor vehicle or heavy equipment.

If the victim has no pulse, their heart has stopped or they have stopped breathing, start cardiopulmonary resuscitation (CPR) or mouth –to-mouth resuscitation immediately.

Use a portable defibrillator if one is available.

8.

Keep clear of any materials that can conduct electricity such as wire fences and gates, metal pipes, poles, rails and tools.

4.

9.

Stay at least 15m (50 feet) away from metal objects such as a fuel tank, a vehicle or machinery without a cab, motorcycle, ATV, etc.

Be careful about staying in the storm to take care of the victim. You can get hit by lightning too. If you can, move the victim to a building as soon as possible.

To further increase your awareness about lightning safety, see the following web sites.

National Weather Service Lightning Safety http://www.lightningsafety.noaa.gov

10. Stay at least 5m (16 feet) apart from any other members of a group so that lightning won’t travel between you.

National Lightning Safety Institute http://www.lightningsafety.com

11. Do not use the telephone except for emergencies.

1.20

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Safety

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 to a minimum.

1. Maintain a CHARGED fire extinguisher on the machine at all times and KNOW HOW TO USE IT. 2. Remove debris and blow out dust regularly from the air intake doors, engine radiator and charge air cooler, hydraulic oil cooler, diesel fuel cooler and air conditioning condenser core to prevent overheating of the engine and hydraulics and to maintain efficient operation of the machine. Refer to CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR in SECTION 2 of the OPERATOR’S MANUAL. 3. Blow off all forest debris and fine organic material 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 when working in logging conditions where large amounts of combustible forest debris are present.

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

4.

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.

5.

Inspect the machine regularly for any signs of diesel fuel or hydraulic system leakage.

Check for worn or eroded fuel or hydraulic lines before starting up any equipment.

6.

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

7.

Steam clean the engine, hydraulic pumps, transmission, brake, fuel and hydraulic tank compartments and all machine belly pans at least once a month or more frequently when working in logging conditions where large amounts of combustible forest debris are present.

Use only nonflammable solutions for cleaning the machine and components.

8.

9.

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.

10. 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.

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

12. Never leave the machine parked with boom, arch or blade suspended off the ground. Should their supporting hydraulic hoses burn through during a fire, pressurized hydraulic oil may be injected into the fire and the boom, arch or blade will fall rapidly to the ground.

1.21

Tigercat 234 Loader

Safety 19. Store rags and other combustible materials in a safe, fireproof location.

13. Turn the battery disconnect switch to OFF at shut down to de-energize all electrical circuits.

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

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

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

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

•

Prevent the fire from happening in the first place by ensuring that all machine systems are frequently inspected and always well maintained.

•

Ensure that any hand held fire extinguishers are charged and in working order. Fire extinguishers require routine care. Follow the manufacturer’s instructions for inspection and maintenance shown on the label of the fire extinguisher and in the extinguisher manufacturer's manual.

•

Ensure that any pressurized water systems on the machine (if applicable) are charged and in working order. Refer to PRESSURIZED WATER SYSTEM MAINTENANCE in SECTION 3 of the OPERATOR’S MANUAL.

•

Ensure that you have the proper fire extinguishers on site. Most fires involving mobile forestry equipment will be Class A or B. Dry chemical extinguishers should be rated ABC and pressurized water extinguishers should be rated A.

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

Class A fires involve ordinary combustibles such as wood, cloth, paper, rubber and many plastics, Class B fires occur with flammable liquids such as diesel fuel, oil and grease and Class C fires apply to energized electrical equipment.

17. AFTER transporting (trucking) a machine from one job site 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.

•

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

•

1.22

Ensure that the nozzle of any hand held extinguisher and pressurized water system available on the machine and at the work site fits within the fire extinguisher access holes in the doors of the machine.

Ensure that your fire detection system* is in working order. Refer to FIRE DETECTION SYSTEM in SECTION 2 of the OPERATOR’S MANUAL.

Tigercat 234 Loader •

•

•

•

•

Safety WHAT TO DO WHEN A MACHINE FIRE OCCURS

Ensure that your fire suppression system** is charged and in working order. Refer to FIRE SUPPRESSION SYSTEM in SECTION 2 of the OPERATOR’S MANUAL. Ensure that you are familiar with the recommended procedures for fire contained in the emergency action plan of your company.

Ensure that you follow all national, state / provincial and local regulations dealing with fire fighting in effect in your specific geographic region. Regulations will vary from region to region but most will usually require that: 1. Workers assigned to fire fighting duties must be physically capable of performing them safely and effectively.

2. Workers designated to use fire fighting equipment as part of an emergency action plan must receive full and proper training from a qualified instructor.

3. Whenever portable fire extinguishers are provided for use in the workplace, training must be provided to familiarize workers with the general principles of fire extinguisher use and the hazards involved with fire fighting.

4. Training must be provided upon initial employment and at least annually thereafter.

Ensure that after you have received the training as outlined above, that you know how to use the fire extinguisher, the pressurized water system (if applicable)

•

If operating the machine when a fire occurs: 1. Lower all working attachments to the ground.

2. Shut the engine off.

3. Activate the fire suppression system**.

4. Radio or call for help. Be certain to report a fire immediately.

5. Exit the machine taking fire extinguisher and pressurized water system hose (if applicable) with you.

6. 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. All fires can be very dangerous and life threatening.

7. Only if you can safely do so, turn OFF the battery disconnect switch.

•

Before deciding to fight the fire, be certain that: 1. The fire is small and not rapidly spreading.

2. There is always a clear, safe escape route to your back.

3. You have received training in the use of the available fire extinguishing systems and are confident that you can operate them effectively.

4. If in any doubt about whether or not to fight the fire – DON’T. Instead stand well clear of the fire and wait for help to arrive.

and the fire suppression system** on your machine. There is not enough time available to read instructions during a fire emergency.

Ensure that all information necessary for you to immediately contact all sources of help (local fire department, etc) in the event of a fire emergency is recorded and readily available at all times.

5. Be aware that engine coolant , diesel fuel or hydraulic hoses could fail during a fire.

If this happens, hot coolant, fuel or oil could possibly be ignited by the fire.

6. If possible a dry chemical fire extinguisher or fire suppression system** should be used first to fight a machine fire.

Then immediately afterwards use the pressurized water hose supplied with the machine (if applicable) or a pressurized water extinguisher (if available). A fire suppressed by dry chemical may re-ignite from the heat retained by any debris or hot machine components in the area.

The water will cool the area, reducing the chances of re-ignition.

1.23

Tigercat 234 Loader

Safety WHAT TO DO AFTER A MACHINE FIRE HAS OCCURRED

Use the PASS method. This is the most effective use of a fire extinguisher.

•

Pull the pin at the top of the extinguisher that keeps the handle from being pressed.

Break the plastic seal as the pin is pulled.

•

•

1. Ensure that the cause of the fire is determined and all appropriate repairs are completed.

Aim the nozzle at the base of the fire. Do not aim the nozzle at the flames. In order to put out the fire, you must extinguish the fuel, not the flames. Hose nozzles are often clipped to the extinguisher body.

Release the hose before taking aim.

•

2. Ensure that the fire detection system*

or the fire suppression system** is properly serviced and in working order (if applicable).

Squeeze the handle to release the pressurized extinguishing agent. The handle can be released at any time to stop the discharge.

•

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

•

Sweep from side to side at the base of the fire until the fire is completely out or the fire extinguisher is empty

•

Before returning the machine to work.

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

*NOTE:

Fire detection systems are offered

by Tigercat as an optional installation on some Tigercat product lines. Please disregard any references made to fire detection systems if not installed on your machine.

**NOTE: Dry chemical fire suppression systems

are offered by Tigercat as an optional installation on some Tigercat product lines. Please disregard any references made to fire suppression systems if not installed on your machine.

20229A

• • •

• •

TYPICAL FIRE EXTINGUISHER ACCESS HOLE

Place the nozzle of the fire extinguisher into the appropriate fire extinguisher access hole and discharge the extinguisher.

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

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

Ensure that the machine and all components have cooled down sufficiently after a fire so that re-ignition does not occur.

Remain with the machine until help arrives.

1.24

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Safety

DRY CHEMICAL CLEANUP PROCEDURES

3.

Both ABC dry chemical fire extinguishers and fire suppression systems discharge a chemical powder to extinguish the fire. The chemical makeup and the small particle size of the powder as well as the force of the discharge all contribute to the fire fighting capability. These same characteristics also permit the powder to penetrate into and fully cover all components in the vicinity of the discharge.

To break down the caked dry chemical, spray or wash these areas with a 50/50 mixture of hot water and isopropyl alcohol. Allow this mixture to stand in place for several minutes.

The caked dry chemical when exposed to moisture is also mildly acidic. Therefore when the break down procedure has been completed, follow this immediately with the neutralizing procedure as described in step 2.

The following are recommendations for the cleanup and neutralizing of areas exposed to dry chemical powder.

Workers performing this work should wear protective clothing, safety goggles and a fine particle dust mask to minimize their personal exposure to the dry chemical powder.

Ensure that all electrical systems have been completely de-energized prior to any cleanup.

1.

In areas of the machine that remained cool and dry during the fire, the dry chemical will stay in powder form.

Be certain to clean these areas immediately to prevent any settled residual powder from coming into contact with moisture whether through direct contact or humidity in the air.

Remove the powder residue by blowing off with air, sweeping, dusting or vacuuming using a HEPA filter capable of trapping the small dry chemical particles. Then wipe all surfaces with a damp cloth.

2.

In areas exposed to heat during the fire, the dry chemical powder will melt forming a coating that cakes or crusts on all surfaces.

In areas exposed to moisture, the dry chemical powder will combine with water to form a paste that is mildly acidic. Note that all surfaces covered by this dry chemical paste including electrical contacts are vulnerable to corrosive attack.

To neutralize the acidic paste on large surfaces, spray or wash these areas with a mixture of 3 parts hot water to 1 part baking soda. Allow this mixture to stand for several minutes before rinsing with warm water.

Wash the area with a mild soap and water solution. Rinse thoroughly with water. Blowdry to remove all residual water.

Cleaning of electrical contacts should be done using an electrical contact cleaner that has no flash or fire point and is non-corrosive and non-conductive such as CRC Contact Cleaner 2000.

1.25

Tigercat 234 Loader

Safety USE THE SEAT BELT AT ALL TIMES!

SAFETY LABELS SAFETY LABELS The following safety labels must be periodically cleaned and inspected to ensure legibility is maintained. Replace any label that becomes illegible, damaged or removed.

READ OPERATOR'S MANUAL

The operator's seat is equipped with a lap belt.

Use this restraint system at all times when operating the machine. DO NOT ATTEMPT TO MOVE OR OPERATE the machine until the seat belt is installed and properly fastened up.

KEEP CLEAR

Always read the operator’s manual before operating the machine. Pay close attention to WARNINGS and HAZARD identifications.

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

43424BUNI R0

This label warns persons outside the cab to keep clear of the machine while in use.

OPERATOR'S MANUAL LOCATION

Always keep clear of an operating machine.

When approaching an operating machine on foot, keep a safe distance away until the operator recognizes your presence. Make sure that all equipment has been shut down before advancing to the machine.

Maintain a safe operating distance between the machine and workers and all other personnel.

It is the duty of the operator to ensure that no person approach the machine while in use.

This label indicates the storage location of the operator's manual.This label is located on the outside of the operator's manual case inside the cab.

Before moving machine, be sure all persons are clear of the area.

Always be alert for bystanders moving into the work area. Use horn to warn bystanders before moving the machine.

When using a signal person, keep the person in view at all times.

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Tigercat 234 Loader

Safety

SLIPPERY SURFACE WHEN WET

NO RIDERS

This label is located on the access area of the upper platform it warns of a slippery surface when wet. 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.

NO RIDERS INSIDE OR OUTSIDE OF THE MACHINE . Do not carry passengers either in the cab or anywhere else on the machine. The vehicle seating accommodation is for one operator only.

Persons riding on the outside of the machine are subject to hazards such as falling off the machine, crush hazards, thrown object hazards and many other hazards WHICH COULD RESULT IN DEATH OR SERIOUS INJURY. If any person attempts to climb onto the machine during operation, STOP THE MACHINE IMMEDIATELY. Do Not Operate the machine until other personnel are a safe distance away from the machine.

1.27

Tigercat 234 Loader

Safety

ENTANGLEMENT HAZARD

ELECTROCUTION HAZARD!

This label warns of an ENTANGLEMENT HAZARD (rotating parts) zone. The label is located on each side of the engine cooling fan shroud which is near the engine serpintine drive belt. DO NOT PLACE HANDS OR FINGERS IN THIS AREA. Rotating parts such as pulleys, belts and drives can cause entanglement of body parts resulting in serious injury.

This label is located in the cab. It warns of a potential ELECTROCUTION HAZARD. Contact with electric lines WILL RESULT IN DEATH OR SERIOUS INJURY! Before beginning work in any area study the area thoroughly and become familiar with any potential hazards especially electrocution hazards from electric lines.

KEEP HANDS AND FINGERS CLEAR OF ROTATING BELT, DRIVE OR PULLEY! Before performing any service work on these parts or in this area, shut engine off and wait for rotating parts to come to a complete stop.

DO NOT MOVE ANY PART OF THE MACHINE OR LOAD WITHIN 3m (10 FEET ) PLUS 2 TIMES LINE INSULATOR LENGTH OF ANY ELECTRIC LINES!

1.28

Tigercat 234 Loader

Safety

CRUSH HAZARD

CRUSH HAZARD

This label is located in four places on the lower frame near each of the cylinder and lock valves.

It warns of the CRUSH HAZARD caused by a tipping or falling machine.

This label is located in the cab, it warns of the CRUSH HAZARD caused by the delimber knives and that approaching personnel are subject to crush injuries by delimber knives WHICH COULD RESULT IN DEATH OR SERIOUS INJURY. Do Not Operate the machine until all personnel are a safe distance away from the machine.

Do not service the stabilizer cylinder or lock valve while the machine is supported by the stabilizers! Servicing the stabilizer cylinder or lock valve while the machine is supported by the stabilizers could cause the machine to tip or fall WHICH COULD RESULT IN DEATH OR SERIOUS INJURY.

The delimber knives will close automatically when the engine is shut down. Do Not approach the delimber arms until the engine is shut down and the delimber arms are closed.

Do not operate the machine when any personnel approach! If any person attempts to approach the machine during operation, STOP THE MACHINE IMMEDIATELY.

Never loosen or remove bolts, hoses or valves from the stabilizer cylinder or lock valve while the machine is supported by the stabilizers.

Before servicing the stabilizer cylinder or lock valve, lower the machine to the ground or trailer, so that the lower frame is resting completely on the ground or trailer frame ensuring the machine can not tip or fall; 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 the location of other personnel who are working in the area and be prepared to stop operations if they enter your working area without warning. Be prepared for this potential and take appropriate action if required!

1.29

Tigercat 234 Loader

Safety

CRUSH HAZARD

FIRE PREVENTION!

This label warns of the CRUSH HAZARD caused by the boom when it is not properly supported.

Never work under or near an unsupported boom or attachment. Contact with a falling boom COULD RESULT IN DEATH OR SERIOUS INJURY! Always lower the boom to the ground so that the weight of the boom and grapple is resting on the ground. Properly support and brace boom and shut off engine before performing service work.

This label advises operator's of the following: READ UNDERSTAND AND FOLLOW THE FIRE PREVENTION GUIDELINES IN THIS MANUAL. These guidelines provide all the necessary action required to preventing fires on this machine. DO NOT OPERATE THIS MACHINE until you have read these instructions and have performed any necessary maintenance required that will prevent the potential of a fire from starting on this machine.

EXPLOSION HAZARD

WARNING • EXPLOSION HAZARD. • DO NOT USE ETHER. • ENGINE EQUIPPED WITH HEATER STARTING AID. • USE OF ETHER COULD RESULT IN DEATH OR SERIOUS INJURY.

It is also important to note that fire prevention inspections and maintenance MUST BE PERFORMED FREQUENTLY (several times per day). A clean combustible free machine as well as frequent inspections of the exhaust components, hydraulic hoses and electrical cables and performing any necessary repairs immediately will help prevent fires.

36782BENG R0

This label warns of an EXPLOSION HAZARD. This label is located on the end of the air cleaner (air filter housing). The engine is equipped with a heater starting aid, DO NOT USE ETHER to assist in starting the engine.

Maintain a CHARGED fire extinguisher on the machine at all times, know where it is and KNOW HOW TO USE IT!

USING ETHER COULD CAUSE AN EXPLOSION WHICH COULD RESULT IN DEATH OR SERIOUS INJURY.

1.30

Tigercat 234 Loader

Safety

CHECK DAILY

EXTERIOR LABELS - SELF PROPELLED MACHINES The following safety labels are installed on the exterior of self-propelled machines. These labels are located on the machine in the area where the specific safety concern is applicable. Labels must be periodically cleaned and inspected to ensure legibility is maintained. Replace any label that becomes illegible, damaged or removed.

ENTANGLEMENT HAZARD

This label is installed in the cab. In addition to the previous label it is a reminder to check the machine daily for the possibility of debris build-up, leaks, damaged wires and hoses and take the necessary action required to clean up any debris accumulation, repair any leaks, damaged wires or hoses.

The label also advises to check and ensure that all fire fighting devices are in good working order.

FIRE EXTINGUISHER ACCESS HOLE

This label warns of an ENTANGLEMENT HAZARD. This label is located on the rear chassis.

The machine is equipped with exposed drive shafts in the rear chassis and center joint. Not keeping a safe distance from rotating exposed drive shafts could result in death or serious injury.

This label indicates the location of each FIRE EXTINGUISHER ACCESS HOLE. The label is installed on each fire extinguisher hole on the engine door, pump compartment door and L.H. service door.

1.31

Tigercat 234 Loader

Safety

CRUSH HAZARD

STORED ENERGY HAZARD

This label warns of the crush zone in the center joint area. This can occur when the machine steering is used. DO NOT WORK IN THIS AREA UNTIL THE ARTICULATION LOCK BAR IS INSTALLED!

This label warns of a STORED ENERGY HAZARD. The machine is equipped with an accumulator for the brake system. The accumulator has stored energy in the form of hydraulic pressure.

Servicing the accumulator or any hydraulic components before releasing pressure could result in death or serious injury.

RETAINING PIN

FRONT CHASSIS

LYNCH PIN

SPAC-002

LOCK BAR

DO NOT SERVICE ACCUMULATOR OR ANY HYDRAULIC COMPONENTS BEFORE RELEASING PRESSURE.

REAR CHASSIS

LOCK BAR IN LOCKED POSITION

Refer also to RELEASING BRAKE SYSTEM PRESSURE in SECTION 2 of the operator's manual and SECTION 4 of the service manual.

RETAINING PIN

FRONT CHASSIS

LYNCH PIN

SPAC-003

LOCK BAR

REAR CHASSIS

LOCK BAR IN STORED POSITION

Before working in the center joint area, lifting or transporting the machine to another vehicle, INSTALL THE CHASSIS ARTICULATION LOCK BAR between the chassis and center joint to prevent accidental articulation which could result in death or serious injury.

Refer to ARTICULATION LOCK in SECTION 2 of THIS MANUAL for complete instructions.

1.32

Tigercat 234 Loader SECTION 3 – LUBRICATION AND MAINTENANCE CONTENTS - SECTION 3

ISSUE 3.1, JULY 2015

AIR CLEANER, 2340601 TO 2341100 FILTER RESTRICTION INDICATOR.................................................................................................... 3.29 IMPORTANT STEPS TO FOLLOW...................................................................................................... 3.28 IMPROPER SERVICING...................................................................................................................... 3.28 MAINTENANCE.................................................................................................................................... 3.28 TUBING AND JOINTS.......................................................................................................................... 3.29 UNLOADER VALVE.............................................................................................................................. 3.29 AIR CLEANER, 2341101 TO 2341200 FILTER RESTRICTION INDICATOR.................................................................................................... 3.30 IMPORTANT STEPS TO FOLLOW...................................................................................................... 3.31 IMPROPER SERVICING...................................................................................................................... 3.31 MAINTENANCE.................................................................................................................................... 3.30 TUBING AND JOINTS.......................................................................................................................... 3.31 UNLOADER VALVE.............................................................................................................................. 3.31 AIR CLEANER, 2341201 TO 2342000 FILTER RESTRICTION INDICATOR.................................................................................................... 3.32 IMPORTANT STEPS TO FOLLOW...................................................................................................... 3.32 IMPROPER SERVICING...................................................................................................................... 3.32 MAINTENANCE.................................................................................................................................... 3.32 TUBING AND JOINTS.......................................................................................................................... 3.33 UNLOADER VALVE.............................................................................................................................. 3.33 AIR CONDITIONING................................................................................................................................ 3.34 AIR FILTER 2340601 TO 2341100........................................................................................................................... 3.28 2341101 TO 2341200........................................................................................................................... 3.30 2341201 TO 2342000........................................................................................................................... 3.32 AIR FILTER RESTRICTION INDICATOR 2340601 TO 2341100........................................................................................................................... 3.29 2341101 TO 2341200........................................................................................................................... 3.30 2341201 TO 2342000........................................................................................................................... 3.32 APPROVED HYDRAULIC OILS.............................................................................................................. 3.13 CASE DRAIN STRAINER, HYDRAULIC OIL........................................................................................... 3.22 EMERGENCY CAB EXITS......................................................................................................................... 3.8 FILTERS CHARGE PRESSURE, SWING PUMP................................................................................................ 3.23 ENGINE................................................................................................................................................3.26 ENGINE AIR 2340601 TO 2341100........................................................................................................................ 3.28 2341101 TO 2341200........................................................................................................................ 3.30 2341201 TO 2342000....................................................................................................................... 3.32 FUEL FILTER/WATER SEPARATOR.......................................................................................... 3.26, 3.27 FUEL TANK STRAINER....................................................................................................................... 3.24 PILOT, HYDRAULIC............................................................................................................................. 3.22 RETURN, HYDRAULIC OIL................................................................................................................. 3.20 FIRE PREVENTION................................................................................................................................... 3.8 FIRST 125 HOUR INSPECTION AND SERVICE...................................................................................... 3.4 FUEL FILTER AND FUEL FILTER/WATER SEPARATOR.............................................................. 3.26, 3.27 FUEL - REFUELING PROCEDURE......................................................................................................... 3.25 FUEL TANK..............................................................................................................................................3.24

Tigercat 234 Loader

Lubrication and Maintenance

HAND FILL PUMP, HYDRAULIC OIL....................................................................................................... 3.19 HYDRAULIC OIL CASE DRAIN STRAINER..................................................................................................................... 3.22 FILTERS CHARGE PRESSURE, SWING PUMP............................................................................................. 3.23 PILOT PRESSURE........................................................................................................................... 3.22 RETURN...........................................................................................................................................3.20 RETURN DIFFUSERS/STRAINERS.................................................................................................... 3.22 TANK.....................................................................................................................................................3.18 HYDRAULIC TANK VACUUM SYSTEM.................................................................................................. 3.19 LUBRICATION AND SERVICE POINTS.................................................................................................. 3.14 NEW MACHINE MAINTENANCE.............................................................................................................. 3.4 OIL LOST FROM LEAKAGE...................................................................................................................... 3.7 OIL SAMPLE COLLECTION PROCEDURES............................................................................................ 3.6 OIL SAMPLING PROGRAM............................................................................................................... 3.5, 3.6 PAG OIL...................................................................................................................................................3.34 PRE-DELIVERY INSPECTION.................................................................................................................. 3.4 PRESSURE SETTINGS........................................................................................................................... 3.40 PREVENTIVE MAINTENANCE SCHEDULE............................................................................................. 3.4 REFRIGERANT........................................................................................................................................3.34 REFUELING PROCEDURE..................................................................................................................... 3.25 ROTARY MANIFOLD LUBRICATION...................................................................................................... 3.17 SCHEDULED MAINTENANCE EVERY 8 HOURS................................................................................................................................... 3.9 EVERY 24 HOURS............................................................................................................................... 3.10 EVERY 125 HOURS............................................................................................................................. 3.10 EVERY 250 HOURS............................................................................................................................. 3.11 EVERY 500 HOURS............................................................................................................................. 3.11 EVERY 1000 HOURS........................................................................................................................... 3.12 EVERY 2000 HOURS........................................................................................................................... 3.12 GENERAL...............................................................................................................................................3.7 SERVICE AND LUBRICATION POINTS.................................................................................................. 3.14 STRAINER, CASE DRAIN....................................................................................................................... 3.22 SWING DRIVE LUBRICATION GEARBOX LOWER BEARINGS......................................................................................................... 3.16 GEARBOX UPPER GEARING............................................................................................................. 3.16 TORQUE CHART..................................................................................................................................... 3.39 TORQUE, FLUID CONNECTIONS...................................................................................... 3.36, 3.37, 3.38 TORQUE SPECIFICATIONS - GENERAL............................................................................................... 3.41 UNLOADER VALVE 2340601 TO 2341100........................................................................................................................... 3.29 2341101 TO 2341200........................................................................................................................... 3.31 2341201 TO 2342000........................................................................................................................... 3.33 VACUUM SYSTEM, HYDRAULIC TANK................................................................................................. 3.19 WEIGHTS OF COMMERCIAL WOOD..................................................................................................... 3.42

3.2

Tigercat 234 Loader

Lubrication and Maintenance

3.3

Tigercat 234 Loader

Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE NEW MACHINE MAINTENANCE

*INITIAL PRE-DELIVERY INSPECTION:PERFORM THE INITIAL PRE-DELIVERY INSPECTION USING Tigercat FORM NUMBERS 5337 AND 5347; "PDI AND 125 HOUR INSPECTION REPORT"

*FIRST 125 HOUR INSPECTION AND SERVICE REPORT:WITH THE OWNER'S MECHANIC PRESENT, PERFORM AN INSPECTION AND SERVICE ACCORDING TO THE Tigercat FORM NUMBERS 5337 AND 5347; "PDI AND 125 HOUR INSPECTION REPORT" THIS MUST BE COMPLETED WITHIN THE FIRST 125 HOUR TIME FRAME.

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

WARNING

All hydraulic connections Hose clamps Pin retainers Center joint pin securing bolts (if applicable) Check torque on swing bearing retaining bolts

WARNING, HOT FLUIDS AND HOT MACHINE SURFACES CAN CAUSE SERIOUS BURNS!

Engine mounting bolts Pump mounting bolts Pilot pump mounting bolts

•

Before servicing the machine, allow the engine cooling system, fuel system, exhaust system, hydraulic system and machine surfaces to cool down.

•

Use a thermometer to check surface and system temperatures to ensure it is safe to begin service work.

•

DO NOT begin service work until the surface or system temperature has cooled down to below 100°F (38°C)!

Swing gearbox mounting bolts Swing motor mounting bolts Cab securing bolts Boom pin nuts Heel pin nuts Trailer mounting studs Transmission securing bolts (if applicable) Axle mounting bolts (if applicable) Wheel retaining bolts (if applicable) Any other loose nut, bolt or fitting

CAUTION All handles, steps and platforms must be kept free of grease, oil, fuel mud, snow ice and forest debris to prevent risk of personal injury.

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

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

3.4

Tigercat 234 Loader

Lubrication and Maintenance

TIGERCAT OIL SAMPLING PROGRAM Effective for all 2008 model year 200 series log loaders sold in U.S.A. and Canada, oil sampling must be performed during the warranty period as per the schedule below. Warranty coverage of Powertrain components, specifically main pump, pilot pump (if applicable), swing pump (if applicable), rotary manifold, swing motor, swing gearbox and swing bearing, main control valves, track motors and final drive gearboxes (if applicable) is contingent on performance of regular oil sampling at the owner’s expense during the warranty period.

Location

200 Series First Sample

Follow-up Samples

Hydraulic Oil

125 hrs

Every 1000 hours or 6 Months

Swing Drive Gearbox

125 hrs

Every Oil Change (500 hours or 3 Months)

Track Drive Gearboxes (if applicable)

125 hrs

Every 1000 hours or 6 Months

Transmission (if applicable)

125 Driving hrs

Every Oil Change (500 hours or 3 Months)

Front & Rear Axles (if applicable)

125 Driving hrs

Every Oil Change (1000 hours)

FIRST SAMPLE There will be no charge for the first oil samples required to be taken during the 100-Hour Inspection Service that will be scheduled and performed by your Tigercat dealer. Refer to NEW MACHINE MAINTENANCE in THIS SECTION. FOLLOW-UP SAMPLES All follow-up samples must be taken as indicated in the chart above and will be the responsibility of the machine owner.

Copies of all oil analysis results must be forwarded to the Tigercat Warranty Department for continued warranty coverage. If samples are taken using the Tigercat Oil Analysis Program, a copy of all results will automatically be sent to Tigercat.

Tigercat Oil Analysis Kits are available from your Tigercat dealer parts department. If required, arrangements can also be made with your Tigercat dealer to supply and perform all of the required followup oil samples.

Refer also to OIL SAMPLE COLLECTION PROCEDURES in THIS SECTION for sample valve and drain plug locations.

TIGERCAT OIL ANALYSIS KITS Each kit includes a Pre-paid Sample Bottle and Sample Information Form. Pre-printed mailing labels are also included to ensure all samples are quickly returned directly to the lab for immediate analysis and results within 24 hours of receipt.

The same type of sample bottle can be used for all types of oil testing including: Hydraulic Circuits, Final Drives, Axles, Gearboxes, Engines, etc.

To ensure accurate and meaningful results are obtained, each kit also includes detailed instructions on how properly collect, prepare and ship the oil samples.

Contact your Tigercat Dealer Parts Department to order Kits.

3.5

Tigercat 234 Loader

Lubrication and Maintenance

TIGERCAT OIL SAMPLING PROGRAM OIL SAMPLE COLLECTION PROCEDURES Fill out the Sample Information Form (SIF) completely and accurately. When taking multiple oil samples, fill out all of the required SIF forms in their entirety, prior to taking any oil samples. Then, immediately package each completed SIF form together with the matching oil sample in the black outer shipping container as each individual sample is taken. This will reduce the possibility of mixing up or incorrectly identifying the SIF forms and oil samples. Incorrectly identified samples could result in a false warning alarm.

FILTER RESTRICTION INDICATOR

OIL SAMPLING CONNECTOR

234E-200

HYDRAULIC OIL RETURN MANIFOLD

The accuracy of the lab analysis results is very dependent on the quality of the oil sample taken. Collection of clean oil samples that are representative of the main body of oil are essential if meaningful lab results are to be obtained.

Hydraulic Oil Samples: • Hydraulic oil samples should be taken from the circulating oil flow at operating temperature, with no functions actuated, using sample valves that are permanently located on the machine whenever possible.

Erroneous readings may result if proper collection, handling, packaging and shipping practices are not followed prior to the sample being tested by the lab. To be able to accurately compare and trend the lab results over time, all follow-up samples should be consistently taken from the same location using the same techniques as all previous samples.

•

To obtain a representative oil sample, sample valves must be purged before the actual oil sample is taken. Drain a minimum of 3 or 4 ounces of oil into a separate container and discard this oil using approved recycling methods.

•

Replace the dust cover on the sample valve immediately after taking the oil sample and sealing the sample bottle.

•

Ensure that all sample valves and drain plugs are clean and free of debris.

•

Remove the sample bottle cap only when ready to take the sample. Keep the cap clean – do not put it in your pocket or let it get contaminated in any way.

•

Do not allow any airborne dirt, etc. to enter the sample bottle.

•

Avoid contamination of the sample – replace the sample bottle cap immediately after filling the bottle to approximately ¾ full. All samples taken should be immediately forwarded to the lab for processing.

Gearbox Samples: • These samples can be taken during the oil change process.

•

To obtain a representative oil sample, ensure the oil is warm and has not settled very long (within 30 minutes of shutdown).

•

Place the required drain container under the machine to capture the used oil to be discarded using approved recycling methods.

•

Remove the drain plug and allow approximately 50% of the oil to drain, then place the sample bottle in the stream of draining oil to obtain a representative sample.

Contact your Tigercat dealer to purchase additional or replacement hydraulic sample valves or drain plugs.

Transmission and Axles Samples: • These samples can be taken during the oil change process.

In cases where oil samples must be pumped or otherwise drawn out of a reservoir or housing, a hand operated oil suction pump is also available from your Tigercat dealer.

•

To obtain a representative oil sample, ensure the oil is warm and has not settled very long (within 30 minutes of shutdown).

•

Place the required drain container under the machine to capture the used oil to be discarded using approved recycling methods.

•

Remove the drain plug and allow approximately 50% of the oil to drain, then place the sample bottle in the stream of draining oil to obtain a representative sample.

3.6

Tigercat 234 Loader

Lubrication and Maintenance

GENERAL 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.

CAUTION All handles, steps and platforms must be kept free of grease, oil, fuel mud, snow ice and forest debris to prevent risk of personal injury.

Clean around filler caps before checking or adding fluids.

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.

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

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.

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.

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

Clean up oil spills in engine enclosure immediately.

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

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.

*OIL LOST FROM LEAKAGE

PER LEAKAGE RATE DAY ONE DROP IN 10 SECONDS 0.424 ONE DROP IN 5 SECONDS 0.852 ONE DROP PER SECOND 4.26 THREE DROP PER SECOND 14.2 DROPS BREAK INTO STREAM 90.83

LOST 0IL (LITERS) LOST 0IL (GALLONS) PER PER PER PER PER MONTH YEAR DAY MONTH YEAR 12.72 152.0 0.112 3.36 40.0 25.6 306.6 0.225 6.75 81.0 127.76 1533.1 1.125 33.75 405.0 425.86 5110.31 3.75 112.5 1350.0 2725.5 32706.0 24.00 720.0 8640.0

3.7

Tigercat 234 Loader

Lubrication and Maintenance

GENERAL CHECK EMERGENCY EXIT, MONTHLY:~ An alternate exit route is provided: the right side window can be used as an emergency exit. This exit is only to be used if the side door cannot be opened.

234T-031

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.

IMPORTANT! 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 repositioned itself onto the engine and exhaust parts due to wind turbulence caused by the journey.

SLIDING WINDOW HANDLE

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.

Open the right side window by lifting the latch handle and slide the window open.

1

1

INSIDE CAB

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

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

234T-046B 234T-047

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

R.H. WINDOW SCREEN

On machines equipped with window screens, there are two hand knobs (1), one on the inside and one on the outside that can be removed to open the window screen. Only one hand knob has to be removed to open the window screen as follows:

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

From inside the cab: Open the cab window and turn the inside hand knob (1) counterclockwise to remove the hand knob and open the window screen. Push the window screen out to open it. Exit the cab if you can safely do so.

From outside the cab: The window screen can also be opened from the outside by unscrewing the hand knob on the outside (1) and remove it. When the hand knob is removed the screen can be swung open.

It is therefore essential that this exit be inspected monthly to ensure it is operational.

3.8

Tigercat 234 Loader

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 8 HOURS:~

Clean:~ • Oil cooler, charge air cooler, engine radiator and a/c condenser • Remove potentially damaging limbs or sticks and all debris

• • • •

Check engine coolant level Check engine oil level Drain fuel/water separator Check swing gearbox oil level. Fill reservoir to half way mark.

• Check air cleaner unloader valve.

• Check air intake filter restriction indicator.

Replace primary filter if indicator is in red zone.

Replace secondary (safety) filter every third primary filter change to guarantee maximum performance and reliability.

• Check hydraulic oil level

Check:~ • All engine air intake system components (including charge air cooler) rubber elbows, connector hoses, tubes and clamps for damage, hardening, wear, cracks, leaks, loose clamps or loose hanger bracket hardware and repair or replace immediately.

• For leakage around hydraulic components and flexible hoses • For loose nuts, bolts and fittings • Condition and tension of fan belts.

• Exhaust system for leaks.

• Conduct an overall visual inspection.

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

Lubricate:~ • Rotary Manifold; 1-fitting - 1 shot while swinging • Swing bearing; 1-fitting - 4 shots while swinging • Swing pinion; 1-fitting - 10 shots while swinging • *Boom joint; 2-fittings - purge • *Stick joint; 2-fittings - purge • *Cylinder pins; boom, stick & tilt; 4-fittings - purge *Lubricating cylinder pins and boom joints: 1. Ensure machine is on level ground.

2. Fully extend stick boom cylinder.

3. Lower main boom and force opened grapple firmly into ground but do not lift machine.

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

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

• Yoke pins; 2-fittings - purge • Grapple rotate pinion; 1-fitting - 4 shots, rotate 90° after each shot • Grapple arm pins; 6-fittings - purge • Grapple cylinder pins; 4-fittings - purge

3.9

Tigercat 234 Loader

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 24 HOURS:~

EVERY 125 HOURS:~

• Perform 8 hour maintenance And in addition:~ • Lubricate stabilizer arm pins; 8-fittings - purge • Lubricate stabilizer cylinders; 8-fittings - purge

• Perform 8 hour maintenance • Perform 24 hour maintenance And in addition:~ • Check return filter restriction indicator with engine running at high idle and oil flow Check:~ • Fluid level in batteries unless maintenance free

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

• Engine RPM • All hydraulic pressures • Hydraulic pumps and motor securing bolts • Torque tightening points as per new machine maintenance Visually check for damage to:~ • Main and stick booms and cylinders • Lower frame, stabilizer arms and cylinders • Swing bearing area • Attachment Make repairs immediately Visually inspect for:~ • Frayed electrical wiring and hydraulic hoses • Wear in any other components Clean/replace:~ • Air conditioner re-circulation filter • Cab fresh air filter • Refer to diesel engine service manual and attachment manual for additional required maintenance at this scheduled time period.

3.10

Tigercat 234 Loader

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 250 HOURS:~

EVERY 500 HOURS:~

• Perform 8 hour maintenance

• Perform 8 hour maintenance

• Perform 24 hour maintenance

• Perform 24 hour maintenance

• Perform 125 hour maintenance

• Perform 125 hour maintenance

And in addition:~ • Check fire extinguisher and turn it to mix contents

• Perform 250 hour maintenance And in addition:~ • Replace engine fuel filter

• Lubricate swing gearbox lower bearing; 2-fittings - 5 shots each †

• Replace fuel/water separator filter

NOTE: Do not use a power grease gun. † With gearbox at operating temperature slowly add 5 shots of lithium based EP2 grease to each side of the gearbox. Note: during cold weather applications the swing function must operate for several hours to achieve operating temperature. Caution: Do not force grease, gearbox failure may result. Do not use winter grease. Grease should purge from gearbox pinion seal.

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

• Replace oil in swing gearbox. Fill reservoir to half way mark • Replace hydraulic oil return filters † • Replace swing pump charge pressure filter † • Replace hydraulic oil pilot pressure filter † • Lubricate door and cover hinges; 8 fittings - 1 shot Check:~ • Torque on swing bearing and swing gearbox retaining bolts • 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.

3.11

Tigercat 234 Loader

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 1000 HOURS:~

EVERY 2000 HOURS:~

• Perform 8 hour maintenance

• Perform 8 hour maintenance

• Perform 24 hour maintenance

• Perform 24 hour maintenance

• Perform 125 hour maintenance

• Perform 125 hour maintenance

• Perform 250 hour maintenance

• Perform 250 hour maintenance

• Perform 500 hour maintenance

• Perform 500 hour maintenance

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

• Replace air cleaner unloader valve.

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

• Perform 1000 hour maintenance And in addition:~ • Drain and refill hydraulic oil tank with recommended hydraulic oil. Refer to APPROVED HYDRAULIC OILS in THIS SECTION. • Replace all air intake rubber components such as elbows and connectors - High temperatures in this area can cause the rubber to harden.

See AIR INTAKE MAINTENANCE in THIS SECTION. • 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.

3.12

Tigercat 234 Loader

Lubrication and Maintenance

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

IMPORTANT! The machines hydraulic oil is used in the Tigercat Self Propelled Articulating Carrier's drive system. For axle, transmission and park brake oil see the Service and Lubrication chart in section 3 of the carrier's manual.

3.13

Tigercat 234 Loader

Lubrication and Maintenance

LUBRICATION AND SERVICE POINTS

3.14

Tigercat 234 Loader

Lubrication and Maintenance

Tigercat Loader SERVICE AND LUBRICATION POINTS

REFER TO Tigercat OPERATOR’S MANUAL FOR ADDITIONAL INFORMATION

COOLING SYSTEM

2

ENGINE OIL AND FILTER

3

FUEL FILTER (ENGINE)

4

FUEL/WATER SEPARATOR

5

INTANK FUEL STRAINER

CHK CHK

•

DRN

24

7

60/40 ANTIFREEZE/DISTILLED WATER **

•

•

• SEE ENGINE MANUFACTURER'S MAINTENANCE MANUAL FOR PROCEDURES, CAPACITIES AND REPLACEMENT INTERVALS

DESCRIPTION QTY

2000

1000

500

250

CHANGE COOLANT EVERY 2 YEARS

US GAL

1

125

ITEM

LITER

CAPACITY

SERVICE EVERY

8

SERVICE POINT NO.

®

REP

1

REP

1 CHK

1

AIR CLEANER PRIMARY ELEMENT

CHK

1

AIR CLEANER SAFETY ELEMENT

CHK

1

7

AIR CLEANER UNLOADER VALVE

CHK

8

AIR INTAKE CONNECTIONS

CHK

REP

9

HYDRAULIC TANK

CHK

D/R 250

10

RETURN FILTERS † . 3 STANDARD FILTERS . 1 WATER ABSORBING FILTER

6

11

PRESSURE FILTER, PILOT †

12

SWING GEARBOX

13

SWING PUMP CHARGE PRESSURE FILTER

14 15

REP

CHK

CHK

CHECK FILTER RESTRICTION INDICATOR. REFER TO 8 HOUR SCHEDULED MAINTENANCE FOR DETAILS.

1

REFER TO OPERATOR'S MANUAL SECTION 2 FOR DETAILS

1

CHECK FOR LOOSE CLAMPS AND DAMAGED RUBBER COMPONENTS. REPLACE RUBBER COMPONENTS. DRAIN AND REFILL AS REQUIRED BY SEASONAL OIL CHANGE. REFER TO APPROVED HYDRAULIC OILS.

66

REP

4

REP

1

CHECK FILTER RESTRICTION INDICATOR, ON HYDRAULIC OIL RETURN MANIFOLD, WITH ENGINE RUNNING AT HIGH IDLE WITH OIL FLOW HALF FILL RESERVOIR-SAE 75W90 EP OIL

D/R REP

1 SEE LUBRICATION POINTS DIAGRAM

GRAPPLE, Tigercat

SEE MANUFACTURER'S MAINTENANCE SCHEDULE

GRAPPLE, OTHER MANUFACTURERS FIRE EXTINGUISHER

DRAIN TANK, CLEAN OR REPLACE AS NECESSARY

CHK

1

TURN TO MIX CONTENTS

LEGEND LUBRICATION POINT WITH A DESIGNATED NUMBER OF FITTINGS (2 FTG) AND HOURS BETWEEN SERVICING (125 ). EXCEPT WHERE SPECIFIED, PURGE WITH LITHIUM BASED EP2 GREASE CONTAINING MOLYBDENUM DISULFIDE "MOLY".

** ANTIFREEZE MUST MEET GM 6038M SPECIFICATIONS

- SEE ENGINE MANUFACTURER'S MAINTENANCE MANUAL.

*** DO NOT USE A POWER GREASER. REFER TO SCHEDULED MAINTENANCE: EVERY 250 HOURS IN SECTION 3 OF THE MANUAL FOR DETAILED INSTRUCTIONS. INCORRECT LUBRICATION MAY RESULT IN GEARBOX FAILURE.

†

USE OF FILTERS OTHER THAN GENUINE TIGERCAT REPLACEMENT FILTERS IS NOT RECOMMENDED.

3.15

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

Tigercat 234 Loader

Lubrication and Maintenance

SWING DRIVE LUBRICATION

HALF FILL RESERVOIR WITH RECOMMENDED OIL.

LUBRICATION OF SWING DRIVE GEARBOX LOWER BEARINGS The cavity in the lower portion of the gearbox where the two lower bearings are housed is completely filled with grease.

WINDSHIELD WASHER FLUID RESERVOIR

LOWER BEARING GREASE FITTINGS CONNECTING HOSE TO GEARBOX 234E-236

SWING DRIVE GEARBOX OIL RESERVOIR

LUBRICATION OF SWING DRIVE GEARBOX UPPER GEARING

234E-260

SWING DRIVE GEARBOX ENCLOSURE

Open the swing drive gearbox enclosure and locate the grease fittings. Using a hand grease gun and with the gearbox at operating temperature slowly add 5 shots of lithium based ep2 grease to each side of gearbox every 250 hours. DO NOT OVERGREASE.

The swing gearbox upper gearing is filled with gear oil. Check oil level in the bottle every 8 hours.

The oil reservoir is located on the side of the swing drive gearbox enclosure. Oil level in the bottle must be kept at the half full mark at all times. Drain and replace swing drive gearbox upper bearing gear oil every 500 hours. Use 75W-90 or 80W-140 gear oil.

For additional information refer to SECTION 15 in the SERVICE MANUAL.

Note: During cold weather applications the swing function must operate for several hours to achieve operating temperature. If machine is not warmed up, the lower seal can be damaged.

Important!: Do not force grease, gearbox failure may result. Do Not use a power grease gun to lubricate this machine. Use a hand grease gun only.

For additional information refer to SECTION 15 in the SERVICE MANUAL.

3.16

Tigercat 234 Loader SWING PINION GREASE FITTING

Lubrication and Maintenance ROTARY MANIFOLD LUBRICATION

SWING BEARING GREASE FITTING

ROTARY MANIFOLD GREASE FITTING

SWING FOOT PEDAL 250C-005 LUBRICATION OF SWING PINION AND SWING BEARING

250C-005

To lubricate the swing bearing, apply 4 shots of grease while swinging every 8 hours to the right grease fitting located by the swing foot pedal in the operator's cab. To lubricate the swing pinion (or teeth) apply 10 shots grease every 8 hours while swinging to the left grease fitting located by the swing foot pedal. The grease fittings are clearly labelled.

SWING FOOT PEDAL

LUBRICATION OF ROTARY MANIFOLD To lubricate the rotary manifold, apply 1 shot of grease while swinging every 8 hours to the center grease fitting located by the swing foot pedal in the operator's cab. The grease fittings are clearly labelled.

For lubrication schedule, refer to SCHEDULED MAINTENANCE in THIS SECTION.

For lubrication schedule, refer to SCHEDULED MAINTENANCE in THIS SECTION. For additional information refer to SECTION 15 in the SERVICE MANUAL.

3.17

Tigercat 234 Loader

Lubrication and Maintenance

HYDRAULIC OIL RESERVOIR RESERVOIR SIGHT GAUGE

HYDRAULIC OIL FILTERS HYDRAULIC PUMPS

234E-016

HYDRAULIC OIL RESERVOIR

SIGHT GAUGE

LOW LEVEL SENDING UNIT 234E-017

HYDRAULIC OIL SIGHT GAUGE/SENDER

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.

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

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.

3.18

Tigercat 234 Loader

Lubrication and Maintenance

HYDRAULIC TANK VACUUM

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

AIR VENT CHECK VALVE VACUUM PUMP

Do not attempt to START the machine or turn key to the RUN position.

VACUUM SWITCH

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

AIR VENT BREATHER

HYDRAULIC HAND FILL PUMP

RELAY

HYDRAULIC TANK 234E-259

OIL FILL SHUT-OFF VALVE

SOLENOID VALVE

HYDRAULIC TANK VACUUM SYSTEM

By creating a vacuum in the hydraulic tank, it becomes possible to perform service work on the hydraulic system without the need to drain the hydraulic tank. The vacuum inside the tank will "hold" the oil in the tank.

HAND FILL PUMP

SUCTION HOSE IN STORED POSITION

VACUUM SWITCH 'ON' POSITION

VACUUM SWITCH 'OFF' POSITION 244-035

HYDRAULIC TANK VACUUM SWITCH

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.

The hydraulic tank vacuum switch is located on the instrument panel in the cab. The location of the swich varies depending on the machine options This is a two position ON/OFF switch. The light in the switch will come ON to indicate that the vacuum switch is turned ON.

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.

With the key switch in the OFF position and the key removed, turn the vacuum switch to the ON position to run the vacuum pump This will create a vacuum condition (9 in.Hg) in the hydraulic tank.

The vacuum pump will automatically start and stop as necessary to maintain the tank vacuum.

The vacuum switch will also lock out the start solenoid to prevent the engine from being started.

Relieve the vacuum in the tank by placing the vacuum switch in the OFF position. NOTE: The engine will not start until the tank vacuum has been relieved.

3.19

Tigercat 234 Loader

Lubrication and Maintenance

HYDRAULIC OIL RETURN FILTERS

OIL SAMPLING CONNECTOR

HYDRAULIC OIL BYPASS SWITCH

FROM HAND FILL PUMP

RETURN MANIFOLD

FILTER RESTRICTION INDICATOR

1-WATER ABSORBING RETURN FILTER (COLOUR BLUE) HYDRAULIC FILTERS

FROM MAIN VALVE 234E-200

234E-016

FROM MAIN VALVE

FROM ROTARY MANIFOLD

HYDRAULIC OIL RETURN MANIFOLD

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 saw cut machine function operating, the filter restriction indicator should be in the GREEN zone. If the pointer is in the RED zone replace all four filter elements.

HYDRAULIC RETURN FILTERS

The majority of return oil entering the hydraulic tank passes through 4 spin-on hydraulic oil filters.

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

Later machines are equipped with a 20 psi hydraulic oil filter bypass switch which will activate should the filters become restricted. The following Alert message will appear on the computer screen.

3.20

Tigercat 234 Loader

Lubrication and Maintenance

Changing the filters:

FILTER HEAD

1. Ensure Loader is on level ground with stabilizers down. Lower grapple to ground and stop engine.

GASKET

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

FILTER ELEMENT

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.

FILTR_SEALS 2

 'O' Ring Gasket

5. 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.

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)

FILTER HEAD

GASKET

FILTR_SEALS 2

'O' RING GASKET INSTALLATION

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

FILTER ELEMENT

SQUARE SECTION GASKET INSTALLATION

6. Start the engine and check for leaks.

 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.

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

3.21

Tigercat 234 Loader

Lubrication and Maintenance CASE DRAIN STRAINER

HYDRAULIC PILOT FILTER

LOCATED LOWER LEFT SIDE OF ENGINE COMPARTMENT

PILOT FILTER ELEMENT

250B-016

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.

234E-017

CASE DRAIN STRAINER

The case drain strainer is used to filter all case drain oil from the pumps and motors before it returns to the reservoir.

The strainer element requires no regular maintenance over the life of the machine. This element requires maintenance only in the case of damage or contamination due to a hydraulic pump or motor failure.

IMPORTANT: The strainer element is NOT a filter element.

Always use the correct replacement element. Use of an incorrect (filter type) element will result in pump damage.

RETURN DIFFUSERS/STRAINERS From machine #2341296 there are two diffuser/ strainers fitted to the return tubes inside the tank.

DIFFUSER/ STRAINERS

234-196

3.22

HYDRAULIC TANK

Tigercat 234 Loader

Lubrication and Maintenance

SWING PUMP CHARGE PRESSURE FILTER

Changing the filter or strainer: 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.

234-003

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

CHARGE PUMP FILTER

The swing pump charge pressure filter is a full flow filter mounted on a filter head with built-in bypass. The filter is located in the output side of the charge pump.

For service and replacement intervals see SERVICE AND LUBRICATION CHART in THIS SECTION.

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

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.

9. Start the engine and check for leaks.

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

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

Machines are equipped with a charge oil filter bypass switch which will activate should the filter become restricted. The following Alert message will appear on the computer screen.

3.23

Tigercat 234 Loader

Lubrication and Maintenance

FUEL TANK STRAINER FUEL CAP

S≤15 mg/kg ULTRA LOW SULFUR FUEL ONLY

FUEL LEVEL SIGHT GAUGE FILLER TUBE 234E-003

36686AUNI R0

DRAIN PLUG

IMPORTANT! Machines 2341101 to 2342000 have a Tier 4 engine and use Ultra Low Sulfur Fuel ONLY. Refer to engine manufacturer’s operation manual for fuel specification details.

FUEL TANK

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.

AIR VENT PASSAGE FILLER TUBE

INNER FILL TUBE

FUEL LEVEL SIGHT GAUGE

234E-219

FUEL TANK AND FILLER 248-20

FUEL FILL TUBE

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.

3.24

Tigercat 234 Loader

Lubrication and Maintenance

REFUELING PROCEDURE Park machine on level ground, shut off engine and allow machine to cool.

D DO NOT refuel while smoking or near an open flame or sparks.

Clear obstructions from steps and handles needed to access fuel tank.

Open cover on top of fuel tank (if equipped)and clear any debris from around the fill cap.

Remove filler cap slowly to allow pressure to escape from tank.

Inspect fill cap gasket.

Inspect fuel strainer located under the fill cap for debris or damage.

Attach grounding strap if the fueling tank or nozzle is so equipped.

Fill tank until fuel level reaches the strainer or the full mark on the sight gauge if equipped. Do not leave nozzle unattended or spillage may occur.

Remove nozzle and ground strap (if applicable), then install fill cap hand tight before closing fill cap cover.

Before restarting the machine, check that no other personnel have moved into the hazardous area and sound the horn.

3.25

Tigercat 234 Loader

Lubrication and Maintenance

ENGINE FILTERS - REMOVE AND REPLACE

WARNING

This machine is equipped with two fuel filters.

The secondary fuel filter is a combination unit, with a replaceable fuel filter with drain valve and a reusable water in fuel sensor. For service and replacement intervals see SERVICE AND LUBRICATION POINTS in THIS SECTION. Refer also to engine manufacturer's manual for more detailed information.

SECONDARY FUEL FILTER/ WATER SEPARATOR

HAND PRIMER

The fuel pump high-pressure fuel lines and fuel rail contain very high pressure fuel.

Never loosen any fittings while the engine is running. Personal injury and property damage can result.

PRIMARY FUEL FILTER AND SECONDARY FUEL FILTER/WATER SEPARATOR Changing the primary fuel filter: 1. Park machine on level ground, lower stabilizers and grapple to the ground, stop engine.

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

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

PRIMARY FUEL FILTER

4. Wearing face protection (in case of a fuel spray) unscrew the old filter. Dispose of any fuel and the fuel filter properly.

DRAIN TAP

5. Check the seating area for the o-ring on the filter head and wipe clean.

6. Lubricate the o-ring on top of the new filter with clean engine oil. DO NOT PRE-FILL the new filter.

ENGINE FUEL FILTER AND FUEL FILTER/ 234E-262 WATER SEPARATOR IMPORTANT !

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

7. Screw the new filter on to the filter head as specified by the filter manufacturer. Note: Mechanical overtightening can damage the filter element.

8. Prime the fuel system using the hand primer on the secondary fuel filter/water separator before starting the engine.

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 manual.

Tier III and IV engines typically use filters with a very fine micron rating. If the fuel supply is dirty, the fuel filter must be replaced more frequently than recommended in the owner’s manual. Operating the machine with a clogged fuel filter will result in low engine power. It is also recommended that the fuel/water separator bowl be drained daily.

Loosen the plug on the top of the secondary fuel filter. Pump the hand primer until fuel begins to seep out around the loosened plug, continue to pump until no air bubbles are visible (approximately 30 pumps). Tighten the plug. Pump the hand primer 30 more times.

9. Start the engine and check for leaks. Refer to STARTING ENGINE in SECTION 2 of the OPERATOR'S MANUAL.

When installing a new fuel filter, do not pre-fill with diesel fuel, or engine fuel pump damage will result.

This type of failure is not warrantable by the engine manufacturer.

To prolong the operating life of the fuel filter, ensure that the fuel supply storage tank is clean and free of water and that the fuel is pre-filtered prior to adding it to the machine.

3.26

WARNING

Drain fuel filter into a container and dispose of all fluids properly.

Tigercat 234 Loader PLUG

Lubrication and Maintenance 13. Prime the fuel system using the hand primer on the secondary fuel filter/water separator before starting the engine.

HAND PRIMER

SECONDARY FUEL FILTER/ WATER SEPARATOR

DRAIN TAP

234E-263

Loosen the plug on the top of the secondary fuel filter. Pump the hand primer until fuel begins to seep out around the loosened plug, continue to pump until no air bubbles are visible (approximately 30 pumps). Tighten the plug. Pump the hand primer 30 more times.

WATER IN FUEL SENSOR

14. Start the engine and check for leaks. Refer to STARTING ENGINE in SECTION 2 of the OPERATOR'S MANUAL.

SECONDARY FUEL FILTER/ WATER SEPARATOR

WARNING

Changing the secondary fuel filter/water separator:

Drain fuel filter into a container and dispose of all fluids properly.

1. Park machine on level ground, lower stabilizers and grapple to the ground, stop engine.

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

3. Place a suitable container under the filter and/ or place rags below to catch the spillage of fuel.

4. Use filter drain to drain fuel out of the filter for approximately 5 seconds. This will prevent fuel from running over the top of the filter when it is removed.

ENGINE OIL FILTER

5. Disconnect the water in fuel sensor from the wiring harness.

6. Wearing face protection (in case of a fuel spray) unscrew the old filter. Dispose of any fuel properly .

ENGINE OIL FILTER

7. Remove the water in fuel sensor from the fuel filter. Dispose of the fuel filter properly.

8. Install the water in fuel sensor in the new filter.

(Inspect water in fuel sensor for damage and replace as required.)

234E-261

9. Check the seating area for the o-ring on the filter head and wipe clean.

10. Lubricate the o-ring on top of the new filter with clean engine oil. DO NOT PRE-FILL the new filter.

ENGINE OIL FILTER

Refer to the appropriate engine manufacturer's operation and maintenance manual for correct procedures and time intervals when servicing the engine oil filter.

11. Screw the new filter on to the filter head as specified by the filter manufacturer. Note: Mechanical overtightening can damage the filter element.

12. Connect water in fuel sensor to the wiring harness.

3.27

Tigercat 234 Loader

Lubrication and Maintenance

AIR CLEANER MAINTENANCE 2340601 TO 2341100

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

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

AIR CLEANER

234-006

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

IMPROPER SERVICING

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

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

SAFETY ELEMENT

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

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

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

4. Always clean the inside of the outlet tube.

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

PRIMARY ELEMENT

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.

3.28

AIR CLEANER

AIR FILTER ELEMENTS

Tigercat 234 Loader

Lubrication and Maintenance

INDICATOR SAFETY ELEMENT

250B-023

FILTER RESTRICTION INDICATOR

FILTER RESTRICTION INDICATOR A filter restriction indicator is located beside the air cleaner. The indicator is connected to the outlet side of the air filter with a 1/4" diameter hose.

Replace the primary air filter when the indicator shows RED. This indicator provides a continuous reading whether the engine is running or is shut down. After replacing the filter, reset the indicator by pressing the reset button.

NOTE: Replace the safety element every third primary filter change.

PRIMARY ELEMENT UNLOADER VALVE AIR CLEANER

AIR FILTER ELEMENTS

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

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

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

The valve should suck closed at engine warm-up speed.

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

INTAKE TUBING AND JOINTS Check all air intake system components, rubber elbows, connector hoses, tubes and clamps for damage, hardening, wear, cracks, leaks, loose clamps or loose hanger bracket hardware and repair or replace immediately.

Replace all air intake rubber components such as elbows and connectors every 2000 hours - High temperatures in this area can cause the rubber to harden.

3.29

Tigercat 234 Loader

Lubrication and Maintenance

AIR CLEANER MAINTENANCE 2341101 TO 2341200

AIR CLEANER AIR CLEANER INTAKE HOSE PRECLEANER HOUSING

AIR FILTER RESTRICTION INDICATOR AIR CLEANER ASSEMBLY AIR CLEANER UNLOADER VALVE

ENGINE COMPARTMENT FRONT ACCESS

234E-198

INDICATOR

SAFETY ELEMENT PRIMARY ELEMENT

234E-202

AIR FILTER RESTRICTION INDICATOR

UNLOADER VALVE

AIR FILTER ELEMENTS 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.

A filter restriction indicator is located in the engine enclosure beside the air cleaner. The indicator is remote mounted and is connected to the outlet side of the air filter with a 1/4" diameter hose.

Replace the primary air filter when the restriction indicator shows RED. This indicator provides a continuous reading whether the engine is running or is shut down. After replacing the filter, reset the indicator by pressing the reset button.

NOTE: Replace the safety element every third primary filter change.

3.30

Tigercat 234 Loader

Lubrication and Maintenance 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

UNLOADER VALVE 234E-201

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

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

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

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

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

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

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

INTAKE TUBING AND JOINTS Check all air intake system components, rubber elbows, connector hoses, tubes and clamps for damage, hardening, wear, cracks, leaks, loose clamps or loose hanger bracket hardware and repair or replace immediately.

Replace all air intake rubber components such as elbows and connectors every 2000 hours - High temperatures in this area can cause the rubber to harden.

IMPORTANT STEPS TO FOLLOW WHEN CHANGING FILTER ELEMENTS 1. Release the cover latches gently to reduce the amount of dust dislodged.

2. Avoid dislodging dust from filter element(s) by gently pulling the element out of the housing.

3. Check your old filter sealing surfaces, This will help detect foreign material on the sealing surface that is causing leakage.

NOTE: Filter elements should never be cleaned and reused. Cleaning causes dust to bypass the filter and be deposited on the inner surface of the filter media. The dust is then drawn directly into the engine.

4. Always clean the inside of the housing.

5. Always clean the sealing surface before inserting a new filter element.

6. Inspect the new filter for damage.

7. Insert the new filter properly. Apply pressure to the filter frame not the pleated filter surface.

8. Check connections hoses and tubes for an air tight fit. Ensure that all clamps, bolts and connections are tight. Check rubber elbows for splits or wear points. Leaks in these locations send dust directly to the engine.

NOTE: Refer to diesel engine manufacturer's operation and maintenance manual for more details and additional required maintenance of the Air Cleaner or replacement of the air filter elements.

3.31

Tigercat 234 Loader

Lubrication and Maintenance

AIR CLEANER MAINTENANCE 2341201 TO 2342000

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

SAFETY ELEMENT

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

PRIMARY ELEMENT UNLOADER VALVE

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

AIR FILTER ELEMENTS

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.

IMPORTANT STEPS TO FOLLOW

FILTER RESTRICTION INDICATOR

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.

FILTER RESTRICTION SENSOR

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.

250B-023A

FILTER RESTRICTION INDICATOR

FILTER RESTRICTION INDICATOR A filter restriction indicator is connected to the outlet side of the air filter. Service to the air 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 the reset button on the end of the indicator.

NOTE: Replace the safety element every third primary filter change.

3.32

Tigercat 234 Loader

Lubrication and Maintenance

The machine is also equipped with an engine air filter restriction sensor which sends a signal to the computer control system in the event of filter restriction. When the air filter is getting close to maximum restriction this ALERT message appears.

AIR CLEANER UNLOADER VALVE 234E-234

AIR CLEANER

AIR CLEANER UNLOADER VALVE

This message can be hidden and will not appear until the next engine start up.

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.

If the ALERT message is ignored and the filter reaches maximum restriction, this CRITICAL message will appear indicating that service to the air filter has reached a critical state.

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

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

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

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

NOTE: Replace the safety element every third primary filter change.

INTAKE TUBING AND JOINTS Check all air intake system components, rubber elbows, connector hoses, tubes and clamps for damage, hardening, wear, cracks, leaks, loose clamps or loose hanger bracket hardware and repair or replace immediately.

Replace all air intake rubber components such as elbows and connectors every 2000 hours - High temperatures in this area can cause the rubber to harden.

3.33

Tigercat 234 Loader

Lubrication and Maintenance

CHECKING AIR CONDITIONING SYSTEM 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.

Any service work must be performed by authorized A/C technicians. The system should be charged with R134a refrigerant (see table below for capacity). 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.

R134a REFRIGERANT 3 LBS. 4 OZ.

PAG OIL (polyalkylene glycol) 2 OZ.

Use the following checklist to maintain system between service intervals. The compressor is located on the left side of the engine. The charge valves and the receiver dryer are located in the lower engine compartment beside the front right engine mount and accessible from either underneath the engine compartment or through the engine compartment door on the rear of the machine.

Perform the following checks on system: a. Check and adjust compressor drive belt tension. Do not over tighten. b. Check fresh air filter and re-circulating air filter.

Clean or replace as required. c. Check to see that compressor clutch will engage. d. Check blower operation and air vents.

A/C COMPRESSOR DRIVE BELT

250B-023

e. Check the condenser core for dirt and debris.

A/C COMPRESSOR

A/C COMPRESSOR

3.34

Tigercat 234 Loader CLEANING A/C CONDENSER AND COOLER PACKAGE

Lubrication and Maintenance PROCEDURE:

The A/C condenser core is located on the right side of the machine in front of the engine. It is one of the cooler cores in the stack of four cores of the cooler package. The cooling fan is mounted on the front of the engine. The fan draws air from the right side of the machine through the door screen, the A/C condenser, the cooler package blowing it out of the opposite side of the machine.

CHARGE AIR COOLER

RADIATOR

250B-009

A/C CONDENSER

ENGINE COMPARTMENT RIGHT SIDE

Remove the six bolts and washers and remove the screen door on the right side of the engine compartment.

OIL COOLER

CAUTION • If using compressed air for cleaning, use at 30 psi. or less.

• Always use personal protective equipment to guard against flying debris.

234-044

A/C CONDENSER AND COOLER PACKAGE

The A/C condenser core and cooler package should be manually checked every 8 hours (every shift) or more often where conditions cause accumulation of twigs, leaves, pine needles and dust. All of the engine enclosure doors should also be checked.

This cooling assembly must be checked daily and may require thorough cleaning on a regular basis depending on operating conditions. Compressed air or water may be used for cleaning. Use personal protective equipment to guard against flying debris.

If an oil leak occurs in this area it should be thoroughly power-washed with a mild soap to ensure that all of the oil is removed. The presence of oil causes dust and dirt to cling to surfaces which will impair the reversible fan's ability to remove dust and dirt particles.

Care must be taken when cleaning this assembly, as the components can be damaged by careless handling and cleaning.

3.35

Tigercat 234 Loader

Lubrication and Maintenance

Parker

Assembly Torque The four-bolt port is simply a circular opening (flow passage) surrounded by four tapped holes in a certain pattern for acceptance of the flange clamping bolts. The flat surface of the port compresses the O-ring contained in the groove in the flange head when the clamp bolts are torqued. In some instances, the groove is in the port and not in the flange head. The bolts, through the clamp halves, clamp down the flange head on to the flat surface of the port compressing and trapping the O-ring in the groove and leaving no gap for it to extrude under pressure. The hydraulic pressure is thus sealed by the compressed O-ring as long as the bolts are tightened enough to maintain solid metal to metal contact between the flange head at the outside diameter of the O-ring and the top of the port.

The 4-Bolt Split Flange consists of four main components: • A body (flange head) • An O-ring • One “captive” or two “split” flange clamps

• Four bolts and washer

WASHERS BOLTS FLANGE CLAMP

Flange Port Assembly The steps to properly assemble the flange port clamping bolts are: 1. Make sure sealing surfaces are free of burrs, nicks, scratches or any foreign particles.

2. Lubricate the O-ring.

3. Position flange and clamp halves.

4. Place lock washers on bolts and insert through clamp halves.

5. Hand tighten bolts.

6. Torque bolts in diagonal sequence (see Fig. T9) in small increments to the appropriate torque level listed in Table T6 or Table T7 on this page.

FLANGE HEAD O-RING TAPPED HOLES

FLANGE

Fig. T8 - 4 Bolt Split Flange Components

FLANGE2

Fig. T9 - Flange Bolt Tightening Sequence

Dash Size

Flange Size

Inch Bolt (J518)

Torque lbf-ft

Metric Bolt (ISO 6162)

Torque Nm

Dash Size

Flange Size

Inch Bolt (J518)

Torque lbf-ft

Metric Bolt (ISO 6162)

Torque N-m

8 12 16 20 24 32 40 48 56 64 80

1/2 3/4 1 1-1/4 1-1/2 2 2-1/2 3 3-1/2 4 5

5/16-18 3/8-16 3/8-16 7/16-14 1/2-13 1/2-13 1/2-13 5/8-11 5/8-11 5/8-11 5/8-11

17 +/- 2 25 +/- 3.5 31 +/- 4.5 41 +/- 5 52 +/- 6 60 +/- 6 85 +/- 9 144 +/- 15 125 +/- 8 125 +/- 8 125 +/- 8

M8 M10 M10 M12 M12 M12 M12 M16 M16 M16 M16

25 49 49 85 85 135 95 220 220 220 220

8 12 16 20 24 32

1/2 3/4 1 1 1/4 1 1/2 2

5/16-18 3/8-16 7/16-14 1/2-13 5/8-11 3/4-10

17 +/- 2 30 +/- 4.5 46 +/- 4.5 69 +/- 6 125 +/- 8 208 +/- 20

M8 M10 M12 M14 M16 M20

25 49 85 135 210 425

* Does not meet ISO 6162 specification.

Table T7 - Code 62 Flange Recommended Bolt Torque

* Does not meet ISO 6162 specification.

Table T6 - Code 61 Flange Recommended Bolt Torque

3.36

Tigercat 234 Loader

Lubrication and Maintenance

Parker

Assembly Torque

JIC 37 Degree Flare SAE Dash Size

Thread Size

-2 -3 -4 -5 -6 -8 -10 -12 -14 -16 -20 -24 -32 -40

NPTF

Tube Connection Swivel or Hose Connection FFWR FFWR

5/16-24 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 3/16-12 1 5/16-12 1 5/8-12 1 7/8-12 2 1/2-12 3-12

NA NA 2 2 1 1/2 1 1/2 1 1/2 1 1/4 1 1 1 1 1 1

SAE Dash Size

NA NA 2 2 1 1/4 1 1 1 1 1 1 1 1 1

-2 -3 -4 -5 -6 -8 -10 -12 -14 -16 -20 -24 -32 -40

F.F.W.R : Flats From Wrench Resistance All values are for Steel, Stainless Steel and Brass

1/8-27 NA 1/4-18 NA 3/8-18 1/2-14 7/8-14 3/4-14 NA 1-11 1/2 1 1/4-11 1/2 1 1/2-11 1/2 2-11 1/2 NA

Thread Size

-2 -3 -4 -5 -6 -8 -10 -12 -14 -16 -20 -24 -32 -40

NA NA 1/4 TO 1/2 NA 1/4 TO 1/2 1/4 TO 1/2 1/4 TO 1/2 1/4 TO 1/2 NA 1/4 TO 1/2 1/4 TO 1/2 1/4 TO 1/2 NA NA

2-3 NA 2-3 NA 2-3 2-3 NA 2-3 NA 1.5-2.5 1.5-2.5 1.5-2.5 1.5-2.5 NA

BSPT

Tube Connection Swivel or Hose Connection FFWR FFWR

NA NA 9/16-18 NA 11/16-16 13/16-16 1-14 1 3/16-12 NA 1 7/16-12 1 11/16-12 2-12 NA NA

2-3 NA 2-3 NA 2-3 2-3 NA 2-3 NA 1.5-2.5 1.5-2.5 1.5-2.5 1.5-2.5 NA

T.F.F.T. : Turns from finger tight All pipe values are for Steel, Stainless Steel and Brass

O'ring Face Seal / Seal-Lok SAE Dash Size

Tube Connection Swivel or Hose Connection TFFT TFFT

Thread Size

SAE Dash Size

NA NA 1/2 TO 3/4 NA 1/2 TO 3/4 1/2 TO 3/4 1/2 TO 3/4 1/3 TO 1/2 NA 1/3 TO 1/2 1/3 TO 1/2 1/3 TO 1/2 NA NA

-2 -3 -4 -5 -6 -8 -10 -12 -14 -16 -20 -24 -32 -40

F.F.W.R : Flats From Wrench Resistance All values are for Steel, Stainless Steel and Brass

Thread Size

Tube Connection Swivel or Hose Connection TFFT TFFT

1/8-28 NA 1/4-19 NA 3/8-19 1/2-14 NA 3/4-14 NA 1-11 1 1/4-11 1 1/2-11 2-11 NA

2-3 NA 2-3 NA 2-3 2-3 NA 2-3 NA 1.5-2.5 1.5-2.5 1.5-2.5 1.5-2.5 NA

2-3 NA 2-3 NA 2-3 2-3 NA 2-3 NA 1.5-2.5 1.5-2.5 1.5-2.5 1.5-2.5 NA

T.F.F.T. : Turns from finger tight All pipe values are for Steel, Stainless Steel and Brass

SAE J1926 Straight Thread Port Assembly Torques ASSEMBLY TORQUE = 10 % -0 SAE DASH SIZE

2 3 4 5 6 8 10 12 14 16 20 24 32

THREAD SIZE

5/16-24 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 3/16-12 1 5/16-12 1 5/8-12 1 7/8-12 2 1/2-12

Nm

TRIPLE-LOK FERULOK PIPE FITTINGS lbf-ft Nm (lbf-in)

20 20 20 40 46 80 135 185 235 270 340 415 510

(85) (155) (260) (280) (350) (620) 85 135 175 200 250 305 375

SEAL-LOK lbf-ft (lbf-in) (310) (310) (310) (360) (420) 60 100 135 175 200 250 305 375

PLUGS

ADJUSTABLE

NON-ADJUSTABLE

10 18 29 32 40 70 115 183 237 271 339 414 509

SEAL-LOK lbf-ft (lbf-in) (310) (310) (310) (360) (420) 60 100 135 175 200 250 305 375

3.37

Nm 20 20 20 40 46 80 135 185 235 270 340 415 510

TRIPLE-LOK FERULOK PIPE FITTINGS lbf-ft Nm (lbf-in) (60) (100) (180) (250) (350) (620) 85 135 175 200 250 305 375

7 11 20 28 40 70 115 183 237 271 339 414 509

HOLLOW HEX HP5ON-S lbf-ft (lbf-in) (30) (55) (120) (170) (410) 60 100 135 175 200 250 305 375

Nm 3.5 6 13.5 19 46 80 135 185 235 270 340 415 510

HEX HEAD P5ON-S lbf-ft (lbf-in) (85) (155) (260) (280) (350) (620) 85 135 175 200 250 305 375

Nm 10 18 29 32 40 70 115 183 237 271 339 414 509

Tigercat 234 Loader

Lubrication and Maintenance

EATON Aeroquip

Assembly Torque

Recommended Parallel Connection Assembly torque

Eaton recommends that a Torque wrench be used to assure proper fitting assembly of these connections.

Straight Thread O-Ring Boss Low Pressure with 37º (SAEJ514)

Straight Thread O-Ring Boss High Pressure with ORS (J1453)

Thread Size (inches) 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 3/16-12 1 5/16-12 1 5/8-12 1 7/8-12 2 1/2-12

Dash Size -03 -04 -05 -06 -08 -10 -12 -14 -16 -20 -24 -32

The values listed are for steel connections. Contact Teaton for torque values for other materials.

Jam Nut or Jam Nut or Straight Straight Fitting Torque Fitting Torque lb.-ft.

Newton Meters 8-9 12-13 13-15 18-20 14-15 19-21 23-24 32-33 40-43 55-57 43-48 59-64 68-75 93-101 83-90 113-122 112-123 152-166 146-161 198-218 154-170 209-230 218-240 296-325

Dash Size -03 -04 -05 -06 -08 -10 -12 -14 -16 -20 -24

ORS

Dash Size -04 -06 -08 -10 -12 -16 -20 -24

Thread Size (inches) 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 3/16-12 1 5/16-12 1 5/8-12 1 7/8-12

Jam Nut or Jam Nut or Straight Straight Fitting Torque Fitting Torque lb.-ft.

Newton Meters 8-10 11-16 14-16 20-22 18-20 24-27 24-26 33-35 50-60 68-78 72-80 98-110 125-135 170-183 160-180 215-245 200-220 270-300 210-280 285-380 270-360 370-490

SAE 37º (JIC) Thread Size (inches) 9/16-18 11/16-20 13/16-16 1-14 1 3/16-12 1 7/16-12 1 11/16-12 2-12

Swivel Nut Torque lb.-ft.

10-12 18-20 32-35 46-50 65-70 92-100 125-140 150-165

Swivel Nut Torque Newton Meters 14-16 24-27 43-47 62-68 88-95 125-136 170-190 204-224

Dash Size -04 -05 -06 -08 -10 -12 -16 -20 -24 -32

Metric Thread Size mm M10x1 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M20x1.5 M22x1.5 M26x1.5 M27x2 M33x2 M42x2 M48x2

Thread Size (inches) 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 5/16-12 1 5/8-12 1 7/8-12 2 1/2-12

Swivel Nut Torque lb.-ft.

11-12 15-16 18-20 38-42 57-62 79-87 108-113 127-133 158-167 245-258

Swivel Nut Torque Newton Meters 15-16 20-22 24-28 52-58 77-85 108-119 148-154 173-182 216-227 334-352

BSPP Straight Adapter or Locknut Torque lb.-ft.

Newton Meters 13-15 18-20 15-19 20-25 19-23 25-30 33-40 45-55 37-44 50-60 52-66 70-90 55-70 75-95 81-96 110-130 96-111 130-150 162-184 220-250 170-192 230-260 258-347 350-470

Nominal Thread Size Straight Adapter or Locknut Torque inches** lb.-ft.

Newton Meters G1/8-28 13-15 18-20 G1/4-19 19-23 25-30 G3/8-19 33-40 45-55 G1/2-14 55-70 75-95 G3/4-14 103-118 140-160 G1-11 162-184 220-250 G1 1/4-11 170-192 230-260 G1 1/2-11 258-347 350-470 ** "G" denotes parallel threads, other than ISO 6149 (Port connection only)

Eaton Aeroquip Fluid Conveyance Products A-HOOV-MC001-E January 2005

3.38

Tigercat 234 Loader

Lubrication and Maintenance

TORQUE CHART LOCATION

THREAD DIAMETER

Cylinders Hoist, Piston nut Hoist, Gland bolts Stick, Piston nut Stick, Gland bolts Stabilizer, Piston nut Stabilizer, Gland bolts Heel, Piston nut Heel, Gland bolts Grapple, Piston nut Grapple, Gland

TORQUE (LUBRICATED) lbf-ft Nm

M60 M14-2 (10.9) M60 M14-2 (10.9) M60 M14-2 (10.9) 2" -12 UNF (GC) M14-2 (10.9) 1 3/4"-12 UNF (GC) 1/2"-13 UNC (G8)

2480 111 2480 111 2480 111 2100 111 1750 80-88

3362 150.5 3362 150.5 3362 150.5 2847 150.5 2355 109-119

3/4"-10 UNC (G8)

282-310

393-420

2"-12 UNF (GC)

400

540

Fixed Heel to Stick boom pin retaining nut

1 1/2"- 6 UNC (GC)

400

540

Heel to Stick boom pin retaining nut

1 3/4"-12 UNF (GC)

400

540

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

400-450 400-450

540-610 540-610

7/8"-9 UNC (G8) M20 (12.9)

400-450 400

540-610 540

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

400-450 40 218 40

540-610 54 296 54

Pump drive Drive plate to flywheel Bell housing to engine

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

33-36 47

45-49 63

Pump mounting Main Pump to Engine Swing Pump to Main Pump

3/4"-10 UNC (G8) 5/8"-11 UNC (G8)

280 160

380 216

Boom joint and cylinder pin retaining bolts Main and Stick boom pin retaining nut

Cab securing bolts Trailer mounting studs

*

Swing bearing bolts Swing gearbox mounting bolts

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

3.39

Tigercat 234 Loader

Lubrication and Maintenance

PRESSURE SETTINGS Engine rpm, Tier 3................................................................1875 rpm Engine rpm, Tier 4................................................................1850 rpm Engine rpm, Tier 3 and Tier 4.................................................900 rpm

@ Full throttle (no load) @ Full throttle (no load) @ Idle (no load)

Pilot System Main Relief ......................................................

@ Idle

500 psi + 1/2 turn in

Main Valve High Pressure Limiting Control Margin Pressure (‘PX’ - ‘PL’) (See note 6)............................. 375 psi Load Sense Relief (‘PL’)...................................................... 3800 psi

@ Idle @ Full throttle

Main Valve Port reliefs Hoist DOWN........................................................................ **Mode 3 6.5 Seconds @ Full throttle Hoist UP.............................................................................. **Mode 3 7 Seconds @ Full throttle Stick IN................................................................................ **Mode 3 5.5 Seconds @ Full throttle Stick OUT............................................................................ **Mode 3 6 Seconds @ Full throttle Feed Reducer Grapple OPEN............................................. 2500 psi Feed Reducer Grapple CLOSE........................................... 2500 psi Feed Reducer Saws RETRACT.......................................... 2500 psi Feed Reducer Saws CUT.................................................... 2500 psi Feed Reducer Grapple Rotate CCW (See Note 5).............. 1750 psi Feed Reducer Grapple Rotate CW (See Note 5 )................ 1750 psi Feed Reducer Delimber OPEN............................................ 2500 psi @ Idle Feed Reducer Grapple Saw CUT (Option)........................... 3000 psi @ Idle Feed Reducer Stabilizer DOWN.......................................... 3000 psi @ Idle Feed Reducer Stabilizer UP................................................. 2000 psi @ Idle Feed Reducer Steer RIGHT................................................ 2000 psi Feed Reducer Steer LEFT.................................................. 2000 psi Feed Reducer Drive FORWARD......................................... 2500 psi Feed Reducer Drive REVERSE.......................................... 2500 psi * Gauge on 'PL' port ** See Machine Mode Adjustment in section 2 of this manual for details.

Swing Pump Swing Pump Charge Pressure ............................................... 360 psi @ Idle Pump POR ........................................................................... 4200 psi @ Full throttle HIGH PRESSURE RELIEF Swing CCW.............................. 4500 psi @ Idle HIGH PRESSURE RELIEF Swing CW................................ 4500 psi @ Idle Swing machine slowly 5 times in each direction before setting pressures. Do not hold pressure over relief more than 8 seconds at a time. Wait 5 seconds to avoid overheating.

NOTES: 1. SYSTEM TO BE AT OPERATING TEMPERATURE WHEN SETTING PRESSURES. 2. ALL PRESSURES MEASURED IN PSI. ALL SPEEDS MEASURED IN SECONDS. 3. F - DENOTES PRESSURES SET AT FULL ENGINE RPM. I - DENOTES PRESSURES SET AT ENGINE IDLE. 4. PORT RELIEFS CANNOT BE ADJUSTED. EACH PORT RELIEF HAS A SPECIFIC SETTING AND SHOULD NOT BE INTERCHANGED WITH OTHER PORT RELIEFS. 5. FOR ROTOBEC HD(HEAVY DUTY) AND HULTDINS GRAPPLES SET ROTATE TO 3000 PSI. 6. SET MARGIN PRESSURE WITH PILOT SYSTEM ACTIVATED (DO NOT USE ANY FUNCTIONS).

3.40

Tigercat 234 Loader

Lubrication and Maintenance

GENERAL TORQUE SPECIFICATIONS

IMPERIAL

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.

GRADE 8 BOLTS

GRADE 5 BOLTS

IMPERIAL BOLT TORQUE SPECIFICATIONS GRADE 5 BOLTS GRADE 8 BOLTS LUBRICATED DRY LUBRICATED COARSE lbf-ft Nm lbf-ft Nm lbf-ft Nm THREAD 8 - 10 11 - 13 1/4" - 20 7- 8 10 - 11 8 - 10 11 - 13 20 - 28 27 - 38 5/16" - 18 14 - 18 19 - 24 10 - 15 13 - 20 33 - 36 45 - 49 3/8" - 16 31 - 34 42 - 46 23 - 25 31 - 34 52 - 57 71 - 77 7/16" - 14 49 - 54 66 - 73 37 - 41 50 - 55 80 - 88 109 - 119 1/2" - 13 75 - 83 102 - 112 57 - 63 77 - 85 115 - 127 156 - 172 9/16" - 12 109 - 120 148 - 162 82 - 90 111 - 122 159 - 175 216 - 237 5/8" - 11 150 - 165 204 - 223 113 - 124 152 - 168 282 - 310 393 - 420 3/4" - 10 266 - 293 360 - 397 200 - 220 271 - 298 455 - 501 617 - 679 7/8" - 9 394 - 433 535 - 586 296 - 326 402 - 441 682 - 750 925 - 1016 1" - 8 591 - 649 802 - 879 443 - 489 601 - 663 966 - 1062 1310 - 1441 1 1/8" - 7 794 - 873 1077 - 1183 596 - 656 808 - 889 1360 - 1496 1844 - 2027 1 1/4" - 7 1120 - 1232 1519 - 1670 840 - 924 1139 - 1252 FINE DRY LUBRICATED LUBRICATED lbf-ft Nm lbf-ft Nm lbf-ft Nm THREAD 10 - 13 14 - 17 1/4" - 28 9 - 10 12 - 13 9 - 10 12 - 13 18 - 25 25 - 33 5/16" - 24 17 - 22 23 - 29 16 - 20 21 - 27 37 - 41 50 - 55 3/8" - 24 35 - 39 48 - 53 26 - 29 35 - 39 58 - 64 79 - 86 7/16" - 20 55 - 61 75 - 83 41 - 45 56 - 61 90 - 99 122 - 134 1/2" - 20 85 - 94 116 - 127 64 - 70 87 - 95 128 - 141 174 - 191 9/16" - 18 121 - 133 164 - 180 91 - 100 124 - 135 180 - 198 244 - 268 5/8" - 18 170 - 187 231 - 253 128 - 141 174 - 191 315 - 347 427 - 470 3/4" - 16 297 - 327 403 - 443 223 - 245 303 - 332 501 - 550 679 - 745 7/8" - 14 434 - 477 589 - 646 326 - 359 442 - 486 746 - 821 1012 - 1113 1" - 12 646 - 711 876 - 965 484 - 534 657 - 724 1083 - 1191 1469 - 1613 1 1/8" - 12 891 - 980 1208 - 1328 668 - 735 906 - 996 1509 - 1660 2046 - 2250 1 1/4" - 12 1240 - 1364 1682 - 1849 931 - 1024 1262 - 1387 4.8

METRIC

8.8

9.8

10.9

4.8

8.8

9.8

10.9

12.9

4.8

8.8

9.8

10.9

12.9

10

5 5

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

10

10

5

10

12.9

12.9

12

10

12

METRIC BOLT TORQUE SPECIFICATIONS

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

12.9

12

DRY lbf-ft Nm 11 - 12 15 - 16 26 - 30 35 - 40 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

10

COARSE THREAD 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 THREAD 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" - 14 1 1/8" - 12 1 1/4" - 12

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

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

M6 M8 M10

4.8 12.0 23.0

3.5 8.5 17.0

6.0 15.0 29.0

4.5 11.0 21.0

9.0 22.0 43.0

6.5 16.0 32.0

11.0 28.0 55.0

8.5 20.0 40.0

13.0 32.0 63.0

9.5 24.0 47.0

17.0 40.0 80.0

12.0 30.0 60.0

15.0 37.0 75.0

11.5 28.0 55.0

19.0 47.0 95.0

14.5 35.0 70.0

M12 M14 M16

40.0 63.0 100.0

29.0 47.0 73.0

50.0 80.0 125.0

37.0 60.0 92.0

75.0 120.0 190.0

55.0 88.0 140.0

95.0 150.0 240.0

70.0 110.0 175.0

110.0 175.0 275.0

80.0 130.0 200.0

140.0 225.0 350.0

105.0 165.0 225.0

130.0 205.0 320.0

95.0 150.0 240.0

165.0 260.0 400.0

120.0 190.0 300.0

M18 M20 M22

135.0 190.0 260.0

100.0 140.0 190.0

175.0 240.0 330.0

125.0 180.0 250.0

260.0 375.0 510.0

195.0 275.0 375.0

330.0 475.0 650.0

250.0 350.0 475.0

375.0 530.0 725.0

275.0 400.0 540.0

475.0 675.0 925.0

350.0 500.0 675.0

440.0 625.0 850.0

325.0 560.0 460.0 800.0 625.0 1,075.0

410.0 580.0 800.0

M24 M27 M30

330.0 490.0 675.0

250.0 360.0 490.0

425.0 625.0 850.0

310.0 650.0 450.0 950.0 625.0 1,300.0

M33 900.0 M36 1,150.0

475.0 825.0 600.0 925.0 675.0 1,150.0 850.0 1,075.0 800.0 1,350.0 1,000.0 700.0 1,200.0 875.0 1,350.0 1,000.0 1,700.0 1,250.0 1,600.0 1,150.0 2,000.0 1,500.0 950.0 1,650.0 1,200.0 1,850.0 1,350.0 2,300.0 1,700.0 2,150.0 1,600.0 2,700.0 2,000.0

675.0 1,150.0 850.0 1,750.0 1,300.0 2,200.0 1,650.0 2,500.0 1,850.0 3,150.0 2,350.0 2,900.0 2,150.0 3,700.0 2,750.0 850.0 1,450.0 1,075.0 2,250.0 1,650.0 2,850.0 2,100.0 3,200.0 2,350.0 4,050.0 3,000.0 3,750.0 2,750.0 4,750.0 3,500.0

TORQUECHARTGENERAL.XLS

3.41

Tigercat 234 Loader

Lubrication and Maintenance

Weights of Commercial Wood

Species

kg/m3

lb/ft3

Species

kg/m3

lb/ft3

Alder, Red Ash, White Aspen, Quaking Bald Cypress Basswood, American Beech, American Birch, Paper Birch, Yellow Cedar, Alaska Cedar, Incense Cedar, Northern White Cedar, Port-Orford Cedar, Western Red Cherry, Black Cottonwood, Eastern Douglas Fir, Coast Douglas Fir, Inland North Elm, American Fir, Alpine Fir, Balsam Fir, Nobel Fir, Red Fir, Silver Fir, White Gum, Black Gum, Blue Gum, Red Gum, Tupelo Hemlock, Eastern Hemlock, Western Hickory, Pecan Hickory, True Larch, Western Locust, Black Magnolia, Cucumber

737 769 689 817 673 865 801 929 577 721 449 897 433 721 785 881 577 865 449 721 481 769 577 753 721 1121 801 897 801 657 993 1009 769 929 785

46 48 43 51 42 54 50 58 36 45 28 36 57 45 49 55 36 54 28 45 30 48 36 47 45 70 50 56 50 41 62 63 48 58 49

Maple, Big Leaf Maple, Black Maple, Red Maple, Silver Maple, Sugar Oak, Black Oak, Chestnut Oak, Red Oak, Red, Swamp Oak, Swamp Chestnut Oak, White Oak, White, Swamp Pine, Jack Pine, Loblolly Pine, Lodgepole Pine, Long Leaf Pine, Norway, Red Pine, Short Leaf Pine, Slash Pine, Sugar Pine, Western Yellow Pine, White-Western Pine, White-Eastern Poplar, Yellow Redwood Spruce, Black Spruce, Engleman Spruce, Red Spruce, Sitka Spruce, White Sweetgum Sycamore, American Tamarack Walnut, Black Willow, Black

753 865 801 721 897 1009 977 1009 1073 1041 993 1105 801 993 625 993 673 993 993 817 721 561 577 609 801 513 625 545 529 545 801 833 753 929 801

47 54 50 45 56 63 61 63 67 65 62 69 50 62 39 62 42 62 62 51 45 35 36 38 50 32 39 34 33 34 50 52 47 58 50

Note: The values shown here are green weights.

3.42

Tigercat 234 Loader SECTION 4 – HYDRAULIC SYSTEM CONTENTS - SECTION 4 C

ISSUE 2.0, JULY 2015

CIRCUIT DIAGRAM LOAD SENSING SYSTEM................................................................................................................... 4.14 E

ELECTRONIC CONTROLS DESCRIPTION 2340601 TO 2341050............................................................................................................................. 4.6 2341051 TO 2341100............................................................................................................................. 4.7 2341101 TO 2342000............................................................................................................................. 4.8 H

HYDRAULIC OIL RESERVOIR DESCRIPTION....................................................................................................................................... 4.2 HYDRAULIC OIL RESERVOIR 2340601 TO 2341295.......................................................................... 4.3 HYDRAULIC OIL RESERVOIR 2341296 TO 2342000.......................................................................... 4.3 HYDRAULIC PUMPS GENERAL DESCRIPTION..................................................................................................................... 4.4 MAIN PUMP............................................................................................................................................4.4 HYDRAULIC SYSTEM OPERATION MAIN CIRCUIT DESCRIPTION............................................................................................................ 4.13 MAIN HYDRAULIC CIRCUIT................................................................................................................ 4.13 MAIN HYDRAULIC SYSTEM................................................................................................................. 4.2 MARGIN PRESSURE............................................................................................................................. 4.5 PILOT CIRCUIT...................................................................................................................................... 4.2 L

LOAD SENSING BASIC DESCRIPTION CLOSED CENTRE SYSTEM............................................................................................................ 4.12 OPEN CENTRE SYSTEM................................................................................................................. 4.11 BASIC PRINCIPALS............................................................................................................................. 4.10 MARGIN PRESSURE............................................................................................................................. 4.5 OPERATING TIPS................................................................................................................................ 4.13 SET MARGIN PRESSURE................................................................................................................... 4.19 M

MAIN CONTROL VALVE HIGH PRESSURE LIMITING CONTROL VALVE................................................................................. 4.18 MAIN PUMP POR VALVE SETTING........................................................................................................ 4.20 P

POR VALVE SETTING............................................................................................................................. 4.20

Tigercat 234 Loader

Hydraulic system

HYDRAULIC SYSTEM OPERATION

3. PILOT CIRCUIT The pilot circuit is supplied with oil from the main pump via the main control valve. The pilot system is turned on and off by the pilot shut off valve located on the pilot manifold which is controlled by the armrest switch and the pilot reset button. Refer to PILOT SYSTEM description in SECTION 5 of this manual.

The hydraulic system has two separate circuits; 1. Variable-displacement swing drive closed loop hydraulic circuit with internal charge pump.

2. Variable-displacement main hydraulic circuit for the boom hoist and stick/delimber/slasher/ grapple open/close and grapple rotate.

The pilot circuit is supplied oil by the main pump via the main hydraulic valve.

HYDRAULIC OIL RESERVOIR

1. MAIN HYDRAULIC SYSTEM

Also refer to SECTION 2 of the OPERATOR'S MANUAL for additional service information.

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

Located at the left rear corner of the machine, the hydraulic reservoir (or tank) has a capacity of 66 U.S. gallons (250 L).

Hydraulic oil is drawn from the tank by the pumps through the suction hose and tube at the base of the tank. The bulk of the oil returning to the tank is directed to the return manifold and the four return filters and from there to the return tubes in the hydraulic tank. There is a bypass valve built into each filter head preset at 25 psi. which will open in the event the elements become restricted. From machine serial # 8341291 there is a filter by-pass switch installed which when activated will sound the alarm and a message will be displayed on the MD3.

This feature improves fuel economy and cuts back on heat generation because power is not wasted on excess pump flow that is not being used. Refer to LOAD SENSING HYDRAULIC SYSTEM in THIS SECTION. The horsepower limiting control is one which ensures that the engine will not lug down below the full load rpm by reducing the output from the main hydraulic pump. Refer to ENGINE ANTI-STALL description in SECTION 9 of this manual.

From machine #2341296 there are two diffuser/ strainers fitted to the return tubes inside the tank.

The main control valves are pressure and flow compensated to provide load independent operation for all functions.

Case drain oil from the main pump, swing pump, swing motor, and pilot return lines go through a spin-on strainer and returns to the reservoir.

This strainer should be changed according to the maintenance schedule but should also be changed any time that a pump or swing motor is replaced.

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

2. SWING SYSTEM This closed loop circuit uses a variabledisplacement piston pump which delivers oil to the swing motor and back to pump. Foot pedal operated pilot valves located in the cab direct pilot oil to the swing pump controller.

The internal charge pump provides make up oil to keep the swing pump charged as well as provide cooling and lubricating oil for the pump.

STRAINER SERVICE NOTE The strainer should be checked whenever the hydraulic tank is drained at the intervals specified in the LUBRICATION AND MAINTENANCE SCHEDULE in SECTION 3 of THIS MANUAL.

The swing motor is a bent axis piston type that is bolted to the swing gearbox. The gearbox is a double reduction planetary gear unit with a spring-applied, hydraulic-release disc brake. This provides continuously variable swing speeds up to 9 rpm. A rotary manifold provides hydraulic connection to the undercarriage and permits continuous 360 degree swing.

4.2

Tigercat 234 Loader HYDRAULIC OIL RESERVOIR

Hydraulic system BREATHER RETURN TUBES

DUAL FILTER HEADS (2)

OIL LEVEL SIGHT GAUGE

RETURN MANIFOLD

RETURN FILTERS (4)

RETURN STRAINER

DRAIN PLUG (UNDER TANK)

234-010

HYDRAULIC OIL RESERVOIR, RETURN STRAINER AND FILTERS 2340601 TO 2341295 HYDRAULIC OIL RESERVOIR

BREATHER

RETURN TUBES DUAL FILTER HEADS (2)

OIL LEVEL SIGHT GAUGE

RETURN MANIFOLD

RETURN FILTERS (4) RETURN STRAINER

DIFFUSER/ STRAINERS DRAIN PLUG (UNDER TANK)

234-196

HYDRAULIC OIL RESERVOIR, RETURN STRAINER,DIFUSSERS AND FILTERS 2341296 TO 2342000 4.3

Tigercat 234 Loader

Hydraulic system

ENGINE BELL HOUSING

MAIN PUMP SWING PUMP

234-057

HYDRAULIC PUMPS

HYDRAULIC PUMPS All hydraulic functions are powered by two pumps.

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

MARGIN PRESSURE ADJUSTING SCREW

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

MAIN PUMP

MAIN PUMP CONTROLLER

For information on the hydraulic circuits that these pumps are part of ; Refer to HYDRAULIC SYSTEM OPERATION in THIS SECTION. MAIN PUMP The main pump is an axial-piston, variabledisplacement pump with load sensing, pressure compensating, and horsepower limiting controls.

234-059

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

4.4

MAIN PUMP CONTROLLER

Tigercat 234 Loader

Hydraulic system MARGIN PRESSURE ADJUSTING SCREW

234-102 234-058

MAIN PUMP

MARGIN PRESSURE When a function control lever is moved, i.e. joystick, to activate a function, LS pressure increases to the point where it is equal to the work port pressure and it shifts the LS control valve.

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

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

The pump then adjusts its output volume until the pump output pressure exceeds the LS pressure by a small amount. This difference is known as MARGIN PRESSURE (Also known as differential pressure Delta P).

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

SWING PUMP

Refer to SET MARGIN PRESSURE in this section.

For the operation and adjustments of this pump refer to SECTION 15 of THIS MANUAL.

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

4.5

Tigercat 234 Loader

Hydraulic system

ELECTRONIC CONTROLS DESCRIPTION 2340601 TO 2341050 LEGEND CAN WIRE WIRE

MD3 COMPUTER MODULE

ELECTRONIC JOYSTICKS

ENGINE ELECTRONIC CONTROL UNIT (ECU)

ELECTRO HYDRAULIC CONTROL VALVES

XA2 EXPANSION MODULE

234-197

Electronic joysticks use electrical signals to turn on electric solenoid controls that activate the main control valves for the boom and grapple functions.

Also on self propelled machines the R.H. joystick can be selected to operate the drive and steer functions. Other switches on the joysticks and instrument panel are used to operate the remaining control valves such as slasher and delimber functions if equipped.

Moving either of the joysticks will send an electronic signal to the MD3 computer module over the CAN network. The signal is then directed to the XA2 expansion module and from the module the signal is directed to the solenoid control for the function that is selected.

The electrical signal activates the solenoid and opens a pilot circuit that directs internal pilot oil to the spool actuator of the control valve selected.

This shifts the spool of the control valve directing pump oil flow to the selected function.

The main valve is supplied with oil from the main pump. The valves receive oil at the inlet section of the main control valve and direct the oil through the spool sections when either of the joysticks are activated.

4.6

Tigercat 234 Loader

Hydraulic system

ELECTRONIC CONTROLS DESCRIPTION 2341051 TO 2341100 MD3 COMPUTER MODULE

LEGEND CAN WIRE XS2 CAB MODULE

WIRE

ELECTRONIC JOYSTICKS

ENGINE ELECTRONIC CONTROL UNIT (ECU)

ELECTRO HYDRAULIC CONTROL VALVES

XA2 EXPANSION MODULE

234-198

Electronic joysticks use electrical signals to turn on electric solenoid controls that activate the main control valves for the boom and grapple functions.

Also on self propelled machines the R.H. joystick can be selected to operate the drive and steer functions. Other switches on the joysticks and instrument panel are used to operate the remaining control valves such as slasher and delimber functions if equipped.

Moving either of the joysticks or activating the buttons will send an electronic signal to the XS2 cab module. The signal is then directed to the XA2 expansion module and from the module the signal is directed to the solenoid control for the function that is selected.

The electrical signal activates the solenoid and opens a pilot circuit that directs internal pilot oil to the spool actuator of the control valve selected.

This shifts the spool of the control valve directing pump oil flow to the selected function.

The main valve is supplied with oil from the main pump. The valves receive oil at the inlet section of the main control valve and direct the oil through the spool sections when either of the joysticks are activated.

4.7

Tigercat 234 Loader

Hydraulic system

ELECTRONIC CONTROLS DESCRIPTION 2341101 TO 2342000 MD3 COMPUTER MODULE

LEGEND CAN WIRE XS2 CAB MODULE

WIRE

ELECTRONIC JOYSTICKS

ENGINE ELECTRONIC CONTROL UNIT (ECU) XA2 -A1 EXPANSION MODULE (OPTIONAL WITH CIRCLE SAW)

ELECTRO HYDRAULIC CONTROL VALVES

XA2 - A0 EXPANSION MODULE

234-199

Electronic joysticks use electrical signals to turn on electric solenoid controls that activate the main control valves for the boom and grapple functions.

Also on self propelled machines the R.H. joystick can be selected to operate the drive and steer functions. Other switches on the joysticks and instrument panel are used to operate the remaining control valves such as slasher and delimber functions if equipped.

Moving either of the joysticks or activating the buttons will send an electronic signal to the XS2 cab module. The signal is then directed to the XA2 - A0 expansion module and from the module the signal is directed to the solenoid control for the function that is selected.

The electrical signal activates the solenoid and opens a pilot circuit that directs internal pilot oil to the spool actuator of the control valve selected.

This shifts the spool of the control valve directing pump oil flow to the selected function.

The main valve is supplied with oil from the main pump. The valves receive oil at the inlet section of the main control valve and direct the oil through the spool sections when either of the joysticks are activated.

4.8

Tigercat 234 Loader

Hydraulic system

ELECTRONIC JOYSTICK FUNCTION Components and Operation: When not actuated the lever (1) is held in neutral position by the return springs (8). When operating the lever (1), the plunger (5) pushes against return spring (8). The magnet (7) mechanically linked to the plunger (5) moves upward or downward while following the levers actuation direction. The electrical signal generated by the sensor (4) is proportional to the deflection of the lever. A rubber boot (6) protects the mechanical components of the housing from external contamination.

MAIN VALVE SPOOL SECTIONS All of the main valve spool sections are equipped with proportional electro-hydraulic solenoid controls. The spools are spring centered to the neutral position. Sending an electrical signal to the desired electro-hydraulic solenoid control causes the solenoid to shift and direct internal pilot oil to the chosen spool actuator shifting the spool and directing pump oil flow to the selected cylinder or motor.

234-053

FEED REDUCER

PORT RELIEF ‘B’ SIDE

PORT RELIEF ‘A’ SIDE

ELECTRONIC JOYSTICK

24V PROPORTIONAL ELECTRO-HYDRAULIC SOLENOID CONTROLS

SPOOL

PRESSURE COMPENSATOR 234-068

CROSS SECTION OF ELECTRO-HYDRAULIC OPERATED SPOOL SECTION

4.9

Tigercat 234 Loader

Hydraulic system

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

FLOW

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

WASTED

W

853SM18

USED

FIG. 1

FIXED DISPLACEMENT PUMP

PRESSURE

FIG. 2

HP

The power wasted in the horsepower control system is still considerable and still requires constant "throttling" by the operator if he wants the speeds to remain as selected.

ANT NST

=CO

FLOW

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

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

853SM16

WASTED

W

USED 853SM19

FIG. 3

HP REGULATED PUMP

PRESSURE

FIG. 4

853SM16

= HP

FLOW

T

N STA

N CO

∆p LS W USED PRESSURE

853SM17

FIG.5

LOAD SENSING (FLOW ON DEMAND) 4.10

FIG.6

853SM16

Tigercat 234 Loader

Hydraulic system

LOAD SENSING BASIC DESCRIPTION OPEN CENTRE VS. CLOSE CENTRE OPEN CENTRE SYSTEM:

853SM21

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

853SM20

With the control valve in neutral all of the oil from the pump “bypasses” through the open center passage directly to tank. There is no back pressure created by the control valve to force oil into the work port (the work port is actually blocked off when the spool is in neutral, and unblocked when the spool begins to move).

853SM21

853SM20

This type of system exhibits the following characteristics;

When the control valve lever is moved to actuate a cylinder or motor, the open center passage is blocked off in proportion to the amount the lever is moved. This creates back pressure forcing oil into the valve work port to move the load.

1. If the load against the cylinder or motor changes, the speed of the function will change.

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

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

853SM20

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

4.11

Tigercat 234 Loader

Hydraulic system

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

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

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

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

853SM22

853SM22

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

853SM22

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

853SM22

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

Changing the control valve lever changes the size of the opening in the valve and upsets the balance of the stroking piston. The stroking piston then 4.12

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

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

Tigercat 234 Loader

Hydraulic system

OPERATING TIPS

MAIN HYDRAULIC CIRCUIT

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

The main hydraulic circuit utilizes a piston pump, which supplies oil to a load sense system, which operates the hoist, stick, live heel option, grapple open/close and the saws functions. The control valve is a seven-section plus mid-inlet section, sectional valve, which sends a load sense signal, from the LS port, to the pump controller whenever one of the functions is activated. Its own spool supplies oil for each function. When all spools are in neutral, no oil is flowing through the valve and hence the system is closed-centre. The pump maintains a stand-by pressure of approximately 500 psi and supplies just enough oil to make up for leakage when all control valves are in neutral.

The hoist, stick, and grapple valve sections utilize cylinder spools, which trap oil in their circuits when the spools are in neutral. The stabilizer and saws valve sections use a motor spool which has a passage between the work ports and the return passage when the spool is in neutral.

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

Refer to SET MARGIN PRESSURE in this section.

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

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

4.13

Tigercat 234 Loader

Hydraulic system

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

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

Without this system, an operator moving control levers halfway on the boom up and stick out controls would find that the lowest pressure function would move and the other would not move.

To make both functions move the operator would have to move the high load lever much more than the low load lever. In other words, the operator would have to restrict oil flow to one function while opening up the valve fully to the other.

This is what the load compensation system does automatically.

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

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

MAIN PUMP

SWING PUMP

'LS' SIGNAL

234-135

LOAD SENSING SYSTEM CIRCUIT DIAGRAM 4.14

Tigercat 234 Loader STICK IN/OUT SECTION

Hydraulic system SAW CUT/ RETRACT SECTION

GRAPPLE OPEN/ CLOSE SECTION

GRAPPLE ROTATE SECTION

DELIMBER OPEN GRAPPLE SAW OPTION SECTION

STABILIZER UP/ DOWN SECTION

B

B

UP

CW

B

A

A

A DOWN

B

B

OPEN

B

B

CCW

CUT

A

RET

CLOSE

A

OPEN

OUT

A

IN

A

DOWN

UP

HOIST UP/DOWN SECTION

UP FEED REDUCER

A GRAPPLE CLOSE FEED REDUCER

GRAPPLE ROTATE FEED REDUCER BOTH DIRECTIONS

A B GRAPPLE OPEN FEED REDUCER

SAW CUT FEED REDUCER

B SAW RETRACT FEED REDUCER

234-131

MAIN CONTROL VALVE FUNCTIONS

234-072

MAIN CONTROL VALVE 4.15

DELIMBER OPEN FEED REDUCER

DOWN FEED REDUCER

GRAPPLE SAW OPTION FEED REDUCER

Tigercat 234 Loader

175 167

Hydraulic system

173

174

172

164

165

163

171

170

70

162

160

71

40275BUNI R1

254

184

234-137

273

185

MAIN CONTROL VALVE 40275BUNI R2

MAIN VALVE DESCRIPTION

INLET SECTION

The main valve is located in the upper frame. It can easily be accessed by removing the valve compartment cover on the left side of the upper frame.

The inlet section is equipped with connection ports to the main pump, tank, a load sense signal (‘LS’) to the main pump, 'PX and 'PL' test ports and 'YS' pilot pressure supply. Also integrated into the inlet section are the main pressure relief, a load sense signal copy valve, and a counter pressure valve.

The main valve is a load sensing and pressure compensated proportional valve and consists of seven* spool sections (*Note: the number of sections installed in the valve will vary with options selected). The valve also includes a mid inlet section and two end sections.

Pilot pressure supply Pilot pressure supply is provided as an internal function of the Main Valve. Pressure is regulated internally to 35 bar (508 psi).

4.16

Tigercat 234 Loader

Hydraulic system

Main Pressure Relief Valve The inlet section of the main valve houses a 330 bar (4785 psi) direct acting port relief. This pressure relief valve is intended to protect the main pump and main valve from pressure peaks in the system. The relief cartridge is not adjustable. Refer to REPLACING MAIN PRESSURE RELIEF VALVE CARTRIDGE in THIS SECTION. Load sensing system Shuttle valves installed in each spool section of the main valve provide the load sense signal from the main valve function sending the highest pressure signal. The load sense signal is sent from the PL port in the main valve to PL port on the main pump.

SPOOL SECTIONS All of the main valve spool sections are equipped with proportional, electro-hydraulic spool actuators. The actuators are spring centered to the neutral position, and are shifted by sending a 24 volt proportional current signal to the appropriate solenoid.

Spools Each of the spools installed in the main valve is selected specifically for the function it is controlling. For example, the hoist boom section spool has different characteristics than the saw cut/retract spool. These spools cannot be interchanged

234-138

SCHEMATIC DIAGRAM OF "LS" CONTROL & VALVE SECTION Feed Reduction Valves

Pressure Compensation

Feed reduction valves (also known as P.O.R. – Pressure Override) are installed in the "Grapple Open/Close", "Gapple Rotate", Saws Cut/ Retract", "Delimber Open","Grapple Saw Option" and "Stabilizer" sections of the main valve. The purpose of the feed reduction is to limit the maximum pressure for those functions flowing oil over relief.

The primary purpose of pressure compensation is to maintain a constant flow rate to function (ie: maintain the same speed of movement), regardless of pressure variations in the system.

The pressure compensator also contains a load-hold check valve. An orifice is installed immediately down stream of the pressure compensator to smoothly regulate the response of the compensator.

Port Reliefs The main valve is equipped with port reliefs on each side of the stick and hoist spool sections as well as the grapple rotate section. The function of the port relief is to protect the valve and the function cylinder or motor from pressure peaks in the system. The port reliefs also act as anticavitation valves, which means they allow oil to flow from the tank gallery in the valve to the service ports in the event of underpressure. The port reliefs cannot be adjusted.

4.17

Tigercat 234 Loader

Hydraulic system

PRESSURE LIMITING CONTROL MARGIN PRESSURE ADJUSTING SCREW

MAIN PUMP CONTROLLER

PUMP 'POR' VALVE

234-058

MAIN PUMP CONTROLLER

The main pump is protected by a POR valve set to 262 bar/3800 psi (Gauge at 'PL' test port on the inlet section of the main valve) . A main relief valve located in the main valve assembly at P1 port also acts as protection from high pressure.

MARGIN PRESSURE ADJUSTING SCREW

MAIN PUMP

234-103

PUMP 'POR' VALVE

MAIN PUMP CONTROLLER

234-059

MAIN PUMP CONTROLLER

The differential pressure (or the difference between 'PX' port pressure and 'PL' port pressure, observed while a function is operating is set to 26 bar/375 psi) is known as margin pressure.

See SET MARGIN PRESSURE in THIS SECTION. The hydraulic system is also equiped with a solenoid actvated pump control valve that is used by the anti-stall circuit to destroke the main pump whenever high loads are detected by the anti-stall system. The pump control valve uses pilot oil to provide a hydraulic signal at port Pf on the main pump horsepower controller. This hydraulic signal shifts the controller spool and destrokes the pump reducing the pump load on the engine.

234-061

4.18

PUMP CONTROL VALVE

Tigercat 234 Loader

Hydraulic system

SET MARGIN PRESSURE MARGIN PRESSURE ADJUSTING SCREW

Margin pressure is set at the factory to 26 bar/375 psi. If required the margin pressure can be adjusted as follows:

MAIN PUMP

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

PUMP 'POR' VALVE

2. With hydraulic oil at operating temperature, connect one side of the differential pressure gauge to the 'PL' gauge test port located on the mid-inlet section of the main control valve and the other side of the gauge to the pressure 'PX' gauge test port.

MAIN PUMP CONTROLLER

234-059

3. Start the engine and and set engine speed to Low Idle.

MAIN PUMP CONTROLLER

MARGIN PRESSURE is the difference between the LOAD SENSE pressure and the PUMP OUTPUT pressure with engine at Idle and pilot circuit engaged. For the load sensing system to operate correctly the differential pressure at 'PX' should be 26 bar/375 psi higher than 'LS'

4. Press PILOT RESET button to activate pilot system with anti-stall switch OFF. 5. Observe gauge.

MARGIN PRESSURE ADJUSTING SCREW

**NOTE: If the margin pressure is not set correctly, the machine controls response may be jerky or sluggish.

MAIN PUMP CONTROLLER

PUMP 'POR' VALVE

234-058

MAIN PUMP CONTROLLER

6. Loosen locknut on margin pressure adjusting screw on main pump controller and turn adjusting screw until the differential reading on gauge/s is 26 bar/375 psi**. (Turn OUT to decrease Margin pressure).

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

234-104

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

INLET SECTION SCHEMATIC

The margin pressure adjustment is made at the main pump controller attached to the main pump.

The pressure gauge connections are the 'PL' and 'PX' gauge test ports on the bottom of the main valve mid-inlet section.

7. Allow a short time for pressure reading to stabilize then tighten locknut on adjusting screw.

4.19

Tigercat 234 Loader

Hydraulic system

MAIN PUMP POR VALVE SETTING

4. Start the engine, and put the throttle control to the FULL position. Lower left arm rest and depress the pilot reset switch to activate the pilot system.

CAUTION

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

5. While holding the L.H. joystick in the HOIST UP position (fully extended), check gauge pressure reading. Should be 262 Bar (3800 psi).

CAUTION

While holding the L.H. joystick in the HOIST DOWN position (fully retracted), check gauge pressure reading. Should be 262 Bar (3800 psi).

Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

If less than set value in one direction but OK in the other direction the port relief valve for the low reading circuit is malfunctioning, replace the port relief valve.

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

If less than set value in both directions turn pump POR valve adjusting screw in (the pressure reading should increase if the POR was set too low) until set value is obtained on gauge.

CHECKING 'POR' VALVE SETTING Main pump POR setting .......... 262 Bar/3800 psi Main relief setting .................... 330 Bar/4785 psi

If when adjusting POR setting the pressure does not change then the main relief is malfunctioning and should be replaced.

Hoist up port relief setting ...... 330 Bar/4785 psi Hoist down port relief setting .330 Bar/4785 psi NOTE: The main and port relief valves are not adjustable, the following procedure is for checking main pump 'POR' pressure only.

MARGIN PRESSURE ADJUSTING SCREW

1. Position machine on flat level ground.

MAIN PUMP CONTROLLER

PUMP 'POR' VALVE

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

'PX' TEST PORT

'PL' TEST PORT

234-058

234E-191

MAIN PUMP CONTROLLER

6. After checking pressures and if POR valve was adjusted reset the POR to 262 Bar (3800 psi). Tighten locknut on POR adjusting screw taking care not to turn the adjusting screw.

MAIN VALVE TEST PORTS

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

3. Connect a0-350 Bar ( 0 - 5000 psi) pressure gauge to the "PL" valve test port on the inlet section of the main control valve.

4.20

Tigercat 234 Loader SECTION 5 – PILOT SYSTEM CONTENTS - SECTION 5 P

ISSUE 2.0, JULY 2015

PILOT CONTROL SYSTEM CIRCUIT DIAGRAM 2340601 TO 2341050............................................... 5.10 PILOT CONTROL SYSTEM CIRCUIT DIAGRAM 2341051 TO 2341100............................................... 5.11 PILOT CONTROL SYSTEM CIRCUIT DIAGRAM 2341101 TO 2342000............................................... 5.12 PILOT HYDRAULIC SCHEMATIC............................................................................................................. 5.5 PILOT SHUT-OFF CIRCUIT DIAGRAM 2340601 TO 2341050................................................................ 5.7 PILOT SHUT-OFF CIRCUIT DIAGRAM 2341051 TO 2341100................................................................ 5.8 PILOT SHUT-OFF CIRCUIT DIAGRAM 2341101 TO 2342000................................................................ 5.9 PILOT SYSTEM COMPONENTS............................................................................................................... 5.2 FOOT PEDALS....................................................................................................................................... 5.4 GENERAL DESCRIPTION..................................................................................................................... 5.2 PILOT MANIFOLD.................................................................................................................................. 5.2 PILOT SUPPLY VALVE........................................................................................................................... 5.2 PRESSURE SETTINGS........................................................................................................................... 5.13

Tigercat 234 Loader

Pilot system

PILOT SYSTEM COMPONENTS

PILOT RELIEF VALVE 234-082

PILOT MANIFOLD

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

PILOT SUPPLY VALVE (pressure reducing/relieving valve)

The pilot manifold distributes oil through 6 ports.

Ports P1, P2 and P3 are supplied pilot oil when the pilot shut-off valve is activated. Ports A, B and C are supplied pilot oil when the pilot shut-off valve and the corresponding solenoid valve are activated.

The pilot supply valve is a pressure reducing relief valve built into the mid-inlet section of the main control valve. The reducing/relieving valve is not adjustable and is set at 500 psi. Refer to SET PILOT PRESSURE in THIS SECTION.

The pilot manifold distributes oil to the following circuits:

LOCATED LOWER LEFT SIDE OF ENGINE COMPARTMENT

PILOT FILTER ELEMENT

250B-016

PILOT MANIFOLD

GAUGE TEST PORT

GENERAL DESCRIPTION The pilot circuit is supplied with oil by the main pump via the main valve. A pilot supply valve located in the main valve reduces and maintains the pressure of the oil from the main pump to 500 psi for the pilot system. The pilot oil (500 psi) is then supplied to the pilot pressure filter and then to the pilot manifold. Pilot oil is distributed by the pilot manifold to the various pilot actuated functions of the machine. Solenoid operated pilot valves, within the pilot manifold, control the flow of pilot oil to various functions. A foot pedal distributes pilot oil to shift a control valve in the swing pump to stroke the pump to the selected swing direction.

HYDRAULIC PILOT FILTER

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

5.2

• Load Sense Pilot supply to main valve

P1

• Pilot Supply to main valve

P2

• Foot pedal swing control

P2

• Grapple Pilot Valve (2341051 and up)

P2

• Gauge Test Port

P3

• Spare (Solenoid Valve)

A

• Delimber Open Hold (Solenoid Valve)

B

• Spare (Solenoid Valve)

C

Tigercat 234 Loader

Pilot system

Pilot oil enters the manifold through the inlet port.

The pilot shut off valve, which is an integral part of the pilot manifold, controls the flow of oil from the INLET port to the outlet ports labelled (P1, P2, P3, and G,) and to the solenoid operated pilot valves. The pilot shut off valve is activated by pressing the pilot reset switch in cab (with the left armrest down).

Two outlet ports ('P1 and P2') on each end of the pilot manifold, feed the main control valve PS port, the swing foot pedal valve,the grapple pilot valve and the load sense pilot supply to the LSP port on the main valve. A gauge test port (P3) has a quick connect fitting installed for connecting a pressure gauge to perform pressure setting procedures.

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

Two tank ports ('T1 and T2') collect oil from all pilot controls. Tank port T3 drains the return oil to the reservoir.

'P2' TO MAIN VALVE 'PS' PORT AND FOOT PEDAL PILOT SUPPLY GAUGE TEST SPARE PORT

DELIMBER OPEN

SPARE

PILOT SHUT OFF VALVE

'P1' TO MAIN VALVE 'LSP'

INLET PILOT RELIEF VALVE

RETURN OIL TO TANK 234-021A 234-013A

PILOT MANIFOLD

5.3

'T' RETURN OIL AND SWING FOOT PEDAL TO TANK

Tigercat 234 Loader

Pilot system

FOOT PEDALS These pilot valves are manually operated, directional control valves and operate on the same principle as a direct operating pressure reducing valve. Operated by foot these valves direct pilot oil to the main control valve pilot end caps. The corresponding spool valve then shifts from its centre position and directs pump flow to operate a function.

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

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

1 5

3 TANK PORT

4 8 2 WORK PORT

AW017

PRESSURE PORT

WORK PORT

FOOT PEDAL PILOT VALVE

5.4

Tigercat 234 Loader

234-200

Pilot system

PILOT HYDRAULIC SCHEMATIC 5.5

Tigercat 234 Loader

Pilot system

PILOT SYSTEM ELECTRICAL CIRCUIT 2340601 TO 2341050

PILOT SYSTEM ELECTRICAL CIRCUIT 2341101 TO 2342000

With the engine running, the pilot on valve solenoid is not energized until the left armrest is down and the pilot ON reset switch is momentarily pressed.

With the engine running, the pilot on valve solenoid is not energized until the left armrest is down and the pilot ON reset switch is momentarily pressed.

When the pilot reset switch is pressed, an input signal is sent to the MD3 module on wire TAN 95.

The left armrest signal is also sent to the MD3 module on wire TAN 33.

When the pilot reset switch is pressed current is supplied to wires 36A-TN and 36-TN. 36TN connects to the armrest switch. When this switch is closed (armrest down) current flows through wire 33A-TN, the relay coil and G33-BK to energize the pilot reset relay. When this relay is activated current is supplied to wire 36B-TN in the cab and the pilot on valve is activated. When the pilot reset switch is released the relay remains latched until the armrest is lifted.

A CAN message is sent to the XA2 module to turn on the PILOT ON output. The CAN circuit goes from the MD3 module to the 2 joysticks and then to the XA2 module.

When the PILOT ON ouput is activated voltage is supplied to the Pilot on solenoid on wire GREEN 185. The pilot ON icon will be activated (GREEN) on the MD3 display.

When the pilot reset relay is activated current is suppplied to the Pilot On Input on the MD3 on wire 33-TN. The pilot ON icon will be activated (GREEN) on the MD3 display.

Whenever the left armrest is placed in the up position the pilot on solenoid is turned off disabling the pilot system. The pilot ON icon will change to YELLOW on the MD3 display.

Whenever the left armrest is placed in the up position the pilot reset relay and pilot on solenoid are turned off disabling the pilot system. The pilot ON icon will change to YELLOW on the MD3 display.

PILOT SYSTEM ELECTRICAL CIRCUIT 2341051 TO 2341100 With the engine running, the pilot on valve solenoid is not energized until the left armrest is down and the pilot ON reset switch is momentarily pressed.

When the pilot reset switch is pressed, an input signal is sent to the MD3 module on wire TAN 95.

The left armrest signal is also sent to the MD3 module on wire TAN 33.

A CAN message is sent to the XA2 module to turn on the PILOT ON output. The CAN circuit goes from the MD3 module to the XS2 module and then to the XA2 module.

When the PILOT ON ouput is activated voltage is supplied to the Pilot on solenoid on wire GREEN 185. The pilot ON icon will be activated (GREEN) on the MD3 display.

Whenever the left armrest is placed in the up position the pilot on solenoid is turned off disabling the pilot system. The pilot ON icon will change to YELLOW on the MD3 display.

5.6

Tigercat 234 Loader

Pilot system

CAB FUSE PANEL

36A-RD

95-TN JOYSTICKS

49-RD

36-RD 33-TN

CAN WIRE "Y" CONNECTORS

185-BK

185-GR

LEGEND CAN WIRE WIRE

234-201

PILOT SHUT-OFF CIRCUIT DIAGRAM 2340601 TO 2341050 5.7

Tigercat 234 Loader

Pilot system

CAB FUSE PANEL

95-TN

49-RD 36A-RD

36-RD

33-TN

185-BK

185-GR

LEGEND CAN WIRE WIRE

234-202

PILOT SHUT-OFF CIRCUIT DIAGRAM 2341051 TO 2341100 5.8

Tigercat 234 Loader

Pilot system

CAB FUSE PANEL

33-TN 49-RD 36B-TN 95A-RD

95-RD 36A-TN G33-BK

PILOT RESET RELAY 33A-TN

36-TN

G36-BK

36C-TN

LEGEND CAN WIRE WIRE

234-203

PILOT SHUT-OFF CIRCUIT DIAGRAM 2341101 TO 2342000 5.9

Tigercat 234 Loader

Pilot system

JOYSTICKS MD3 DISPLAY XA2 EXPANSION MODULE

STABILIZER DIRECTIONAL SWITCH

PILOT ON SOLENOID

PILOT MANIFOLD

185-GR 184-GR 254-GR

175-GR 176A-RD 176-RD 167-GR 174-GR 177A-RD 177-RD 165-GR 173-GR 178A-RD 178-RD 164-GR 172-GR 179A-RD 179-RD 163-GR 162-GR 171-GR 180A-RD 180-RD 170-GR 70-GR 71-GR 160-GR

LEGEND CAN WIRE MAIN VALVE

234-204

PILOT CONTROL SYSTEM CIRCUIT DIAGRAM 2340601 TO 2341050 5.10

WIRE

Tigercat 234 Loader

Pilot system

MD3 DISPLAY

XS2 CAB MODULE

XA2 EXPANSION MODULE

JOYSTICKS

329-GR 328-GR GRAPPLE PILOT VALVE

PILOT ON SOLENOID

STABILIZER DIRECTIONAL SWITCH

PILOT MANIFOLD

185-GR 184-GR 254-GR

175-GR 176A-RD 176-RD 167-GR 174-GR 177A-RD 177-RD 165-GR 173-GR 178A-RD 178-RD 164-GR 172-GR 179A-RD 179-RD 163-GR 162-GR 171-GR 180A-RD 180-RD 170-GR 70-GR 71-GR 160-GR

LEGEND CAN WIRE MAIN VALVE

234-205

PILOT CONTROL SYSTEM CIRCUIT DIAGRAM 2341051 TO 2341100 5.11

WIRE

Tigercat 234 Loader

Pilot system

MD3 DISPLAY

XS2 CAB MODULE

XA2 EXPANSION MODULE

JOYSTICKS

329-GR 328-GR GRAPPLE PILOT VALVE

PILOT ON SOLENOID

STABILIZER DIRECTIONAL SWITCH

TO PILOT RESET RELAY PILOT MANIFOLD 273-GR 184-GR 254-GR

175-GR 176A-RD 176-RD 167-GR 174-GR 177A-RD 177-RD 165-GR 173-GR 178A-RD 178-RD 164-GR 172-GR 179A-RD 179-RD 163-GR 162-GR 171-GR 180A-RD 180-RD 170-GR 70-GR 71-GR 160-GR

LEGEND CAN WIRE MAIN VALVE

234-206

PILOT CONTROL SYSTEM CIRCUIT DIAGRAM 2341101 TO 2342000 5.12

WIRE

Tigercat 234 Loader

Pilot system

SET PILOT PRESSURE GAUGE TEST PORT

PILOT MANIFOLD

PILOT RELIEF VALVE

PILOT MANIFOLD

234-082

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

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

3. Start engine and set throttle in IDLE position.

PILOT MANIFOLD BODY

RELIEF VALVE CARTRIDGE LOCKNUT ADJUSTING SCREW

OUT IN

240B-01

PILOT RELIEF VALVE

4. Loosen locknut on pilot relief valve and turn adjusting screw IN until pressure gauge at pilot manifold reads 500 psi then turn adjusting screw IN an additional 1/2 turn.

5. Stop engine, and remove pressure gauge.

5.13

Tigercat 234 Loader

Pilot system

5.14

Tigercat 234 Loader SECTION 6 – ELECTRICAL SYSTEM AND COMPUTER CONTENTS - SECTION 6 A

ISSUE 2.0, JULY, 2015

ALTERNATOR............................................................................................................................................ 6.4 B

BATTERY COMPARTMENT....................................................................................................................... 6.4 BATTERY DISCONNECT - SWITCH......................................................................................................... 6.4 C

COLD WEATHER STARTING.................................................................................................................. 6.60 COMPUTER ACCESSORIES AUTO SLASHER SAW RETRACT TIME.......................................................................................... 6.30 DELIMBER STATUS......................................................................................................................... 6.30 GRAPPLE SAW RETRACT TIME..................................................................................................... 6.31 TOP SAW RETRACT TIME............................................................................................................... 6.31 ADJUSTMENT MENU.......................................................................................................................... 6.12 ANTI STALL MODE........................................................................................................................... 6.13 CONTROL ADJUSTMENT MENU.................................................................................................... 6.20 DELIMBER STATUS......................................................................................................................... 6.17 GRAPPLE QUICK REVERSAL STATUS.......................................................................................... 6.29 HOIST LIMIT SENSOR STATUS...................................................................................................... 6.28 IDLE DOWN WAIT TIME................................................................................................................... 6.27 LIMP MODE......................................................................................................................................6.21 MACHINE MODE.............................................................................................................................. 6.20 OIL GRADE....................................................................................................................................... 6.13 PASSWORD......................................................................................................................................6.18 PIN CODE.........................................................................................................................................6.18 RESETTING PASSWORD................................................................................................................ 6.18 SAW FLOW ADJUSTMENT.............................................................................................................. 6.18 SLASHER SAW AUTO RETRACT TIME.......................................................................................... 6.15 STICK LIMIT SENSOR STATUS....................................................................................................... 6.28 TOP SAW AUTO RETRACT TIME.................................................................................................... 6.16 ALERT MESSAGES............................................................................................................................. 6.54 DATE/TIME ADJUSTMENT.................................................................................................................. 6.38 DISPLAY ADJUSTMENT...................................................................................................................... 6.36 ELECTRONIC CONTROL & DISPLAY................................................................................................... 6.7 ENGINE SETTINGS ANTI SURGE STATUS...................................................................................................................... 6.34 COLD IDLE SPEED.......................................................................................................................... 6.33 COLD IDLE SPEED STATUS........................................................................................................... 6.33 MAX ENGINE SPEED...................................................................................................................... 6.34 INFORMATION MODE......................................................................................................................... 6.23 MAIN MENU......................................................................................................................................... 6.11 MAIN MENU PAGE............................................................................................................................... 6.23 MD3 MESSAGES ALERT MESSAGE - (YELLOW)....................................................................................................... 6.42 CRITICAL MESSAGE - (RED).......................................................................................................... 6.42 ERROR MESSAGE - (RED)............................................................................................................. 6.42 INFORMATION MESSAGE - (BLUE)................................................................................................ 6.42 MEASURE MENU....................................................................................................................... 6.35, 6.65 MESSAGES - ALERT CHARGE FILTER FAULT.................................................................................................................. 6.55 ENGINE AIR FILTER RESTRICTION............................................................................................... 6.56 ENGINE FAULT CODE MESSAGES................................................................................................ 6.55 HARDWARE FAULT - JOYSTICK..................................................................................................... 6.58 HARDWARE FAULT - MD3............................................................................................................... 6.58

Tigercat 234 Loader

E

Electrical System and Computer

HARDWARE FAULT - XA2................................................................................................................ 6.59 HARDWARE FAULT - XS2................................................................................................................ 6.59 HOIST BOOM LIMIT SENSOR......................................................................................................... 6.57 HYDRAULIC OIL FILTER RESTRICTION........................................................................................ 6.56 STICK BOOM LIMIT SENSOR......................................................................................................... 6.57 MESSAGES - CRITICAL COMMUNICATION FAULT - L.H. JOYSTICK 2340601 TO 2341050............................................... 6.48 COMMUNICATION FAULT - R.H. JOYSTICK 2340601 TO 2341050............................................... 6.48 ENGINE AIR FILTER RESTRICTION............................................................................................... 6.49 ENGINE FAULT CODE MESSAGES................................................................................................ 6.47 ENGINE STOP.................................................................................................................................. 6.44 HARDWARE FAULT - ENGINE......................................................................................................... 6.49 HARDWARE FAULT - MD3............................................................................................................... 6.46 HARDWARE FAULT - XA2................................................................................................................ 6.46 HARDWARE FAULT - XS2................................................................................................................ 6.47 HYDRAULIC OIL LEVEL LOW.......................................................................................................... 6.44 HYDRAULIC OIL TEMPERATURE HIGH......................................................................................... 6.45 MESSAGES - ERROR MODULE NO CONTACT ERROR.................................................................................................... 6.52 MODULE VREF ERROR.................................................................................................................. 6.51 PREFERENCES MENU....................................................................................................................... 6.36 SCREEN SAVER ADJUSTMENT......................................................................................................... 6.37 WARNING BUZZER............................................................................................................................... 6.7 WARNING LIGHT................................................................................................................................... 6.7

ELECTRICAL SCHEMATICS 2340601 TO 2341050 A/C HEATER SCHEMATIC................................................................................................................... 6.86 CAB ACCESSORIES SCHEMATIC...................................................................................................... 6.87 CAB TILT SCHEMATIC......................................................................................................................... 6.89 CAN NETWORK SCHEMATIC............................................................................................................. 6.94 ENGINE MANAGEMENT SCHEMATIC (SHEET 1 OF 2).................................................................... 6.90 ENGINE MANAGEMENT SCHEMATIC (SHEET 2 OF 2).................................................................... 6.91 FUEL HEATER SCHEMATIC................................................................................................................ 6.85 INSTRUMENTATION SCHEMATIC...................................................................................................... 6.92 JOYSTICKS SCHEMATIC.................................................................................................................... 6.95 LIGHTING SCHEMATIC....................................................................................................................... 6.84 STABILIZERS SCHEMATIC................................................................................................................. 6.88 VACUUM PUMP SCHEMATIC 2340601 TO 2342000....................................................................... 6.124 VALVE SCHEMATIC............................................................................................................................. 6.93 ELECTRICAL SCHEMATICS 2341051 TO 2341100 A/C HEATER SCHEMATIC................................................................................................................. 6.100 CAB ACCESSORIES SCHEMATIC.................................................................................................... 6.101 CAB TILT SCHEMATIC....................................................................................................................... 6.103 CAN NETWORK SCHEMATIC........................................................................................................... 6.108 ENGINE MANAGEMENT SCHEMATIC (SHEET 1 OF 2).................................................................. 6.104 ENGINE MANAGEMENT SCHEMATIC (SHEET 2 OF 2).................................................................. 6.105 FUEL HEATER SCHEMATIC................................................................................................................ 6.99 INSTRUMENTATION SCHEMATIC.................................................................................................... 6.106 JOYSTICKS SCHEMATIC.................................................................................................................. 6.109 LIGHTING SCHEMATIC....................................................................................................................... 6.98 STABILIZERS SCHEMATIC............................................................................................................... 6.102 VACUUM PUMP SCHEMATIC 2340601 TO 2342000....................................................................... 6.124 VALVE SCHEMATIC........................................................................................................................... 6.107

6.2

Tigercat 234 Loader

Electrical System and Computer

ELECTRICAL SCHEMATICS 2341101 TO 2342000 CAB ACCESSORIES SCHEMATIC.................................................................................................... 6.115 CAB TILT SCHEMATIC....................................................................................................................... 6.117 CAN NETWORK SCHEMATIC........................................................................................................... 6.122 ENGINE MANAGEMENT SCHEMATIC (SHEET 1 OF 2).................................................................. 6.118 ENGINE MANAGEMENT SCHEMATIC (SHEET 2 OF 2).................................................................. 6.119 FUEL HEATER SCHEMATIC.............................................................................................................. 6.113 HVAC SCHEMATIC............................................................................................................................ 6.114 INSTRUMENTATION SCHEMATIC.................................................................................................... 6.120 JOYSTICKS SCHEMATIC...................................................................................................... 6.123, 6.124 LIGHTING SCHEMATIC..................................................................................................................... 6.112 STABILIZERS SCHEMATIC............................................................................................................... 6.116 VACUUM PUMP SCHEMATIC 2340601 TO 2342000....................................................................... 6.124 VALVE SCHEMATIC........................................................................................................................... 6.121 ELECTRICAL SYSTEM.............................................................................................................................. 6.4 F

FUSES AND RELAYS - CAB - (2340601 TO 2341050)........................................................................... 6.82 FUSES AND RELAYS - CAB - (2341051 TO 2341100)........................................................................... 6.96 FUSES AND RELAYS - CAB - (2341101 TO 2342000)......................................................................... 6.110 FUSES AND RELAYS - REAR PANEL - (2340601 TO 2341100)............................................................ 6.83 FUSES AND RELAYS - REAR PANEL - (2341101 TO 2342000)...........................................................6.111 G

GAUGES AND ALARMS............................................................................................................................ 6.4 L

LOW FUEL LEVEL - FLASHING ICON.................................................................................................... 6.60 M

MD3 COMPUTER...................................................................................................................................... 6.7 MD3 COMPUTER MAIN MENU............................................................................................................... 6.11 S

SCREEN SAVER ADJUSTMENT............................................................................................................. 6.37 SENSORS AND ELECTRICAL COMPONENT LOCATIONS 2340601 TO 2341050................................. 6.5 SENSORS AND ELECTRICAL COMPONENT LOCATIONS 2341051 TO 2342000................................. 6.6 W

WAIT TO START...................................................................................................................................... 6.60

6.3

Tigercat 234 Loader ELECTRICAL SYSTEM

Electrical System and Computer SYSTEM FUSES AND RELAYS Electrical circuit protection is provided by two electrical fuse and relay panels.

234E-147

BATTERY COMPARTMENT

234-062

FUSE AND RELAY PANEL - CAB

One is located below the instrument panel in the cab.

Two 12 volt batteries with 950 cold cranking amps are connected in series to provide a 24 volt electrical power supply.

234-064

FUSE AND RELAY PANEL - ENGINE COMP'T

80 AMP/24 VOLT ALTERNATOR

234-063

An 80 amp, 24 volt alternator is used to charge the electrical system.

BATTERY DISCONNECT SWITCH

234E-145

The other is in the front of the engine compartment.

The fuse and relay panels are discussed in more detail later in this section.

GAUGES AND ALARMS The 234 Loaders are monitored for proper operation by sensors located in the hydraulic system and on the engine. These sensors are connected to the MD3 computer. *NOTE: Panel buzzer sounds when engine oil pressure too low OR engine coolant temperature too high OR hydraulic oil temperature too high OR hydraulic oil level too low.

BATTERY DISCONNECT SWITCH

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.).

6.4

Tigercat 234 Loader

Electrical System and Computer

CONTROL PANEL

PILOT MANIFOLD AND SOLENOIDS

SOLENOID ACTIVATED CONTROL VALVES

PILOT SHUT-OFF SWITCH JOYSTICKS

PILOT PRESSURE RELIEF VALVE

XA2 COMPUTER EXPANSION MODULE

STABILIZER MANIFOLD AND SOLENOIDS

MAIN PUMP CONTROL SOLENOID

FUEL SENSOR

FUSE & RELAY ELECTRICAL BOX (SHOWN MOVED OVER & TURNED UP)

A/C COMPRESSOR

COOLANT LEVEL PROBE

BATTERY DISCONNECT SWITCH

A/C PRESSURE SWITCH

CHARGE FILTER SENSOR

STARTER GRAPPLE RESPONSE VALVE

ALTERNATOR 12 VOLT BATTERIES 24 VOLT SYSTEM

SIGHT GAUGE/SWITCH HYDRAULIC OIL LEVEL (RED LIGHT)

234-154

SENSOR- HYDRAULIC OIL TEMPERATURE

SENSORS AND ELECTRICAL COMPONENT LOCATIONS 2340601 TO 2341050 6.5

SAFETY ALERT HORN (SWITCH ON CONTROL PANEL)

Tigercat 234 Loader

Electrical System and Computer

CONTROL PANEL

GRAPPLE PILOT VALVE PILOT MANIFOLD AND SOLENOIDS

PILOT SHUT-OFF SWITCH JOYSTICKS

SOLENOID ACTIVATED CONTROL VALVES

PILOT PRESSURE RELIEF VALVE

XA2 COMPUTER EXPANSION MODULE

STABILIZER MANIFOLD AND SOLENOIDS

XS2 CAB MODULE

MAIN PUMP CONTROL SOLENOID

FUEL SENSOR

AIR FILTER RESTRICTION SENSOR

FUSE & RELAY ELECTRICAL BOX (SHOWN MOVED OVER & TURNED UP)

A/C COMPRESSOR

COOLANT LEVEL PROBE

BATTERY DISCONNECT SWITCH

A/C PRESSURE SWITCH CHARGE FILTER SENSOR

STARTER GRAPPLE RESPONSE VALVE

SIGHT GAUGE/SWITCH HYDRAULIC OIL LEVEL (RED LIGHT)

234-154

ALTERNATOR 12 VOLT BATTERIES 24 VOLT SYSTEM

SENSOR- HYDRAULIC OIL TEMPERATURE

SENSORS AND ELECTRICAL COMPONENT LOCATIONS 2341051 TO 2342000 6.6

SAFETY ALERT HORN (SWITCH ON CONTROL PANEL)

Tigercat 234 Loader

Electrical System and Computer

WARNING BUZZER

MD3 COMPUTER USB PLUG

WARNING LIGHT MD3 COMPUTER

COLOUR DISPLAY

ARROW (SCROLL) UP OK (ENTER) ARROW (SCROLL) DOWN

F1 234E-006 234E-074

F2

F3

F4

ESC (BACK)

MENU

MD3 COMPUTER, ELECTRONIC CONTROL AND DISPLAY

MD3 COMPUTER ELECTRONIC CONTROL & DISPLAY • Up and down arrow buttons .

Navigation buttons that are used to scroll through selections on a menu page. The buttons are configured by program software to bring up a display page, bring up an adjustment group or act as a virtual input.

The MD3 computer, electronic control and display is the operator interface with the electronic control system. The MD3 is the central unit in the control system which works as both a master controller and a display unit. It has a 3.5" backlit colour graphic transflective display for reading system information.

• OK button .

Pushing this button equals ’enter’. Saves the value or confirms the selection you have made.

The front of the MD3 consists of a control panel with a display and nine buttons. The buttons are arranged on the bottom and right hand side of the display.

• F1 through F4 function buttons

,

• Menu button .

Always brings up the Menu page. It is not programmable.

,

• ’Esc’ or BACK button

, .

Programmed buttons that are configured by program software to bring up a display page, bring up an adjustment group or act as an input.

.

Returns you to the previous display page. May be configured by program software to bring up a display page, bring up an adjustment group or act as a virtual input.

6.7

Tigercat 234 Loader

Electrical System and Computer LEGEND CAN WIRE WIRE

MD3 COMPUTER MODULE

ELECTRONIC JOYSTICKS

ENGINE ELECTRONIC CONTROL UNIT (ECU)

HYDRAULIC CONTROL VALVES

XA2 EXPANSION MODULE

234-197

MD3 COMPUTER ELECTRONIC CONTROL & DISPLAY (2340601 TO 2341050) The MD3 computer control system is part of a network of components (shown above). The system is made up of the following components: •

MD3 Computer and Display Module

•

Electronic Joysticks

•

XA2 Expansion Module

•

Engine Electronic Control Module

•

Hydraulic Control Valve Electronic Solenoids

•

Various controls, switches, sensors and valves not shown.

As an example, the joystick movement/position is transmitted to the MD3 controller electronically over the CAN network. This message is then transmitted to the XA2 expansion module from the MD3 control and on to the hydraulic control valve solenoid controls. The applicable hydraulic control valves will be activated allowing oil to flow to the hydraulic functions activated by the joystick movement.

The engine electronic control module provides electronic information to the MD3 computer via the J1939 CAN BUS link. This information is displayed on the computer display.

The MD3 computer is the main controller in the system. The MD3 computer program is the operating system for the computer display as well as the control system for the machine operating parameters.

6.8

Tigercat 234 Loader

Electrical System and Computer

MD3 COMPUTER MODULE

LEGEND CAN WIRE WIRE

XS2 CAB MODULE

ELECTRONIC JOYSTICKS

ENGINE ELECTRONIC CONTROL UNIT (ECU)

HYDRAULIC CONTROL VALVES

XA2 EXPANSION MODULE

234-198

MD3 COMPUTER ELECTRONIC CONTROL & DISPLAY (2341051 TO 2341100)

The MD3 computer is the main controller in the system. The MD3 computer program is the operating system for the computer display as well as the control system for the machine operating parameters.

The MD3 computer control system is part of a network of components (shown above). The system is made up of the following components: •

MD3 Computer and Display Module

•

Electronic Joysticks

•

XA2 Expansion Module

•

XS2 Cab Module

•

Engine Electronic Control Module

•

Hydraulic Control Valve Electronic Solenoids

•

Various controls, switches, sensors and valves not shown.

As an example, the joystick movement/position will send an electrical signal to the XS2 cab module. This signal is then transmitted to the XA2 expansion module over the CAN network.

The applicable hydraulic control valves will be activated allowing oil to flow to the hydraulic functions activated by the joystick movement.

The engine electronic control module provides electronic information to the MD3 computer via the J1939 CAN BUS link. This information is displayed on the computer display.

6.9

Tigercat 234 Loader

Electrical System and Computer

MD3 COMPUTER MODULE

LEGEND CAN WIRE WIRE

XS2 CAB MODULE

ELECTRONIC JOYSTICKS

ENGINE ELECTRONIC CONTROL UNIT (ECU)

XA2 -A1 EXPANSION MODULE (OPTIONAL WITH CIRCLE SAW)

HYDRAULIC CONTROL VALVES

XA2 -A0 EXPANSION MODULE

234-199

MD3 COMPUTER ELECTRONIC CONTROL & DISPLAY (2341101 TO 2342000)

The MD3 computer is the main controller in the system. The MD3 computer program is the operating system for the computer display as well as the control system for the machine operating parameters.

The MD3 computer control system is part of a network of components (shown above). The system is made up of the following components: •

MD3 Computer and Display Module

•

Electronic Joysticks

•

XA2 -A0 Expansion Module

•

XA2 -A1 Expansion Module (Optional)

•

XS2 Cab Module

•

Engine Electronic Control Module

•

Hydraulic Control Valve Electronic Solenoids

•

Various controls, switches, sensors and valves not shown.

As an example, the joystick movement/position will send an electrical signal to the XS2 cab module. This signal is then transmitted to the XA2 expansion module over the CAN network.

The applicable hydraulic control valves will be activated allowing oil to flow to the hydraulic functions activated by the joystick movement.

The engine electronic control module provides electronic information to the MD3 computer via the J1939 CAN BUS link. This information is displayed on the computer display.

6.10

Tigercat 234 Loader

Electrical System and Computer

MD3 COMPUTER/ELECTRONIC CONTROL/DISPLAY CONT’D 1

2

3

4

13

14

12 5

11

6

7 234-235

8

9

MAIN MENU

MD3 COMPUTER MAIN MENU 1. PILOT RESET ON/OFF 2. ANTI-STALL ON/OFF 3. MACHINE MODE 4. FUEL LEVEL LOW 5. ENGINE TACHOMETER RPM 6. ENGINE MENU - Press F1 to select 7. ADJUSTMENT MENU - Press F2 to select 8. ENGINE COOLANT TEMPERATURE GAUGE 9. INFORMATION MENU - Press F3 to select 10. ALARM INDICATORS - Press F4 to select 11. OIL GRADE INDICATOR 12. HYDRAULIC OIL TEMPERATURE GAUGE 13. ENGINE EMISSION SYSTEM TEMPERATURE 14. COLD IDLE ENABLED 6.11

10

Tigercat 234 Loader

Electrical System and Computer

ENGINE MENU

ADJUSTMENT MENU

From the main menu press the F1 button to select the engine display.

From the main menu press F2 button to select the ADJUSTMENT MENU.

When selected the engine menu icon is on display and the engine functions will also be displayed.

The engine functions on display are as follows: • Charge Air Temperature - °C or °F • Turbocharger Boost Pressure - (Bar or psi) • Engine Load % • Engine Speed rpm • Engine Temperature - °C or °F • Battery Voltage - Volts • Engine Oil Pressure - (Bar or psi)

The adjustment menu screen will be displayed.

The adjustment menu icon is on display and all the adjustment selections will also be displayed.

The adjustment selections are as follows: •

Anti Stall Mode - select F1

•

Oil Grade Adjustments - select F2

•

Slasher Saw Auto Retract Time, Delimber Status (present/not present) and Saw Flow Adjustments - select F3 Control Adjustments - select F4

•

•

Fuel Rate - L/h or gph (instantaneous) Note: To set metric or imperial measure press F1 to change mode.

6.12

Tigercat 234 Loader ANTI STALL MODE SELECTION

Press F1 button to select the ANTI STALL Menu from the ADJUSTMENT MENU. The anti stall menu will appear. Two choices are given, ON or OFF. Press the up or down arrow buttons to scroll to the desired selection and press the OK button when desired mode is selected.

Press the Back button to return to the adjustment menu. Press the Back button again to return to the main menu

Electrical System and Computer .

OIL GRADE SELECTION

Press F2 button to select OIL GRADE Menu from the ADJUSTMENT MENU. The oil grade menu will appear. Five choices are given ISO22, ISO32, ISO36, ISO46 and ISO68.

Press the up or down arrow buttons to scroll to the desired oil grade and press OK when complete.

Press the Back button to return to the adjustment menu. Press the Back button again to return to the main menu.

6.13

Tigercat 234 Loader

Electrical System and Computer •

SAW ADJUSTMENT MODE

Press F3 button to select the SAW ADJUSTMENT Menu from the ADJUSTMENT MENU.

The following adjustments can be selected from the Saw Adjustment Menu: •

Slasher Saw Auto Retract Time - select F1 Note: The display above shows that auto retract time is set to 5 seconds (5.00s)

•

Top Saw Auto Retract Time - select F2 Note: The display above shows that auto retract time is set to 5 seconds (5.00s)

•

Delimber Status - select F3 Note: The display above shows a check mark indicating machine is equipped with a delimber.

6.14

Saw Flow Adjustment - select F4 Note: This adjustment requires entering a PIN Code when F4 is selected the first time in a shift (or after the engine has been shut off).

This procedure is covered later in this section.

Tigercat 234 Loader

Electrical System and Computer

SLASHER SAW AUTO RETRACT TIME

Press F1 button to select the Slasher Saw Auto Retract Time Menu from the SAW ADJUSTMENT MENU.

The value can be set between '0 and 5 seconds' for the Auto Retract Time. This is the amount of time that the saw retract will stay active after the slasher saw cut button has been released. The time should be adjusted to allow the slasher saw bar to retract fully. If the time is set longer than necessary hydraulic heat will be created in the main valve.

If a different value is desired use the up or down arrow buttons to reset the value.

Shown above the value has been adjusted to 2.25 seconds. When the new value is selected, press the OK button to accept the new value and to return to the Saw Adjustment Menu.

The new value for slasher saw auto retract is now displayed (2.25s).

If no other adjustments are required continue to press the back button menu.

NOTE: To disable auto saw retract, set the retract time to 0 seconds.

6.15

to return to the main

Tigercat 234 Loader

Electrical System and Computer

TOP SAW AUTO RETRACT TIME

If a different value is desired use the up or down arrow buttons to reset the value.

Shown above the value has been adjusted to 2.25 seconds. When the new value is selected, press the OK button to accept the new value and to return to the Saw Adjustment Menu.

Press F2 button to select the Top Saw Auto Retract Time Menu from the SAW ADJUSTMENT MENU.

The value can be set between '0 and 5 seconds' for the Auto Retract Time. This is the amount of time that the saw retract will stay active after the top saw cut button has been released. The time should be adjusted to allow the top saw bar to retract fully. If the time is set longer than necessary hydraulic heat will be created in the main valve.

The new value for top saw auto retract is now displayed (2.25s).

If no other adjustments are required continue to press the back button menu.

NOTE: To disable auto saw retract, set the retract time to 0 seconds.

6.16

to return to the main

Tigercat 234 Loader

Electrical System and Computer

DELIMBER STATUS

The photo above shows a check mark beside the delimber icon on the display. This indicates that the delimber option is selected.

Shown above the selection has been changed to No Delimber indicated by the 'X' mark beside the delimber icon and the icon has turned grey to indicate the delimber function is disabled. If the selection is OK then press the back button to return to the previous menu.

If no other adjustments are required continue to press the back button menu.

Press F2 to select delimber status mode. Two choices are available for selection. Delimber or No Delimber. To change the status use the up or down buttons to scroll to the selection desired, then press the OK button to confirm the selection.

6.17

to return to the main

Tigercat 234 Loader

Electrical System and Computer

SAW FLOW ADJUSTMENT

A new message appears on the display "Enter PIN Code. The factory PIN is '0000'. This number will remain the same until the password (PIN Code) is changed. Press the OK button 4 times to enter '0000'.

The saw flow adjustment (F4) provides access to the Top Saw Cut flow rate and Slasher Saw Cut flow rate adjustments.

At this point the check mark will be displayed beside the PIN number to show that the correct PIN code has been selected. The flow adjustment icon will also be displayed above the F4 button If you wish to change the password, select F3 SET PWD. Use the up or down buttons and OK button to enter the new 4 digit PIN. Remember the new PIN code. It will be required after the computer has been turned off when the ignition key has been put in the stop position. See RESETTING THE PASSWORD on this page if you forget the password.

Press F4 button to select the saw flow adjustment from the ADJUSTMENT MENU. This function is password protected and requires entering a 4 digit PIN number to make adjustments.

IMPORTANT! Before making any adjustments make sure you are aware of the flow requirements of your particular saw. Over driving the saw motor with more flow than required can damage your saw.

Select F2 (ENTER PIN) to enter PIN.

RESETTING THE PASSWORD - If you forget the password, hold down on the F1, UP, OK and DOWN buttons

simultaneously. Release the buttons, press the OK button until the 'X' mark appears. Then enter 1234 and press OK. This is the new password. If you wish to change the password, select F3 SET PWD. Use the arrow up/arrow down and OK buttons to enter the new 4 digit PIN.

6.18

Tigercat 234 Loader

When PIN code has been set, a check mark icon will appear and NEW PASSWORD SET message will be displayed on the screen. Also the flow adjustment icon appears on the lower right corner above the F4 button.

Electrical System and Computer

Use the arrow up button to increase the value, or use the arrow down button to decrease the value.

When the desired value has been selected press the OK button to set the value and return to the flow adjustment menu.

NOTE: The PIN code can be reset at any time by selecting F3 SET PWD. Press F4 to select the flow adjustment menu.

The two adjustments are used to control hydraulic flow of the Top Saw (F2) and Slasher Saw (F3).

The adjustments have been factory set. This setting will give a hydraulic flow of 50 GPM to the top saw and 50 GPM to the slasher saw.

IMPORTANT! Before making any adjustments make sure you are aware of the flow requirements of your particular saw. Over driving the saw motor with more flow than required can damage your saw.

Press F3 to select the Slasher Saw Flow adjustment. Use the arrow up button to increase the value, or use the arrow down button to decrease the value. When the desired value has been selected press the OK button to set the value and return to the flow adjustment menu.

Note: To set metric or imperial measure press F1 to change mode.

If no further adjustments are required press the back button

Press F2 to select the Top Saw Flow adjustment.

6.19

to return to the main menu.

Tigercat 234 Loader

Electrical System and Computer

MACHINE MODE ADJUSTMENT SELECTION

The control adjustment (F4) provides access to the machine mode adjustments.

From the main menu press F2 to select the adjust menu.

Press F1 button to select the machine mode from the CONTROL ADJUSTMENT MENU.

In the adjust menu press F4 to select the control adjust menu.

When F1 has been selected a dialogue box will appear in the lower right side of the display. There are four choices to choose from: •

M0 = Training Mode

•

M1 = Machine Mode 1

•

M2 = Machine Mode 2

•

M3 = Machine Mode 3

The machine is factory set at M2. Select M1 for smoother operation and M3 for more aggressive operation. Use the up or down arrow buttons to scroll to the desired selection and press the OK button to set the selection.

Press the back button menu.

6.20

to return to the main

Tigercat 234 Loader

Electrical System and Computer

LIMP MODE OPERATION

The Machine adjust menu appears, press the F4 button to access the Machine Mode Adjustments.

When a critical joystick communication fault occurs the fault warning message appears on the display. The message reads "No contact or invalid data. Limp mode is now available." The limp mode provides the operator with the ability to operate the fault joystick functions using the buttons on the MD3 display.

This will allow the boom to be placed in a safe position before the machine is shut down. Seek service assistance if a joystick fault is active.

The machine mode adjustment menu appears on the display with the Limp Mode Icon located above the F2 button.

Press the F2 button to select the limp mode feature.

To access the limp mode, press the F2 button to hide the warning message.

Press the F2 button to access the machine adjust menu.

6.21

Tigercat 234 Loader

Electrical System and Computer

An information message appears on the display.

The message requires confirmation before the limp mode will be activated. The message is:

Stick Boom In/Out - select and hold F2 button then press arrow up to extend the clinder (boom Out) or arrow down to retract the cylinder (boom In).

Entering Limp Mode Screen commands are now active! Extra care must be taken when manually activating controls.

Pilot system is ACTIVE!

Grapple Rotate - select and hold F3 button then press arrow up to rotate clockwise or arrow down to rotate counterclockwise.

Press the F2 button to hide the message to proceed to the limp mode.

Grapple Open/Close - select and hold F4 button then press arrow up to close the grapple or arrow down to open the grapple.

NOTE: Holding the arrow up or down will increase the function speed to a maximum of 50%. To stop the function, simply release the F1, F2, F3 or the F4 button and the speed will reset to 0%.

The limp mode menu appears on the display and the following functions can be operated: Hoist Boom Up/Down - select and hold F1 button then press arrow up to extend the cylinder (raise the boom) or arrow down to retract the cylinder (lower the boom).

6.22

Tigercat 234 Loader

Electrical System and Computer

INFORMATION MODE SELECTION

MAIN MENU PAGE

Press the F3 button to access the information menu.

Press the menu button menu page.

The information menu displays the following information: •

Engine Hours

•

Machine Hours

•

Hydraulic Oil Temperature

•

Fuel Used in US gal or Liter since last reset

•

Trip Time since last reset

•

Fuel Consumption in US gal/hr or Liter/hr

•

Metric/Imperial Measure Reset - Select F1

•

Fuel Used Reset - Select F2

The main menu page displays the following selections: •

Adjust - Select F1

•

Measure - Select F2

•

Preferences - Select F3

•

Info - Select F4

To return to the Main menu press the back button.

Select F1 to set imperial or metric measure.

Select F2 to reset fuel used and trip time to zero (0).

Press the back button menu.

to go to the main

to return to the main

6.23

Tigercat 234 Loader

Electrical System and Computer

ADJUST MENU

Use the up or down arrow buttons to select the menu item. Press OK to confirm the selection.

From the main menu page press the F1 button (Adjust) to access the adjust menu.

ATTACHMENT FLOW SETTINGS

This menu is an alternate method of accessing the adjustment menu to make machine adjustments. See ADJUSTMENT MENU earlier in this section for details.

Attachment Flow Settings has been selected. Use the up or down arrow buttons to select the menu item. Press OK to confirm the selection.

The Main menu appears and the following menu items can be selected.

• *Attachment Flow Settings • Machine Mode • Machine Parameters • Accessories • Engine *NOTE: Attachment Flow Settings will only appear on this menu when the PIN code has been entered to permit access to this adjustment. For details on entering PIN code see SAW FLOW ADJUSTMENT earlier in this section.

6.24

Tigercat 234 Loader

Electrical System and Computer

TOP SAW FLOW %

SLASHER SAW FLOW %

Top Saw Flow % has been selected. The flow setting value can be adjusted.

Slasher Saw Flow % has been selected. The flow setting value can be adjusted.

IMPORTANT! Before making any adjustments make sure you are aware of the flow requirements of your particular saw. Over driving the saw motor with more flow than required can damage your saw.

IMPORTANT! Before making any adjustments make sure you are aware of the flow requirements of your particular saw. Over driving the saw motor with more flow than required can damage your saw.

Use the up or down arrow buttons to reset the value (0% to 100%). Press OK to confirm the selection.

Use the up or down arrow buttons to reset the value (0% to 100%). Press OK to confirm the selection.

Press the back button to return to the previous menu page.

Press the back button to return to the previous menu page. Continue to press the back button to return to the Adjust menu page.

Press the arrow down to scroll to the slasher saw flow selection and press OK.

Use the up or down arrow buttons to select the Machine Mode menu item. Press OK to confirm the selection.

6.25

Tigercat 234 Loader

Electrical System and Computer

MACHINE MODE

Use the up or down arrow buttons to select the Machine Parameters menu item. Press OK to confirm the selection.

Press the OK button to select Mode Select.

MACHINE PARAMETERS

There are four choices to choose from: •

M0 = Training Mode

•

M1 = Machine Mode 1

In the machine parameters menu the following items can be selected:

•

M2 = Machine Mode 2

•

Anti Stall

•

M3 = Machine Mode 3

•

Oil Grade

•

Idle Down Wait Time

•

Hoist Limit Sensor Status

•

Stick Limit Sensor Status

•

Grapple Quick Reversal Status

The machine is factory set at M2. Select M1 for smoother operation and M3 for more aggressive operation. Use the arrow up button or arrow down button to scroll to the desired selection and press the OK button to set the selection.

Press the back button menu.

to return to the adjust

Use the up or down arrow buttons to scroll to the desired selection and press the OK button to set the selection.

6.26

Tigercat 234 Loader ANTI STALL

In the Anti Stall menu two choices are available, ON or OFF. Use the up or down arrow buttons to scroll to the desired selection and press the OK button to set the selection.

Press the back button to return to the machine parameters menu.

Use the up or down arrow buttons to scroll to the Oil Grade selection and the OK button to set the selection.

OIL GRADE

Electrical System and Computer

Use the up or down arrow buttons to scroll to the Idle Down Wait Time selection and press the OK button to set the selection.

IDLE DOWN WAIT TIME

In the Idle Down Wait Time menu the value can be adjusted from 5 seconds to 60 seconds using the up or down arrow buttons to change the value, then press the OK button to set the new value. The factory default value is 5 seconds. This function is an automatic idle down feature.

AUTO IDLE DOWN - If the engine is set to run at full throttle and no functions are activated for a 5 seconds, the engine will idle down automatically.

The engine will return to the set idle speed as soon as a function is activated.

NOTE: During cold weather the computer limits maximum idle speed until the hydraulic oil has reached a specific temperature based on the oil grade selected. See COLD WEATHER STARTING in this section.

In the Oil Grade menu five choices are available, ISO 22, ISO32, ISO36, ISO46 and ISO 68. Use the up or down arrow buttons to scroll to the desired selection then press the OK button to set selection.

Press the back button to return to the machine parameters menu.

6.27

Tigercat 234 Loader

Electrical System and Computer

HOIST LIMIT SENSOR STATUS 2 proximity sensors are mounted on the hinge point of the stick and hoist booms to provide cushioning of the cylinders as they approach the end of their stroke. This cushioning function can be turned on or off.

STICK LIMIT SENSOR STATUS

Using the up or down arrow buttons scroll to Stick Limit Sensor Status and press OK.

Using the up or down arrow buttons scroll to Hoist Limit Sensor Status and press OK.

Using the up or down arrow buttons to select ON or OFF and press OK. If the limit sensors are enabled the rate at which the cylinders slow down when they approach the end of travel can be controlled through additional adjustments in the IQAN program. See BOOM LIMIT SENSOR ADJUSTMENTS - ELECTRONIC ADJUSTMENT PROCEDURE in SECTION 12 of THIS MANUAL.

Using the up or down arrow buttons to select ON or OFF and press OK.

6.28

Tigercat 234 Loader

Electrical System and Computer

GRAPPLE QUICK REVERSAL STATUS The Grapple Quick Reversal provides a way to quickly open or close the grapple arms if required.

The IQAN computer system monitors the rate of change of joystick movement from open to close or close to open. When it recognizes a rapid change the IQAN system will activate the appropriate grapple pilot valve to apply pilot pressure to the grapple open/close valve on the main valve and override the existing electronic ramp. This function can be enabled or disabled using the MD3 display.

Using the up or down arrow buttons scroll to Grapple Quick Reversal Status and press OK.

Using the up or down arrow buttons to select ON or OFF and press OK. Further Grapple speed and ramp adjustments can be made through the IQAN program. See ELECTRONIC ADJUSTMENT PROCEDURE in SECTION 17 of THIS MANUAL. Press the back button menu.

to return to the Adjust 6.29

Tigercat 234 Loader

Electrical System and Computer AUTO SLASHER SAW RETRACT TIME

Use the up or down arrow buttons to scroll to the Accessories selection and press the OK button to set the selection.

ACCESSORIES

In the Auto Slasher Saw Retract Time selection the value can be adjusted from 0 seconds to 5 seconds. This sets the time after the slasher saw has completed cutting to auto retract.

To reset the value use the up or down arrow buttons to change the value. Then press the OK button to set the value.

In the Accessories menu the following menu items can be selected.

• Auto Slasher Saw Retract Time •

Top Saw Retract Time

•

Grapple Saw Retract Time

•

Delimber Status

Use the up or down arrow buttons to scroll to the Top Saw Retract Time and press the OK button to select the menu item.

Use the up or down arrow buttons to scroll to the desired selection. Then press the OK button to select the choice.

6.30

Tigercat 234 Loader

Electrical System and Computer

TOP SAW RETRACT TIME

GRAPPLE SAW RETRACT TIME

In the Top Saw Retract Time selection the value can be adjusted from 0 seconds to 5 seconds.

This sets the time after the top saw has completed cutting to auto retract.

To reset the value use the up or down arrow buttons to change the value. Then press the OK button to set the value.

In the Grapple Saw Retract Time selection the value can be adjusted from 0 seconds to 5 seconds. This sets the time after the grapple saw has completed cutting to auto retract.

To reset the value use the arrow up or down buttons to change the value. Then press the OK button to set the value.

Use the up or down arrow buttons to scroll to the Grapple Saw Retract Time menu and press the OK button to select the menu item.

Use the up or down arrow buttons to scroll to the Delimber Status menu and press the OK button to select the menu item.

6.31

Tigercat 234 Loader

Electrical System and Computer

DELIMBER STATUS

ENGINE SETTINGS

In the Delimber Status menu two choices can be selected. Delimber or NO Delimber.

Use the up or down arrow buttons to scroll to the desired selection and press the OK button to set the selection. As shown above 'Delimber' is the choice selected.

Press the back button menu page.

Using the up or down arrow buttons scroll to Engine to access the engine adjustment menu.

to return to the Adjust

6.32

Tigercat 234 Loader COLD IDLE SPEED

Electrical System and Computer COLD IDLE SPEED STATUS This setting allows the operator to temporarily set a higher idle speed to assist in warming up the machine when it is cold. This setting will activate a second idle speed ( Cold Idle Speed) that the engine will idle at when the pilot is off. Once the machine is warmed up this setting should be turned off to allow the engine to return to its normal idle speed. When the Cold Idle Speed Status is ON an icon will be activated in the MD3 display.

Using the up or down arrow buttons scroll to Cold Idle Speed and press OK.

Using the up or down arrow buttons scroll to Cold Idle Speed Status and press OK.

Using the up or down arrow buttons set the Cold Idle speed to the desired setting between 950 and 1400 rpm and press OK.

Use the up or down arrow buttons to turn the cold idle function on or off and press OK.

6.33

Tigercat 234 Loader

Electrical System and Computer

ANTI SURGE STATUS The Anti Surge Status is to prevent the engine from lugging down too much when a sudden load is applied like lifting the boom or closing/opening the grapple.

MAX ENGINE SPEED

Using the up or down arrow buttons scroll to Max Engine Speed and press OK. Using the up or down arrow buttons scroll to Anti Surge Status and press OK.

Using the up or down arrow buttons set the Max engine speed to the desired setting between 1450 and 2100 rpm and press OK. Use the up or down arrow buttons to turn the anti surge function on or off and press OK.

6.34

Tigercat 234 Loader

Electrical System and Computer

MEASURE MENU

From the main menu page press the F2 button (Measure) to access the measure menu.

Use the up or down arrow buttons to select the menu item. Press OK to confirm the selection.

This menu is used by Tigercat service technicians.

Refer to SECTION 6 of the SERVICE MANUAL for more information.

Press the back button (or F1) to return to the main menu page.

The following menu items can be selected.

• • • • • • • •

Engine Parameters IQAN Status L.H. Joystick R.H. Joystick Boom Controls Grapple Controls Saw Delimber Input/Output

6.35

Tigercat 234 Loader

Electrical System and Computer

PREFERENCES MENU

DISPLAY ADJUSTMENT

From the main menu page press the F3 button (Preferences) and the preferences menu page appears.

After selecting F1 the display adjustment screen opens and the following adjustments can be selected: RETURN TO MAIN MENU - Select F1 BACKLIGHT ADJUSTMENT - Select F2 SCREEN SAVER - Select F3 BACKLIGHT ADJUSTMENT

The following menu items can be selected.

•

Display

•

Date/Time

•

Language After selecting F2 the backlight adjustment screen opens. Use the up or down arrow buttons to adjust the display backlight. The range is 10 to 100. The default setting is 100.

When the desired setting is selected press the OK button. A good rule to follow is the lower the number the longer the life of the display unit.

6.36

Tigercat 234 Loader

Electrical System and Computer

SCREEN SAVER ADJUSTMENT

Select F3 to open the screen saver adjustment screen. Use the up or down arrow buttons to scroll through the choices. Three choices are available:

•

SCREEN SAVER OFF

•

DIMMED - Timeout 5 seconds

•

BLACK - Timeout 5 seconds

After making a selection press the OK button to confirm selection and press the back button to return to the main menu screen.

6.37

Tigercat 234 Loader

Electrical System and Computer

DATE/TIME ADJUSTMENT

DATE ADJUSTMENT

Press F2 to select the DATE/TIME adjustments in the PREFERENCES menu.

Press F1 to select DATE. Use the up or down arrow buttons to scroll through the YEAR list to select the year. Press OK to confirm year selected.

The DATE/TIME menu screen turns on. Two choices are available for adjustment: DATE - select F1

When the year has been confirmed the display will highlight the MONTH. Use the up or down arrow buttons to select the month. Press OK to confirm month selected.

TIME - select F2

6.38

Tigercat 234 Loader DATE ADJUSTMENT CONT’D

Electrical System and Computer TIME ADJUSTMENT Select F2 Time adjustment from the DATE/TIME display screen.

When the month has been confirmed the display will highlight the DAY. Use the Arrow Up or Arrow Down to select the day. Press OK to confirm day selected.

The Time display screen will turn on. Use the up or down arrow buttons to select the HOUR. Press the OK button to confirm selection. The display will show the MINUTES highlighted.

The display will return to the DATE TIME menu.

Use the up or down arrow buttons to select the minute. Press OK button to confirm the selection.

The display will return to the DATE/TIME menu screen. Press the back button to return to the main menu screen.

6.39

Tigercat 234 Loader

Electrical System and Computer

INFO MENU PAGE

MODULES

From the main menu page press the F4 button (Info) and the Info menu page appears.

Press F1 to select the modules menu. This menu provides information on the following machine modules: •

MD3 Computer Module

•

XA2 Expansion Module

•

Cummins Engine ECM

•

LH Joystick

•

RH Joystick

The following menu items can be selected.

•

Modules - Select F1

•

Logs - Select F3

The machine ID information will be displayed on the screen.

Shown above the MD3 module has been selected. Specific information for the MD3 is displayed on the screen.

This menu is used by Tigercat service technicians.

Refer to SECTION 6 of the SERVICE MANUAL for more information.

Press the back button (or F1) to return to the main menu page.

6.40

Tigercat 234 Loader

Electrical System and Computer

LOGS

Press F3 from the info menu page to select logs.

This menu lists System Logs and Alarm Logs and the number of records within each log. The records are a list of all the fault occurrences in each log.

Use the up or down arrow buttons to select the menu item. Press OK to confirm the selection.

This menu is used by Tigercat service technicians.

Refer to SECTION 6 of the SERVICE MANUAL for more information.

Press the back button (or F1) to return to the main menu page.

6.41

Tigercat 234 Loader

Electrical System and Computer

MD3 MESSAGES MD3 WARNING The MD3 computer displays messages COMPUTER LIGHT and warnings, activates the master alarm and alarm light whenever a system fault occurs. Note that the computer control system will automatically perform a bulb test at engine start up to ensure that master alarm and alarm lightWARNING are functioning.

BUZZER Refer to STARTING ENGINE in THIS SECTION.

There are different types of Messages and Alarms, they appear on the screen as a block message.

The types of messages are: • • • •

CRITICAL MESSAGE - Colour RED ERROR MESSAGE - Colour RED ALERT MESSAGE - Colour YELLOW INFORMATION MESSAGE - Colour BLUE

Messages can be hidden or acknowledged by pressing the F2 button (Hide or OK).

All messages that have been hidden or acknowledged are stored in the computer.

In some instances it will be necessary to immediately stop the machine, shut the engine OFF and repair the problem causing the message.

Active fault messages that have been hidden can be reviewed by pressing the F4 button. Recalled messages will be displayed in order starting with the highest priority first.

6.42

Tigercat 234 Loader CRITICAL MESSAGES (RED)

Electrical System and Computer

Critical messages advise the operator that a critical machine fault is about to occur or a system fault has occurred.

Critical messages have the highest level of priority and are used to alert operator that immediate action must be taken to prevent damage to machine or to ensure operator safety.

When a critical message is displayed, the master alarm and alarm light will sound and flash continuously. The message remains on the screen until the operator hides it.

Critical messages flash the critical symbol above the F4 button when active messages are hidden. The symbol will continue to flash until the problem is resolved and the fault becomes inactive.

Active messages that have been hidden can be reviewed by pressing the F4 button.

The message will give brief details of the fault and advise what action is necessary.

In some instances the machine requires immediate action to correct the problem which requires the operator to STOP machine operation, SHUT THE ENGINE OFF and service the machine to correct the problem.

However, if the machine cannot be stopped immediately for safety reasons, the operator can hide the message. In this instance the machine should only be operated long enough to make the machine safe, then STOP machine operation and SHUT THE ENGINE OFF before serious machine damage can occur!

Messages can be hidden by pressing the F2 button (Hide).

A list of CRITICAL MESSAGES is as follows: Engine Stop Hydraulic Oil Level Low. Hydraulic Oil Temperature High Hardware Fault - MD3 Hardware Fault - XA2 Hardware Fault - Engine Engine Fault Code Messages Communication Fault - L.H. Joystick Communication Fault - R.H. Joystick Engine Air Filter Restrication Engine Coolant Temperature High Engine Coolant Level low Engine CAC Temperature High Engine Oil Pressure Low 6.43

Tigercat 234 Loader

Electrical System and Computer

ENGINE STOP

HYDRAULIC OIL LEVEL LOW

Engine Stop

Hydraulic Oil

Critical engine fault active - contact service.

Level Low.

This message will be displayed, alarm light will flash and alarm will sound when the engine stops while the ignition switch is in the RUN position and/or when critical engine alarms are triggered.

This message will be displayed, alarm light will flash and alarm will sound when the main hydraulic tank oil level is low.

Stop the engine immediately when this alarm is activated. Operating machine with a low hydraulic oil level can cause hydraulic pumps to fail.

Refer to engine manufacturer's manual for specific information regarding the engine.

When this alarm is activated stop the engine and look for signs of broken hoses or other leaks.

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

6.44

Tigercat 234 Loader

Electrical System and Computer

HYDRAULIC OIL TEMPERATURE HIGH

Hydraulic Oil Temperature High.

This message will be displayed, alarm light will flash and alarm will sound when the oil temperature exceeds the recommended operating range for the type of hydraulic oil in use.

If the temperature rises above the recommended operating range for the type of hydraulic oil in use check the following: • • • • • •

Plugged oil cooler Malfunction in a hydraulic system High loads on the hydraulic system Malfunction of the cooling fan Low hydraulic oil level Correct Hydraulic Oil Grade Selection

If hydraulic oil temperature rises above the recommended operating range DO NOT continue to operate the machine.

This alarm must not be used to monitor the hydraulic oil. The operator must use the hydraulic oil temperature gauge on the main menu, together with the operating range chart in SECTION 3 to prevent damage to the hydraulic system.

Hydraulic oil grade information is shown on the main menu below the hydraulic oil temperature gauge.

Operating outside the recommended operating range will shorten hydraulic component life.

Refer to COMPUTER ~ ADJUSTMENT MENU SERVICE SETTINGS ~ HYDRAULIC OIL GRADE in THIS SECTION for hydraulic oil grade selection settings information.

Refer also to APPROVED HYDRAULIC OILS in SECTION 3 of THIS MANUAL for hydraulic oil operating range information.

Refer to COMPUTER ~ INFORMATION MODE MENU ~ HYDRAULIC OIL TEMPERATURE in THIS SECTION for hydraulic oil temperature information display.

6.45

Tigercat 234 Loader

Electrical System and Computer

HARDWARE FAULT - MD3

HARDWARE FAULT - XA2

Hardware Fault - MD3

Hardware Fault - XA2

Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

Hardware Fault - MD3

Hardware Fault - XA2

Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

This message will be displayed, alarm light will flash and alarm will sound when a critical active hardware fault related to the MD3 Display module has been hidden.

This message will be displayed, alarm light will flash and alarm will sound when a critical active hardware fault related to the XA2 module has been hidden.

To recall the original active fault(s) the operator must turn the key off and on.

To recall the original active fault(s) the operator must turn the key off and on.

A VREF error is an example of the type of hardware fault which will be the original active fault which triggers this message.

A VREF and no contact errors are examples of the type of hardware fault which may be the original active fault which triggers this message.

6.46

Tigercat 234 Loader HARDWARE FAULT - XS2

Electrical System and Computer ENGINE FAULT CODE MESSAGES

Hardware Fault - XS2

SPN: 0 FMI: 0 1 of 1

Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

Engine fault parameter - Fault Identifier

SPN: 0 FMI: 0 1 of 1

Hardware Fault - XS2

Engine fault parameter - Fault Identifier

Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

This message will be displayed, alarm light will flash and alarm will sound when a critical active hardware fault related to the XS2 module has been hidden.

Critical engine fault message(s) will be displayed, alarm light will flash and alarm will sound when a critical engine fault message is received from the engine electronic control module.

To recall the original active fault(s) the operator must turn the key off and on.

They provide the SPN code (suspect parameter number) and the FMI code (fault mode identifier) as well as a message describing the fault (when available).

A VREF and no contact errors are examples of the type of hardware fault which may be the original active fault which triggers this message.

Critical engine fault codes are higher priority messages than alert level engine fault code messages. Critical messages can be hidden but immediate action must be taken, STOP machine operation and service engine immediately to resolve the cause of the fault.

An example of a critical engine fault message is shown above.

Note that some less common engine fault codes will appear without a message describing the fault. Make a note of the SPN and FMI codes and contact service for more information.

Refer to engine manufacturer's manual for specific information regarding the engine.

6.47

Tigercat 234 Loader

Electrical System and Computer

COMMUNICATION FAULT - L.H. JOYSTICK 2340601 TO 2341050

COMMUNICATION FAULT - R.H. JOYSTICK 2340601 TO 2341050

LH Joystick Communication

RH Joystick Communication

No contact or invalid data. Limp mode is now available.

No contact or invalid data. Limp mode is now available.

This message will be displayed, alarm light will flash and alarm will sound when a critical communication fault related to the R.H. joystick is activated.

This message will be displayed, alarm light will flash and alarm will sound when a critical communication fault related to the L.H. joystick is activated.

Limp mode is now activated. The limp mode provides alternate operation of the fault joystick using the buttons on the MD3 module. The limp mode should only be used long enough to place the machine in a safe condition then stop machine operation, shut the engine off and repair the joystick malfunction. Refer to LIMP MODE OPERATION in this section for complete details.

Limp mode is now activated. The limp mode provides alternate operation of the fault joystick using the buttons on the MD3 module. The limp mode should only be used long enough to place the machine in a safe condition then stop machine operation, shut the engine off and repair the joystick malfunction. Refer to LIMP MODE OPERATION in this section for complete details.

No contact error (the joystick has lost the CAN connection with the MD3 computer) is an example of the type of fault that triggers this message.

No contact error (the joystick has lost the CAN connection with the MD3 computer) is an example of the type of fault that triggers this message.

6.48

Tigercat 234 Loader ENGINE AIR FILTER RESTRICTION

Electrical System and Computer HARDWARE FAULT - ENGINE

Hardware Fault - Engine Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

Hardware Fault - Engine Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

This message will be displayed, alarm light will flash and alarm will sound when the engine air filter has reached maximum restriction.

To prevent damage to the engine, stop the engine immediately and replace the air filters.

NOTE: Replace the safety element every third primary filter change.

This message will be displayed, alarm light will flash and alarm will sound when a critical active hardware fault related to the Engine has been hidden.

To recall the original active fault(s) the operator must turn the key off and on.

No contact error is an example of the type of hardware fault which may be the original active fault which triggers this message.

6.49

Tigercat 234 Loader ERROR MESSAGES (RED)

Electrical System and Computer

Error messages advise the operator that a critical machine fault is about to occur or a system fault has occurred.

Error messages are computer system generated and are generally triggered by computer system error and fault related conditions.

Error messages have the second highest level of priority and are used to alert the operator that immediate action must be taken to prevent damage to machine or to ensure operator safety.

A list of some types of ERROR MESSAGES is as follows:

Error messages are activated whenever a fault such as an electrical connection is broken/ disconnected. Most error messages are due to computer system hardware or connection faults.

Module VREF Error Voltage Input Error (VIN) Digital Input Error (DIN)

When an error message is displayed, the master alarm and alarm light will sound and flash continuously. The message remains on the screen until the operator hides it.

Digital Output Error (DOUT) Current Output Error (COUT) Module No Contact Error

The message will give brief details of the fault and advise what action is necessary.

* Note that not all error messages are shown.

In some instances the machine requires immediate action to correct the problem which requires the operator to stop machine operation, shut the engine off and service the machine to correct the problem.

However, if the machine cannot be stopped immediately for safety reasons, the operator can hide the message. In this instance the machine should only be operated long enough to move the machine to a safe location then stop machine operation and shut the engine off before serious machine damage can occur!

Messages are acknowledged by pressing the F2 button (OK). To recall active messages turn key off and on. On screen messages will indicate to the operator that an active hardware fault has been hidden.

Error messages flash the Critical symbol

or

the Alert above the F4 button when active messages are hidden depending on the type of error message. The symbol will continue to flash until the problem is resolved and the fault becomes inactive.

Active messages that have been hidden can be reviewed by pressing the F4 button.

6.50

Tigercat 234 Loader ERROR MESSAGES

Electrical System and Computer

MODULE VREF ERROR The module VREF message will be displayed to indicate a problem related to the 5 V reference signal coming from the module.

The module is identified on the display screen.

This message indicates a problem with a sensor, connecting wires or the 5V reference signal itself.

Once acknowledged this message will be replaced with a hardware fault message for the corresponding module when active faults are recalled to the screen. Refer to COMPUTER ~ MESSAGES - CRITICAL ~ HARDWARE FAULT in THIS SECTION.

6.51

Tigercat 234 Loader

Electrical System and Computer

MODULE NO CONTACT ERROR The module no contact error message will be displayed to indicate a loss of communication with or power to a module. The module is identified on the display screen.

When a module goes loses contact all machine functions controlled by that module cease and all messages and warnings associated with that module are triggered. If the problem is with the CAN wires all modules beyond the problem module will also be affected.

Note that if the MD3 display module has a loss of power or other malfunction the screen may go blank and all machine functions controlled by the computer system will be affected.

Once acknowledged this message will be replaced with a hardware fault message for the corresponding module when active faults are recalled to the screen. Refer to COMPUTER ~ MESSAGES - CRITICAL ~ HARDWARE FAULT in THIS SECTION.

6.52

Tigercat 234 Loader

Electrical System and Computer

MD3 MODULE BLANK SCREEN The MD3 module is the central unit in the IQAN control system, which works as both a master and a display unit. Faults or failure in this unit will affect all other IQAN components.

Likely causes are: • Power - Fuse (MD3 module) • Ground • LCD display settings too light to read • Faulty MD3 module

6.53

Tigercat 234 Loader ALERT MESSAGES (YELLOW)

Electrical System and Computer

Alert messages advise the operator that machine operation will be compromised.

Alert messages have the second level of priority and are used to indicate to the operator that action is required to prevent future damage to the machine.

All alert message will give brief details of the fault and advise what action is necessary.

Messages can be hidden by pressing the F2 button (Hide).

Action should be taken to service the machine to correct the problem at the earliest opportunity to prevent future damage to the machine.

Alert computer system generated messages are generally triggered by computer system error and fault related conditions.

When a system generated alert message is displayed the external alarm and light will sound and flash three times to alert the operator of the message.

The message remains on the screen until the operator hides it.

Note that active hardware fault alert messages are acknowledged by pressing the F2 button (OK). To recall these messages turn key off and on. On screen messages will indicate to the operator that an active hardware fault has been hidden.

INTERACTIVE ALERT MESSAGES •

Engine Fault Code Messages - Alert

•

Charge Filter Message - Alert

Active messages that have been hidden can be reviewed by pressing the F4 button. The symbol will continue to flash until the problem is resolved and the fault becomes inactive.

•

Engine Air Filter Restriction - Alert

•

Hydraulic Oil Return Filter Restriction - Alert

•

Hoist Boom Limit Sensor - Alert

Note that if both a critical level fault and an alert level fault are present the critical symbol will take priority until the critical fault becomes inactive.

•

Stick Boom Limit Sensor - Alert

•

Eng Warning MSG - Alert

•

LH Joystick DM1 Alert

•

Module MD3 Alert MSG

•

Module XS2 Alert MSG

•

Module XA2 Alert MSG

•

RH Joystick DM1 Alert

•

COUT hardware fault MSG

•

DOUT hardware fault MSG

•

DIN hardware fault MSG

•

VIN hardware fault MSG

Alert messages flash the alert symbol above the F4 button when active messages are hidden.

There are two types of alert messages: Alert programmed messages generally triggered by machine function related conditions.

When an alert message is displayed, the external alarm and light will sound and flash three times to alert the operator of the message. The message remains on the screen until the operator hides it.

6.54

Tigercat 234 Loader ENGINE FAULT CODE MESSAGES

Electrical System and Computer CHARGE FILTER FAULT

Charge Filter

SPN: 110 FMI: 16 1 of 1

Restricted. Service machine.

Engine coolant temperature high Above normal, severe

Alert engine fault message(s) will be displayed, alarm light will flash and alarm will sound when an alert engine fault message is received from the engine electronic control module.

This message will be displayed when an alert level active fault related to the SWING PUMP HYDRAULIC CHARGE FILTER has been triggered.

They provide the SPN code (suspect parameter number) and the FMI code (fault mode identifier) as well as a message describing the fault (when available).

Restricted. Service machine alert message is an example of the type of fault that triggers this message. The charge pressure filter is restricted and requires service.

Alert engine fault codes are lower priority messages than critical level engine fault code messages. Alert messages can be hidden but action (service engine) is required to resolve the cause of the fault.

An example of an alert engine fault message is shown above.

Note that some less common engine fault codes will appear without a message describing the fault. Make a note of the SPN and FMI codes and contact service for more information.

Refer to engine manufacturer's manual for specific information regarding the engine.

6.55

Tigercat 234 Loader

Electrical System and Computer

ENGINE AIR FILTER RESTRICTION

HYDRAULIC OIL FILTER RESTRICTION

Later machines are equipped with an engine air filter restriction sensor which sends a signal to the computer control system. This alert message will be displayed when the engine air filter gets close to maximum restriction.

Later machines are equipped with a 20 psi hydraulic oil filter bypass switch which will activate should the filters become restricted.

When this message appears it is recommended to change the air filter at the end of the current shift before the restriction becomes critical.

If this message appears, all four hydraulic oil return filters should be replaced to prevent contamination to the hydraulic system which could lead to damage to hydraulic components.

When this switch is activated the above message will appear.

If this message is ignored, a critical message will appear when the air filter reaches it's maximum restriction.

NOTE: Replace the safety element every third primary filter change.

6.56

Tigercat 234 Loader

Electrical System and Computer

HOIST BOOM LIMIT SENSOR

STICK BOOM LIMIT SENSOR

Later machines are equipped with a hoist boom limit sensor to help cushion the hoist cylinder at it's minimum and maximum stroke.

Later machines are equipped with a stick boom limit sensor to help cushion the stick cylinder at it's minimum and maximum stroke.

This message will appear should there be a problem with the hoist boom limit sensor.

Determine what the problem is and have it repaired as soon as possible to prevent damage to the hoist cylinder.

This message will appear should there be a problem with the stick boom limit sensor.

Determine what the problem is and have it repaired as soon as possible to prevent damage to the stick cylinder.

6.57

Tigercat 234 Loader

Electrical System and Computer

HARDWARE FAULT - JOYSTICK

HARDWARE FAULT - MD3

Hardware Fault - MD3 Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

Hardware Fault - MD3 Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

This message will be displayed when an alert level active hardware fault related to the MD3 Display module has been hidden.

To recall the original active fault(s) the operator must turn the key off and on.

This message will be displayed when an alert level active fault related to the Joystick module has been triggered.

High temperature, low supply voltage and high supply voltage module alert messages are examples of the type of hardware fault which will be the original active faults which trigger this message.

Short circuit alert message is an example of the type of fault that triggers this message. Restart power on joystick (turn key off then back on). If problem persists contact the service department.

6.58

Tigercat 234 Loader HARDWARE FAULT - XA2

Electrical System and Computer HARDWARE FAULT - XS2

Hardware Fault - XA2-A0

Hardware Fault - XS2-A2

Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

Hardware Fault - XA2-A0

Hardware Fault - XS2-A2

Active fault has been hidden. Turn key off and on

Active fault has been hidden. Turn key off and on

to recall active hidden hardware faults.

to recall active hidden hardware faults.

This message will be displayed when an alert level active hardware fault related to the XA2-A0 module has been hidden.

This message will be displayed when an alert level active hardware fault related to the XS2-A2 module has been hidden.

To recall the original active fault(s) the operator must turn the key off and on.

To recall the original active fault(s) the operator must turn the key off and on.

High temperature, low supply voltage and high supply voltage module alert messages are examples of the type of hardware fault which will be the original active faults which trigger this message.

High temperature, low supply voltage and high supply voltage module alert messages are examples of the type of hardware fault which will be the original active faults which trigger this message.

6.59

Tigercat 234 Loader

Electrical System and Computer COLD WEATHER STARTING During cold weather, the engine idle speed is controlled by the computer to limit maximum engine speed until the hydraulic system temperature has warmed to a specific temperature based on the oil grade selected.

1

TEMPERATURE

21°C (70°F)

4.5°C (40°F)

LOW FUEL LEVEL - FLASHING ICON This icon

T3 ENGINE T4 ENGINE

(1) is a Low Fuel Level warning.

1400 rpm 1400 rpm

1850 rpm 2100 rpm ENGINE SPEED

The icon will flash ON and OFF when the FUEL level drops below 20 gal. US (76L).

As the machine hydraulic system temperature rises the engine idle speed can be increased. The length of time it takes is dependent on ambient temperature and oil grade selected.

Example: ISO 46 oil grade at 21°C (70°F) or above, engine speed can be increased to Max idle speed.

NOTE: The idle down function will not work until the engine idle speed can be increased to full rpm.

WAIT TO START This icon will appear on the display 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 icon turns OFF automatically.

6.60

Tigercat 234 Loader

Electrical System and Computer B A

XA2 MODULE LED INDICATORS

234E-169

2. CHECK MODULE STATUS INDICATORS The XA2 module also indicates error status through the yellow/red blinking LED.This gives an immediate diagnosis as to the nature of the error that has occurred.

XA2-A0 MODULE NO CONTACT ERROR

(A) Supply Voltage LED (green).

Expect all machine functions controlled by this module to cease and all alarms and warnings associated with this module to be triggered.

LED with green light ON indicates supply voltage is ON. LED OFF indicates supply voltage is OFF.

1. CHECK FOR OTHER ERROR/ALARM MESSAGES ON SCREEN

(B) Status indicator LED (yellow/red).

LED yellow flashing light indicates status is correct.

Press OK to acknowledge each error message. Note that module offline errors will be followed by other alarm messages associated with the module(s) which is(are) out of contact.

LED flashing red light indicates error status as follows: •

Note also that the XA2-A0 module is the terminal module in the series connection.

Therefore failure of this module alone will not affect any other modules in the series.

One red primary flash and one secondary yellow flash indicates an error controlled by the master (MD3).

Two red primary flashes in a row and one yellow secondary flash indicates an error controlled by the master (MD3).

•

If XA2-A0 MODULE NO CONTACT is the only module is NO CONTACT error message the likely causes are: • Power - Fuse (XA2 MODULE) • Ground

•

Three red primary flashes in a row and one yellow secondary flash indicates that the fault is related to the CAN-bus.

•

Three red primary flashes in a row and two yellow secondary flashes in a row indicates that the fault is related to the address.

• Address (ID-Tag) • CAN wire connection If the XA2-A0 MODULE IS OFFLINE error is not the only module is offline error message check other affected modules in order from the MD3 connection (XS2-A0).

LED indicator showing different XS2 and XA2 modes Status

Flash

Normal operation (yel.)

Refer to MODULE NO CONTACT ERROR for each module for more detailed information.

Error code

Error

1:n

See note a

2:n

See note a

3:1

CAN error

3:2

Address error

4:1

Memory errorb

FE

Fatal error

Primary Flash (red) Error category

Secondary Flash (yellow) Error description

a. Error groups 1:n and 2:n are controlled by the master. b. FRAM memory error.

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Tigercat 234 Loader •

Electrical System and Computer

Four red primary flashes in a row and one yellow secondary flash indicates a memory error.

•

Continuous red primary flashing indicates a fatal error.

Internal diagnostics in the master (MD3) can be used to get more information about the XS2 module. The following values are supervised: • • • •

Internal temperature (°C) Power supply (V) Reference voltage (V) CAN address voltage (V)

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Tigercat 234 Loader

Electrical System and Computer B A

XS2 MODULE LED INDICATORS XS2 MODULE NO CONTACT ERROR

2. CHECK MODULE STATUS INDICATORS The XS2 module also indicates error status through the yellow/red blinking LED. This gives an immediate diagnosis as to the nature of the error that has occurred.

Expect all machine functions controlled by this module to cease and all alarms and messages associated with this module to be triggered.

1. CHECK FOR OTHER ERROR/ALARM MESSAGES ON SCREEN

(A) Supply Voltage LED (green).

Press OK to acknowledge each error message. Note that module no contact errors will be followed by other alarm messages associated with the module(s) which is(are) out of contact.

LED with green light ON indicates supply voltage is ON.

If XS2-A0 MODULE NO CONTACT is the only module is NO CONTACT error message the likely causes are:

LED yellow flashing light indicates status is correct.

LED OFF indicates supply voltage is OFF. (B) Status indicator LED (yellow/red).

• Power - Fuse (XS2 MODULE)

LED flashing red light indicates error status as follows:

• Ground

•

One red primary flash and one secondary yellow flash indicates an error controlled by the master (MD3).

If the XS2-A0 MODULE NO CONTACT is followed by an XA2-A0 and XA2-A1 NO CONTACT error the likely cause is:

•

Two red primary flashes in a row and one yellow secondary flash indicates an error controlled by the master (MD3).

• CAN wire connection

•

Three red primary flashes in a row and one yellow secondary flash indicates that the fault is related to the CAN-bus.

•

Three red primary flashes in a row and two yellow secondary flashes in a row indicates that the fault is related to the address.

•

Four red primary flashes in a row and one yellow secondary flash indicates a memory error.

•

Continuous red primary flashing indicates a fatal error.

• Address (ID-Tag)

LED indicator showing different XS2 and XA2 modes Status

Flash

Normal operation (yel.)

Error code

Error

1:n

See note a

2:n

See note a

3:1

CAN error

3:2

Address error

4:1

Memory errorb

FE

Fatal error

Primary Flash (red) Error category

Secondary Flash (yellow) Error description

Internal diagnostics in the master (MD3) can be used to get more information about the XS2 module. The following values are supervised:

a. Error groups 1:n and 2:n are controlled by the master. b. FRAM memory error.

• • • • 6.63

Internal temperature (°C) Power supply (V) Reference voltage (V) CAN address voltage (V)

Tigercat 234 Loader CHANNELS

Electrical System and Computer DIGITAL OUT (DOUT)

The definition ‘channels’ is a collective name for the inputs and outputs found on the different IQAN modules. There are also channels internally in the system, to handle for example, MD3 messages and mathematical calculations. The channels are used to collect and/or send data. Input and output channels are described below.

A PWMOUT with 100% duty cycle is a Digital Out (DOUT). The outputs have a value of low or high.

These are mostly used to activate lamps, on/off valves or to pull relays.

INPUTS

Diagnostic breakout harnesses are available for use to verify computer readings independently.

TROUBLESHOOTING - DIAGNOSTIC BREAKOUT HARNESSES

VOLTAGE IN (VIN)

Refer to ELECTRICAL KIT - SERVICE AND DIAGNOSTICS in this section for more information about diagnostic breakout harnesses.

The input signal at these inputs comes primarily from analog sensors, levers, and switches. These devices use a power/signal/ground system to provide an input value (VIN) between the high (+5V) and low (-5V) signals generated in the modules.

DIGITAL IN (DIN) An input that is typically on or off, such as a switch. This input is often used to determine if an event has occurred, such as pushing a button or engaging a relay.

FREQUENCY IN (FIN) Typical functions are speed measure or revolution measure. This input can count the number of signals per second to determine the speed of a rotating or reciprocating body.

OUTPUTS PWM OUT (PWMOUT) PWM (Pulse Width Modulation) Out is a way of producing an analog signal level with a digital output that turns on and off many times a second.

By varying the ratio between on and off time (duty cycle) an output proportional to the system voltage can be obtained. PWMOUT maintains a constant output voltage, and the output current is governed by output voltage and the resistance in the circuit.

CURRENT OUT (COUT) In this application outputs labeled COUT are actually PWM signals programmed to operate in closed loop mode. The close loop mode features a PWM signal with current regulation. The programmed COUT channel maintains a constant output current to control proportional solenoids.

The voltage is regulated to maintain the constant current based on the programmed input command independant of the resistance of the circuit.

6.64

Tigercat 234 Loader EXAMPLE ~ MEASURE MENU

From the main menu page press the F2 button (Measure) to access the measure menu.

Electrical System and Computer

Use the Arrow Up or Arrow Down to select the menu item. Press OK to confirm the selection.

Use the Arrow Up or Arrow Down move through the list of measured values in a measure group.

Module and pin information for the highlighted channel is shown on screen. The grey arrow(s) to the right at the top and/or bottom of the screen indicate that more channels can be viewed above or below those currently on screen.

Press F2 to toggle between scaled value and raw value readings. Scaled values show the measured value in a scaled unit of measure (°C, %, psi etc). Raw value (where applicable) shows same readings as the raw value (mV, Hz etc) in which they are measured.

The following menu items can be selected.

• • • • • • • • •

Engine Parameters IQAN Status L.H. Joystick (2340601 TO 2341050) R.H. Joystick (2340601 TO 2341050) Joysticks (2341051 TO 2342000) Boom Controls Grapple Controls Saw Delimber Input/Output

Note that for some channel types the raw value selection is not applicable and the reading will be displayed as “-” when viewing raw values. Press F2 to return to the scaled values to view readings for these channels.

Press the back button (or F1) to return to the main menu page.

6.65

Tigercat 234 Loader ELECTRICAL KIT - SERVICE AND DIAGNOSTICS

Electrical System and Computer 6. USB HUB (4 PORT, TYPE A, ISOLATED ) (AN154) This isolated USB hub is used to protect your PC/Laptop and the MD3 module from ground loops. can cause communication signal problems or damage to the PC/Laptop or module.

This kit includes a variety of electrical connectors, tools, cable, IQAN components, diagnostic breakout harnesses and service harnesses (Tigercat part number 20045B).

SELECTED ITEMS

7. ID-TAG ‘1’ (AN069) This is a replacement address tag. Refer to ID-TAG in THIS SECTION for more detailed information.

1. DIAGNOSTIC BREAKOUT HARNESS DEUTSCH CONNECTOR - CURRENT (20036B) This harness is used to check current (amps) flow to a component with a Deutsch connector and verify outputs.

8. ID-TAG ‘2’ (AN070) This is a replacement address tag. Refer to ID-TAG in THIS SECTION for more detailed information.

2. DIAGNOSTIC BREAKOUT HARNESS DEUTSCH CONNECTOR - VOLTAGE (20037B) This harness is used to check voltage (volts) to a component with a Deutsch connector and verify inputs.

9. DEUTSCH 2 POLE SERVICE HARNESS (24860B) This harness is used to bypass a wiring harness while troubleshooting electrical problems. This will identify or eliminate the wiring harness as a cause.

3. DIAGNOSTIC BREAKOUT HARNESS AMP CONNECTOR - CURRENT (20038B) This harness is used to check current (amps) flow to a component with a Amp connector and verify outputs.

10. AMP 2 POLE SERVICE HARNESS (24859B) This harness is used to bypass a wiring harness while troubleshooting electrical problems. This will identify or eliminate the wiring harness as a cause.

4. DIAGNOSTIC BREAKOUT HARNESS AMP CONNECTOR - VOLTAGE (20039B) This harness is used to check voltage (volts) to a component with an Amp connector and verify inputs.

5. USB CABLE (TYPE A-B) (AN155) This cable is used to connect the IQAN MD3 (via the machine USB port) to an isolated USB hub plugged into a PC/Laptop.

IMPORTANT !

Connecting the USB cable directly to the USB port on a PC/Laptop is NOT recommended.

Using an isolated USB hub will protect your PC/Laptop USB port and the MD3 module from ground loops which can cause communication signal problems or damage to the PC/Laptop and MD3 module.

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1

2

9

3

4

10

5

6

7

SER DIAG KIT

8

ELECTRICAL KIT - SERVICE AND DIAGNOSTICS - SELECTED ITEMS 6.67

Tigercat 234 Loader IQAN SOFTWARE

Electrical System and Computer

IQAN Active Studio software can be downloaded from the Tigercat Dealer Website.

All software required for PC/Laptop use is included in this download. A user’s manual in PDF format is also included. Some of the software requires a software key (available from Tigercat).

Contact Tigercat Customer Service for more information about specific hardware requirements for PC/Laptop.

6.68

Tigercat 234 Loader APPLICATION PROGRAM UPDATES FOR PRODUCT SERVICE BULLETINS

Electrical System and Computer

Machine program updates are also available on the Tigercat dealer website. The latest version of the application can be run on any machine provided that all applicable Product Service Bulletin updates have been completed.

DOWNLOADING APPLICATIONS FROM THE TIGERCAT DEALER WEBSITE NOTE: The following downloading instructions apply to the Tigercat dealer website format at the time of printing. If you experience difficulty due to changes on the website contact Tigercat Customer Service for assistance.

3. Select the folder you wish to save the program in.

4. Click on Save.

5. The IQAN program file has now been downloaded.

1. Click on the IDA to the right of the file you wish to download.

2. Click on Save.

6.69

Tigercat 234 Loader SERVICING THE MD3 WITH IQANRUN 2

Electrical System and Computer IQANrun 2 QUICK SUMMARY

REQUIRED EQUIPMENT & INFORMATION

CONNECT TO THE MD3 WITH IQANrun2

PC/Laptop

Servicing the computer system requires a PC/ Laptop, the use of IQANrun2 software, a USB hub and a USB cable. Refer to CONNECT TO THE MD3 WITH IQANrun 2 in THIS SECTION for details.

IQAN MD3 SERVICE KIT (40705B) a. IQAN Active Studio software,Tigercat part number DG047. Refer to IQAN SOFTWARE in THIS SECTION for dealer website download information.

LOGIN Some service operations require username and password access. Refer to LOGIN in THIS SECTION for details.

b. USB hub (4 port, Type A, isolated), Tigercat part number AN155 c. USB cable (Type A-B), Tigercat part number AN154

UPDATE Most commonly used operation. Use to update the MD3 to a newer program or program revision.

Does not overwrite settings. Refer to UPDATE APPLICATION in THIS SECTION for details.

Service Password. Contact Tigercat Service department to obtain passwords and additional information.

GET SETTINGS Gets and saves the existing settings from the MD3. Recommended as a backup prior to tuning or updating the applicaton. Refer to IQANRUN 2 ~ UPDATE APPLICATION ~ GET SETTINGS in THIS SECTION for details.

SEND SETTINGS Sends a previously saved settings file to the MD3.

Overwrites factory default, adjustable and stored values. Only to be used under the direction of Tigercat Customer Service or Engineering. Refer also to important notes on the use of settings files at the end of IQANRUN 2 ~ UPDATE APPLICATION ~ GET SETTINGS in THIS SECTION. GET CLONE Gets and saves the existing application, settings and machine ID from the MD3. Recommended as a backup prior to tuning or updating the application. Refer to IQANRUN 2 ~ UPDATE APPLICATION ~ GET CLONE in THIS SECTION for details.

SEND CLONE Sends a previously saved clone file to the MD3.

Overwites the application, factory defaults, adjustable values, stored values and machine ID. Only to be used under the direction of Tigercat Customer Service or Engineering. Refer also to important notes on the use of settings files at the end of IQAN RUN 2 ~UPDATE APPLICATION ~ GET CLONE in THIS SECTION.

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ADJUST Allows access to adjustment groups. In addition to adjust groups normally accessible on screen additional adjust groups that require sufficient rights restricted by username and password login. Refer to IQANRUN 2 ~ ADJUST in THIS SECTION for details.

MEASURE (GRAPH) Allows the user record, graph and measure group channel readings during machine operation, testing or setup procedures. These recordings can be saved or printed. Refer to IQANRUN 2 ~ MEASURE (GRAPH) in THIS SECTION for details.

LOGS Allows the user to access to logs for service troublshooting, maintenance documentation or clearing. Some log operations require sufficient rights to perform. Refer to IQANRUN 2 ~ LOGS in THIS SECTION for details.

SYSTEM Allows the user to access system information including machine serial number information.

Refer to IQANRUN 2 ~ SYSTEM in THIS SECTION for details.

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CONNECT TO THE MD3 WITH IQANrun 2

IMPORTANT !

Connecting the USB cable directly to the USB port on a PC/Laptop is NOT recommended.

Using an isolated USB hub will protect your PC/Laptop USB port and the MD3 module from ground loops which can cause communication signal problems or damage to the PC/Laptop and MD3 module.

4. Connect the other end of the USB A/B Cable to the MD3 USB connector. Exact location of the connector will vary between machine models.

1. Turn on PC/Laptop and launch IQANrun by double clicking the shortcut on your desktop.

IQANrun is part of the IQAN Active Studio.

2. Turn the machine key switch to the ‘ON’ position, so the MD3 has power. Do not start machine.

5. IQANrun will now indicate that it is online.

Proceed with service operations and login if required. Refer to LOGIN in THIS SECTION. NOTE: If the MD3 does not contain an application (replacement module), the application will have to be Updated, before a user can login. Refer to UPDATE APPLICATION and LOGIN in THIS SECTION.

3. Connect the USB Hub into the PC/Laptop USB jack. Then connect the USB cable into the hub.

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LOGIN 1. Press the Login button on the left.

4. The Login status at the bottom of the screen now indicates the login username.

2. A dialog box will appear, asking for a Username and Password. Contact the Tigercat Service Department for the Username and Password.

5. Note that each username and password combination comes with access rights appropriate for that user’s function.

3. A dialog box will appear to confirm a successful login. Click OK to continue.

If a user has insufficient rights to perform an operation (or is not logged in when login is required) a dialog box will pop up to inform the user that this operation is not possible without the correct login and password.

NOTE - SERVICE PASSWORDS: Contact Tigercat Service department to obtain passwords and additional information.

Note: After a successfully login, Windows provides the option to save the password. If Yes is selected, only the Username will be required at the next login.

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UPDATE APPLICATION

A. GET CLONE FILE

Before updating an application, it is recommended that a Clone file and Settings file are taken from the MD3 and saved.

A. Get Clone file and save (*.irc).

A Clone file contains the application, machine ID, the settings and logs from the MD3. It is a good record of exactly what was in the machine before the update.

B. Get Settings file and save (*.isa).

A Settings file contains only the settings (factory defaults and adjustable values) from the MD3.

C. Update application.

Application programs (*.ida) are available on the Tigercat dealer website. Refer to DOWNLOADING APPLICATIONS FROM THE TIGERCAT DEALER WEBSITE in THIS SECTION.

1. Click on the Get Clone button on the left.

A dialog box will appear prompting the user to select whether or not to get the logs with the clone.

Click on Yes to continue.

2. IQANrun will now get a clone. This might take several minutes.

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Tigercat 234 Loader

3. A dialog box will appear prompting selection of a suitable folder and file name to save the Clone file (.irc).

The file name by default is the machine ID (serial number). It is recommended to use the serial number followed by the date for the file name.

Electrical System and Computer

B. GET SETTINGS FILE 4. Click on the Get Settings button on the left.

5. A dialog box will appear prompting selection of a suitable folder and file name to save the Settings file (.irs).

The file name by default is the machine ID. It is recommended to use the serial number followed by the date for the file name.

Press Save to continue.

IMPORTANT !

A Clone file should rarely be used. It should only be used if updating the application and/ or settings file is not successful in returning a machine’s performance to a previously acceptable state. A Clone file may be date sensitive and should only be used on the day that they were taken.

Press Save to continue.

IMPORTANT !

A Settings file should rarely be used. It should only be used if manually adjusting machine settings is not successful in returning a machine’s performance to a previously acceptable state. Settings files may be date sensitive and should only be used on the day that they were taken.

A Clone should NOT be used on a machine different than that which it was taken from, as machine specific configurations may differ and cause the machine to function improperly.

If a Settings file is used on a machine different than that which it was taken from, all adjustments must be reviewed in IQANrun to ensure machine specific parameters (such as options, pump/motor currents, hour counters) are correct. If this is not done the machine may function improperly.

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C. UPDATE APPLICATION TO MD3 Ensure that a Clone file and Settings file are saved as a backup prior to Update. Refer to GET CLONE FILE and GET SETTINGS FILE in THIS SECTION.

10. IQANrun 2 will provide warning to ensure the machine is not moving and that the engine is shut down (keyswitch in the run position to power the MD3, engine not running).

Press OK to continue, if the machine is inactive.

6. Click on the Update button on the left.

7. A dialog box will appear, prompting the selection of an MD3 application file (.ida).

Select the appropriate application file for the machine.

8. Click on Open to continue.

11. IQANrun will now send the application to the MD3.

9. IQANrun 2 will request confirmation that the application being loaded is correct.

Click on Yes to continue, if the application is correct.

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12. Once the application is loaded successfully, the dialog box will indicate the application was successfully sent.

The MD3 will restart and show the main screen of the application.

The Update is now complete.

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ADJUST 1. Click on the Adjust button on the left.

LOCK SYMBOL INDICATES PIN REQUIRED

EXAMPLE ADJUST SCREEN WITHOUT LOGIN ACCESS

ADJUST

2. The adjust groups available will be shown on the right.

3. Double click an adjust group to adjust channels in that group.

Note that a lock symbol to the left of an adjust group indicates that a PIN/password is required to access that group. Contact Tigercat Service department to obtain password information.

EXAMPLE ADJUST SCREEN WITHOUT LOGIN ACCESS

Note also that some adjust groups are accessible through the MD3 menus unrestricted during normal operation.

Other service related or owner/supervisor use related adjust groups are restricted by passwords on screen or available only through IQANrun 2 with username and password restrictions.

Some adjust groups are only visible on screen for users with the appropriate username and password login rights.

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MEASURE/ GRAPH 1. Click on the Measure button on the left.

START

STOP

PAUSE

STOP

MEASURE EXPAND MEASURE GROUPS

USER DEFINED MEASURE GROUPS

+ADD

-DELETE

2. All of the predefined measure groups available will be shown on the right.

COMMENT

COMMENT

COMMENT

9. User defined measure groups can be customized with the available channels in the existing groups.

It is not possible to add and delete measure groups or items while you are measuring.

Click on the red square to stop measuring and enable the +Add and -Delete buttons.

Each group can be expanded to view the channels in the groups.

3. To graph the channels in a measure group, double click the measure group and the graph will appear. (A single channel can also be chosen for graphing by double clicking on that channel.)

Click the +Add button on screen to add a New measure group. Click on the New measure group, then right click to rename the new measure group appropriately.

Available channels can then be dragged and dropped into the New measure group.

4. Click on the red square to stop measuring.

Click on the green arrow to start measuring.

Click on pause to pause the graph illustration while continuing to measure.

To delete User defined measure groups or items in a group click on the group or item you wish to remove then click the -Delete button.

5. Click on Comment to add comments to the measure file at any time. The measure file data must be saved (*.irm) retain comments for later viewing.

Note that User defined measure groups are automatically saved on your PC. These groups are application program specific and will be available the next time the same application is in use on any machine using the same application program.

6. Click on the red square to stop measuring and access the zoom function. Select an area of the graph to zoom in an view in more detail.

Click on Zoom Out to return to the full graph view.

7. Click on the red square to stop measuring and access save function. Click on Save to save the measure data as a *.irm file.

8. Click on the red square to stop measuring and access print function. Click on print to print the graph and data recorded.

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LOGS 1. Click on the Logs button on the left.

LOGS

2. Logs available to view and/or clear will be shown on the right.

NOTE: User name and password access level rights determine whether the logs can be viewed and/or cleared. Some log items are restricted to higher level users only.

3. Double click on the log you wish to view or click on a log and click on Select to view the records in the log. Click on Done to return to the logs screen.

3. Click on Add Record to add a comment to the system log. For example to record a filter change or other service event in the log.

Entries are restricted to 250 characters.

4. Click on Clear log to clear log entries for the selected log. Note that this function is rights restricted.

5. Click on Get Log to get the log information and save as a *.irf file.

6. Click on Print to print the log being viewed.

7. Click on Save to save the log file as *.irl file.

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SYSTEM 1. Click on the System button on the left.

SYSTEM

2. System info is on the right including the application program name and the Machine ID (Serial Number).

3. The Machine ID (Serial Number) is factory set. However, in the event that the MD3 is replaced, this information would need to be configured for the new module.

Updating Machine ID information requires a Login with sufficient rights.

Click on the Machine Id button. Enter the correct Serial Number. Click Set. If the update is successful a dialog box will pop up. Click OK to acknowlege the update.

A restart of the module will be requested.

Follow the on screen instructions to restart the module before continuing. If further service work is being performed you will need to login to IQANrun2 again.

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234E-147

Electrical System and Computer

FUSE AND RELAY PANEL

FUSE AND RELAY PANEL CAB FUSE AND RELAY PANEL (2340601 TO 2341050) 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.

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FUSES AND RELAYS (ELECTRICAL BOX) (2340601 TO 2341100) This Main Fuse and Relay electrical box is located in the engine compartment.

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234-233

Electrical System and Computer

LIGHTING SCHEMATIC 2340601 TO 2341050 6.84

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234-234

Electrical System and Computer

FUEL HEATER SCHEMATIC 2340601 TO 2341050 6.85

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234-235

Electrical System and Computer

A/C HEATER SCHEMATIC 2340601 TO 2341050 6.86

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234-236

Electrical System and Computer

CAB ACCESSORIES SCHEMATIC 2340601 TO 2341050 6.87

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234-237

Electrical System and Computer

STABILIZERS SCHEMATIC 2340601 TO 2341050 6.88

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234-238

Electrical System and Computer

CAB TILT SCHEMATIC 2340601 TO 2341050 6.89

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JOINS TO NEXT PAGE

234-207

ENGINE MANAGEMENT SCHEMATIC (SHEET 1 OF 2) 2340601 TO 2341050 6.90

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Electrical System and Computer

JOINS TO PREVIOUS PAGE

234-208

ENGINE MANAGEMENT SCHEMATIC (SHEET 2 OF 2) 2340601 TO 2341050 6.91

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234-239

Electrical System and Computer

INSTRUMENTATION SCHEMATIC 2340601 TO 2341050 6.92

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234-240

Electrical System and Computer

VALVE SCHEMATIC 2340601 TO 2341050 6.93

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Electrical System and Computer

Ω

Ω

234-241

CAN NETWORK SCHEMATIC 2340601 TO 2341050 6.94

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234-242

Electrical System and Computer

JOYSTICKS SCHEMATIC 2340601 TO 2341050 6.95

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234E-147

Electrical System and Computer

FUSE AND RELAY PANEL

FUSE AND RELAY PANEL CAB FUSE AND RELAY PANEL (2341051 TO 2341100) 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.

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FUSES AND RELAYS (ELECTRICAL BOX) (2340601 TO 2341100) This Main Fuse and Relay electrical box is located in the engine compartment.

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Electrical System and Computer

LIGHTING SCHEMATIC 2341051 TO 2341100 6.98

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234-234

Electrical System and Computer

FUEL HEATER SCHEMATIC 2341051 TO 2341100 6.99

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234-235

Electrical System and Computer

A/C HEATER SCHEMATIC 2341051 TO 2341100 6.100

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234-236

Electrical System and Computer

CAB ACCESSORIES SCHEMATIC 2341051 TO 2341100 6.101

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234-237

Electrical System and Computer

STABILIZERS SCHEMATIC 2341051 TO 2341100 6.102

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234-238

Electrical System and Computer

CAB TILT SCHEMATIC 2341051 TO 2341100 6.103

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JOINS TO NEXT PAGE

234-207

ENGINE MANAGEMENT SCHEMATIC (SHEET 1 OF 2) 2341051 TO 2341100 6.104

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JOINS TO PREVIOUS PAGE

234-208

ENGINE MANAGEMENT SCHEMATIC (SHEET 2 OF 2) 2341051 TO 2341100 6.105

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234-239

Electrical System and Computer

INSTRUMENTATION SCHEMATIC 2341051 TO 2341100 6.106

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234-243

Electrical System and Computer

VALVE SCHEMATIC 2341051 TO 2341100 6.107

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Electrical System and Computer

Ω

Ω

234-244

CAN NETWORK SCHEMATIC 2341051 TO 2341100 6.108

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234-245

Electrical System and Computer

JOYSTICKS SCHEMATIC 2341051 TO 2341100 6.109

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234E-197

Electrical System and Computer

FUSE AND RELAY PANEL

FUSE AND RELAY PANEL CAB FUSE AND RELAY PANEL (2341101 TO 2342000) 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.

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FUSES AND RELAYS (ELECTRICAL BOX) (2341101 TO 2342000) This Main Fuse and Relay electrical box is located in the engine compartment.

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234-246

Electrical System and Computer

LIGHTING SCHEMATIC 2341101 TO 2342000 6.112

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234-247

Electrical System and Computer

FUEL HEATER SCHEMATIC 2341101 TO 2342000 6.113

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Electrical System and Computer

HVAC SCHEMATIC 2341101 TO 2342000 6.114

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234-249

Electrical System and Computer

CAB ACCESSORIES SCHEMATIC 2341101 TO 2342000 6.115

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234-250

Electrical System and Computer

STABILIZERS SCHEMATIC 2341101 TO 2342000 6.116

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Electrical System and Computer

CAB TILT SCHEMATIC 2341101 TO 2342000 6.117

Tigercat 234 Loader

Electrical System and Computer

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234-251

ENGINE MANAGEMENT SCHEMATIC (SHEET 1 OF 2) 2341101 TO 2342000 6.118

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Electrical System and Computer JOINS TO PREVIOUS PAGE

234-252

ENGINE MANAGEMENT SCHEMATIC (SHEET 2 OF 2) 2341101 TO 2342000 6.119

Tigercat 234 Loader

234-253

Electrical System and Computer

INSTRUMENTATION SCHEMATIC 2341101 TO 2342000 6.120

Tigercat 234 Loader

234-254

Electrical System and Computer

VALVE SCHEMATIC 2341101 TO 2342000 6.121

Tigercat 234 Loader

Electrical System and Computer

Ω

Ω

234-255

CAN NETWORK SCHEMATIC 2341101 TO 2342000 6.122

Tigercat 234 Loader

234-256

Electrical System and Computer

JOYSTICKS SCHEMATIC 2341101 TO 2342000 6.123

Tigercat 234 Loader

Electrical System and Computer

VACUUM PUMP RELAY LOCATED BELOW VACUUM PUMP

INLINE FUSE LOCATED CLOSE TO IGNITION SWITCH

234-258

VACUUM PUMP SCHEMATIC 2340601 TO 2342000 6.124

Tigercat 234 Loader MD3 DISPLAY AND MASTER MODULE

Electrical System and Computer

REAR OF MD3 MODULE 1

2

3

4

The back of the MD3 Module consists of the following.

1. Tag with serial number and part number.

2. CAN bus connector C2 (VIN inputs, USB communication and alarm output).

3. CAN bus connector C1 (voltage supply, CAN communication J1939 and expansion modules).

4. Membrane valve for condensation prevention inside unit.

MD3 MODULE WIRING PIN ASSIGNMENT MD3 MODULE REPLACEMENT 1. Turn battery disconnect switch OFF. 2. Remove the 6 screws holding the instrument panel assembly in place and carefully remove the assembly.

6

DIN-A / VIN-A DIN-B / VIN-B DIN-C / VIN-C DIN-D / VIN-D -VREF USB-D-

USB-D+ +VREF DIN-E / VIN-E DIN-F / VIN-F DIN-G / VIN-G DOUT-A

12

3. Lift the module out of the instrument panel carefully.

5 8

1

12

7 8 9 10 11 12

3. Remove 4 screws holding MD3 in place as shown in the illustration.

1 2 3 4 12 11 10 9

4 9 1 2 3 12 11 10

1

1 2 3 4 5 6

C1

5 8

C2

7 6 7

7 6 7

6

1 2 3 4 5 6

-BAT CAN-A-L CAN-B-L CAN-C-L/Diag RS232 DATA IN Reserved

7 8 9 10 11 12

+RTC RS232 DATA OUT CAN-C-H/Diag CAN-B-H CAN-A-H +BAT

4. Disconnect the wiring harness at the module C1 and C2 connectors.

5. Install module in reverse order as removed.

NOTE: Refer to the MD3 MODULE SCHEMATIC and ELECTRICAL SCHEMATIC in THIS SECTION for detailed pin and wiring assignment.

NOTE: Refer to IQANRUN 2 ~ APPLICATION UPDATE in THIS SECTION for procedure to update the application in an MD3 module.

When replacing a MD3 module the machine serial number information and machine hours will need to be reset. Refer to IQANRUN 2 ~ SYSTEM for more information regarding access and maintenance of logs using IQANrun 2.

6.125

Tigercat 234 Loader

Electrical System and Computer

6.126

Tigercat 234 Loader SECTION 7 – ENGINE AND ANTI-STALL CONTENTS - SECTION 7 A

ISSUE 2.0, JULY 2015

ADJUSTMENT MENU.............................................................................................................................. 7.11 ANTI-STALL SYSTEM COMPONENTS 2340601 TO 2341050............................................................................................................................. 7.9 2341051 TO 2342000........................................................................................................................... 7.10 C

CIRCUIT DESCRIPTION........................................................................................................................... 7.2 COMPUTER ADJUSTMENT MENU.......................................................................................................................... 7.11 ANTI STALL MODE........................................................................................................................... 7.11 E

ELECTRICAL SCHEMATIC - ENGINE MANAGEMENT (SHEET 1 OF 2) 2340601 TO 2341100............. 7.4 ELECTRICAL SCHEMATIC - ENGINE MANAGEMENT (SHEET 1 OF 2) 2341101 TO 2342000............. 7.6 ELECTRICAL SCHEMATIC - ENGINE MANAGEMENT (SHEET 2 OF 2) 2340601 TO 2341100............. 7.5 ELECTRICAL SCHEMATIC - ENGINE MANAGEMENT (SHEET 2 OF 2) 2341101 TO 2342000............. 7.7 EMERGENCY STOP CIRCUIT.................................................................................................................. 7.3 EMERGENCY STOP SWITCH................................................................................................................... 7.3 ENGINE START CIRCUIT CIRCUIT DESCRIPTION, 2340601 TO 2341100................................................................................... 7.2 CIRCUIT DESCRIPTION, 2341101 TO 2342000................................................................................... 7.2 F

FAULT FINDING PROCEDURE, ANTI-STALL QUICK CHECK............................................................... 7.12 FAULT FINDING PROCEDURES, ADDITIONAL..................................................................................... 7.13 S

SELECTING ANTI STALL MODE............................................................................................................. 7.11

Tigercat 234 Loader

Engine and Anti-Stall

ENGINE START CIRCUIT

CIRCUIT DESCRIPTION (2341101 TO 2342000)

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

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

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

When the key switch is turned to the START position, the BATTERY contact is connected to the RELAY and START contacts. Current (voltage) then flows through wire (17) and thru contacts 30 and 87A of the Starter Lockout Relay to energize the coil of the start solenoid relay.

The start solenoid relay contacts also close and current flows from the alternator + RED wire (1) through wire (12) to the starter solenoid coil to close the contacts and operate the start motor to crank the engine. The Starter Lockout Relay is controlled by the engine ECU and is designed to prevent cranking while the engine is running.

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

CIRCUIT DESCRIPTION (2340601 TO 2341100) With the battery disconnect switch ON, current is supplied to the start solenoid contact, the positive connection on the alternator and the BATTERY contact of the key switch (ignition switch).

For the engine electronic control unit (ECU) to supply fuel, there needs to be power at the vehicle key switch input pin on the 50 pin ECU connector.

The key input signal comes from the key input fuse in the cab thru the E-Stop switch and then to wire 110-RD to the ECU, which together with the starter motor, start the engine.

When the key switch is turned to the START position, the BATTERY contact is connected to the RELAY and START contacts. Current (voltage) then flows through wire (17) to energize the coil of the start solenoid relay. The start solenoid relay contacts also close and current flows from the alternator + RED wire (1) through wire (12) to the starter solenoid coil to close the contacts and operate the start motor to crank the engine.

In order to operate the machine functions after starting the engine, the arm rest must be in the DOWN position and the PILOT RESET button pushed. This will energize the pilot reset relay, close the contacts and allow current to energize the pilot shut off solenoid valve on the pilot manifold. After the PILOT RESET button is released current will continue to flow thru the armrest switch to latch the pilot reset relay in the energized position and allow current to flow to the pilot shut off solenoid valve.

For the engine electronic control unit (ECU) to supply fuel, there needs to be power at the vehicle key switch input pin on the 50 pin ECU connector.

The key input signal comes from the key input fuse in the cab thru the E-Stop switch and then to the Ign Relay in the electrical box in the engine compartment. When this relay is activated it provides power to wire 107-RD to the ECU, which together with the starter motor, start the engine.

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

In order to operate the machine functions after starting the engine, the arm rest must be in the DOWN position and the PILOT RESET button pushed. This will send a signal to the pilot reset and the armrest switch inputs on the MD3 module.

A CAN message will be sent to the XA2 Module and the Pilot On output will be activated and allow current to energize the pilot shut off solenoid valve on the pilot manifold. After the PILOT RESET button is released the armrest switch input to the MD3 module will allow current to flow to the pilot shut off solenoid valve.

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

7.2

Tigercat 234 Loader

Engine and Anti Stall

EMERGENCY STOP SWITCH The electrical system is equipped with an emergency stop switch that will kill power to the key input circuit that provides power to the engine ECU. The switch provides a quick engine stop that when activated shuts the engine off and stops all machine functions from operating in the event that an emergency shut down is required.

1

The emergency stop switch is located in the middle of the instrument panel to the right of the operator's seat. When the emergency stop switch (1) is pressed DOWN, it immediately turns OFF electrical power to the engine ECU and the pilot system which, in turn shuts down the engine and hydraulic systems. To return the power to the cab, turn the knob clockwise to allow it to pop back up.

IMPORTANT! Prior to starting the engine check the position of the emergency stop switch to ensure that the switch button is up. The engine will not start until the switch is in the up position.

1

49172BUNI

7.3

INSTRUMENT PANEL

Tigercat 234 Loader

Engine and Anti-Stall

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ELECTRICAL SCHEMATIC - ENGINE MANAGEMENT (SHEET 1 OF 2) 2340601 TO 2341100 7.4

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Engine and Anti Stall

JOINS TO PREVIOUS PAGE

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ELECTRICAL SCHEMATIC - ENGINE MANAGEMENT (SHEET 2 OF 2) 2340601 TO 2341100 7.5

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Engine and Anti-Stall

JOINS TO NEXT PAGE

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ELECTRICAL SCHEMATIC - ENGINE MANAGEMENT (SHEET 1 OF 2) 2341101 TO 2342000 7.6

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Engine and Anti Stall JOINS TO PREVIOUS PAGE

234-210

ELECTRICAL SCHEMATIC - ENGINE MANAGEMENT (SHEET 2 OF 2) 2341101 TO 2342000 7.7

Tigercat 234 Loader

Engine and Anti-Stall

ANTI-STALL GENERAL DESCRIPTION The MD3 computer anti-stall system detects any drop in engine speed and destrokes the main pump to reduce engine load and thus maintain engine speed. This is done without any input from the operator and in most cases he will be unaware of the operation of this system.

The system incorporates the following components:

•

An MD3 computer control and display module mounted in the front panel of the cab.

ENGINE CONTROL MODULE (ECM) ENGINE SPEED SENSOR

718E-031

•

234-060

ENGINE SPEED SENSOR AND ECM LOCATIONS (TYPICAL)

A speed sensor and Engine (ECU) Electronic Control Unit (Cummins engine components).

NOTE: The speed sensor signal is sent to the Engine ECU

234-079

•

XA2 EXPANSION MODULE

An XA2 expansion module mounted in the hydraulic valve compartment of the upper frame.

7.8

PUMP CONTROL VALVE

•

A remote mounted pump control solenoid valve.

•

A wiring harness.

Tigercat 234 Loader

Engine and Anti Stall

ENGINE (ECU) ELECTRONIC CONTROL UNIT

MD3 COMPUTER CONTROL AND DISPLAY MODULE

ENGINE MAIN PUMP

SWING PUMP JOYSTICKS

ENGINE SPEED SENSOR

WIRING HARNESS

PUMP SOLENOID CONTROL VALVE LOCATED ON LOWER FRAME IN ENGINE COMPARTMENT

XA2 EXPANSION MODULE

LEGEND CAN WIRE WIRE

234-211

ANTI-STALL SYSTEM COMPONENTS 2340601 TO 2341050 7.9

Tigercat 234 Loader

Engine and Anti-Stall

ENGINE (ECU) ELECTRONIC CONTROL UNIT

MD3 COMPUTER CONTROL AND DISPLAY MODULE

ENGINE MAIN PUMP

SWING PUMP XS2 CAB MODULE

ENGINE SPEED SENSOR

WIRING HARNESS PUMP SOLENOID CONTROL VALVE LOCATED ON LOWER FRAME IN ENGINE COMPARTMENT XA2 EXPANSION MODULE

LEGEND CAN WIRE WIRE

234-212

ANTI-STALL SYSTEM COMPONENTS 2341051 TO 2342000 7.10

Tigercat 234 Loader

Engine and Anti Stall

SELECTING ANTI STALL MODE

ANTI STALL MODE SELECTION

The anti-stall function can be turned ON or OFF by selecting the anti-stall mode in the adjustment menu as follows ADJUSTMENT MENU

Press F1 button to select the ANTI STALL Menu from the ADJUSTMENT MENU.

From the main menu press F2 button to select the ADJUSTMENT MENU.

The anti stall menu will appear. Two choices are given, ON or OFF. Press the arrow up or arrow down to scroll to the desired selection and press the OK button when desired mode is selected.

Press the Back button to return to the adjustment menu. Press the Back button again to return to the main menu.

The adjustment menu screen will be displayed.

The adjustment menu icon is on display and all the adjustment selections will also be displayed.

The adjustment selections are as follows: •

Anti Stall Mode - select F1

•

Oil Grade Adjustments - select F2

•

Slasher Saw Auto Retract Time, Delimber Status (present/not present) and Saw Flow Adjustments - select F3 Control Adjustments - select F4

•

7.11

Tigercat 234 Loader

Engine and Anti-Stall

FAULT FINDING ~ ANTI-STALL QUICK CHECK

C. ANTI-STALL ON 1. Connect a 0-70 bar/0-1000 psi test gauge to the pump control remote solenoid valve pilot supply port on the main pump.

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

2. Start engine and run at LOW IDLE. 3. Engage pilot reset switch 4. Place anti-stall switch in the ON position, Gauge should read 31-35 bar/450-500 psi at LOW IDLE.

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

5. Slowly increase engine speed.

A. WHEN DOES THE PROBLEM OCCUR ?

Expected Results:

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

•

Gauge pressure should begin to decrease as engine speed increases.

•

Gauge pressure should be 0-0.7 bar/0-10 psi at full throttle.

ANSWERS: •

Occurs with the system ON or OFF The problem is likely hydraulic related. This also includes the pump control remote solenoid valve.

•

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

INSTALL TEST GAUGE HERE

MAIN PUMP

234-070

MAIN PUMP ANTI-STALL PORT

B. ANTI-STALL OFF 1. Connect a 0-70 bar/0-1000 psi test gauge to the pump control remote solenoid valve pilot supply port on the main pump.

2. Start engine and run at LOW IDLE. 3. Place anti-stall switch in the OFF position.

4. Engage pilot reset switch and activate each function 1 at a time.

234-060

Expected Results: •

All functions should operate (Engine may stall).

•

Guage pressure should be 0-0.7 bar/0-10 psi.

7.12

PUMP CONTROL VALVE

Tigercat 234 Loader

Engine and Anti Stall

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

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

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

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

234-079

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

234-060

PUMP CONTROL VALVE

234-179

PUMP CONTROL CIRCUIT

XA2 EXPANSION MODULE

C. SOLENOID VALVE WIRES (AT CONNECTORS) NOTE: If the solenoid or wiring is open circuited or shorted out the MD3 computer will display an error message that the Pump HP Limiter has an Open Load or Overload.

However, if there is no error message and the anti-stall is not functioning check the wiring and coil resistance as follows: 1. Remove the connector from XA2 expansion module.

2. Measure resistance between pin 7 (wire 181-RD) and pin 21 (wire 183-GR) on the connector (see pump control circuit on this page).

• The resistance should be 11.5 to 18.0 ohms (at 21°C-52°C/70 °F to 125 °F hyd oil temp).

7.13

Tigercat 234 Loader

Engine and Anti-Stall

D. SOLENOID VALVE COIL (AT COIL) NOTE: If the solenoid is open circuited or shorted out the MD3 computer will display an error message that the Pump HP Limiter has an Open Load or Overload. However, if there is no error message and the anti-stall is not functioning check the coil resistance as follows: 1. Remove connector from the pump control remote anti-stall solenoid valve.

2. Measure resistance of solenoid coil.

• The resistance should be 11.5 to 18.0 ohms (at 21°C-52°C/70 °F to 125 °F hyd oil temp).

E. ELECTRICAL POWER TO PUMP CONTROL VALVE SOLENOID. When the anti-stall is ON an electrical signal is sent to the pump control valve solenoid from the MD3 Computer via the XA2 expansion module. The signal is current output. The signal value varies from 600mA at low idle (900 rpm) to 0mA at full throttle (1850 rpm).

H855C-51B 234-178

DIAGNOSTIC BREAKOUT HARNESS

NOTE: The pump controller is controlled based on hydraulic oil temperature along with the engine load. The pump will be variably destroked until the hydraulic oil temperature is in operating range.

1. Remove wire connector from main pump control solenoid.

2. Plug in a diagnostic break-out harness 20036B (part of Tigercat electrical kit 20045B) to the solenoid plug and wire harness connector.

3. Connect a multi meter to the banana plugs of the break-out harness. Set multi meter to current flow selection.

4. Start engine, ensure that anti-stall is ON. Observe the meter reading at low idle speed (900 rpm), should be 600 mA. 5. Increase engine speed to full throttle (1850 rpm), meter reading should be (0mA).

234-181

PUMP AND CONTROL VALVE SCHEMATIC

F.

NOTE: When the MD3 computer senses a droop in engine speed the signal to the valve will increase proportionally, this will allow pilot oil to flow to the pf port on the pump to destroke the pump and provide anti-stall.

7.14

MD3 AND XA2 EXPANSION MODULE TEST Refer to ELECTRICAL SYSTEM, SECTION 6 of THIS MANUAL for test procedures.

Tigercat 234 Loader SECTION 10 – RADIATOR, OIL & CHARGE AIR COOLER CONTENTS – SECTION 10

ISSUE 2.0, JULY 2015

C

CHARGE AIR COOLER................................................................................................................ 10.4, 10.6 COMPARTMENT ACCESS, ENGINE.....................................................................................................10.7 COOLING SYSTEM COOLANT FLOW DURING OPERATION............................................................................................10.4 FILLING THE SYSTEM WITH COOLANT............................................................................................10.4 E

ENGINE BELTS.......................................................................................................................................10.3 O

OIL COOLER CIRCUIT DESCRIPTION......................................................................................................................10.8 CIRCUIT DIAGRAM....................................................................................................................10.6, 10.9 R

RADIATOR, OIL COOLER AND CHARGE AIR COOLER.......................................................................10.2

Tigercat 234 Loader

Radiator, Oil and Charge Air Cooler

RADIATOR, OIL COOLER AND CHARGE AIR COOLER

The charge air cooler, hydraulic oil cooler, radiator and the A/C condenser are mounted in front of the engine. The four components are stacked on top of each other to make up the cooler package. The fan draws air from the right side of the machine through the door screen and the cooler package blowing it out of the opposite side of the machine.

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.

234E-288

CHARGE AIR COOLER FILLER CAP RADIATOR

A/C CONDENSER

OIL COOLER

248-25

CHECK ENGINE COOLANT LEVEL

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.

CHECK CHARGE AIR COOLER, RADIATOR, A/C CONDENSER AND OIL COOLER The cooler package should be manually checked every 8 hours (every shift) or more often where conditions cause accumulation of twigs, leaves, pine needles and dust. All of the engine enclosure doors should also be checked.

Part of the engine cooling system is the surge tank. The coolant surge tank (reservoir) can be filled through the access panel located on top of the engine compartment. A level sight gauge is conveniently located in the side of the surge tank.

10.2

Tigercat 234 Loader

Radiator, Oil and Charge Air Cooler

SERPENTINE FAN BELT

A/C COMPRESSOR BELT 250B-034

CHECK ENGINE BELTS

The cooling fan is belt driven and belt tension is automatically tightened by a spring loaded tensioner. The belt condition and tension should be checked every 8 hours (every shift).

220-051

JAM NUTS

A/C COMPRESSOR BELT TIGHTENER The A/C compressor is belt driven and belt tension is tighten by an adjuster on the mounting bracket. Check belt condition and tension every 8 hours (every shift).

Loosen jam nuts and adjust belt to obtain a belt deflection of 6 – 10 mm (1/4 – 3/8 in) between the pulleys in the middle of the belt span.

10.3

Tigercat 234 Loader

Radiator, Oil and Charge Air Cooler

ENGINE COOLING SYSTEM

The engine vent discharges air directly from the top of the engine to the surge tank.

COOLANT FLOW DURING OPERATION

Additional coolant stored in the surge tank flows slowly down the shunt hose to the water pump inlet replacing the air removed from the cooling system.

The water pump circulates coolant through the radiator, engine oil cooler, the engine block and cylinder head. If the thermostat is closed, coolant is returned to the water pump through a bypass inside the engine.

FILLING THE SYSTEM WITH COOLANT The coolant is added through the filler neck in the surge tank. This coolant fills the bottom radiator hose at the water pump through the shunt hose and then fills the radiator from the bottom upwards. Air is displaced through the vent tubes to the surge tank. As the radiator is filled, coolant flows through the water pump and engine oil cooler to fill the engine. Coolant will flow out the top radiator hose through the thermostat bypass and into the engine once the radiator has filled.

The engine and radiator vent discharge air directly to the surge tank.

The thermostat opens when the coolant reaches operating temperature. Then the coolant flows across the radiator core to the outlet and back to the water pump through the bottom radiator hose.

A surge tank is located above the radiator. A small vent tube is connected between the surge tank and the thermostat housing. The anti-freeze/ water solution used in the cooling system always contains small amounts of gas produced by combustion leakage. This gas must be vented to the outside to prevent cavitation of the engine water pump and to promote efficient heat transfer between the engine block and the coolant. These gases separate from the coolant in the radiator top tank and are carried up through the vent tube where they collect in the surge tank and eventually discharge through the pressure cap.

When the engine is at operating temperature and the thermostat has opened, any remaining air is purged through the vent tube and the engine vent.

The system will then require more coolant to fully top-off both the engine and the radiator.

CHARGE AIR COOLER

RADIATOR CAP

SURGE TANK

RADIATOR

SIGHT GAUGE

OIL COOLER

234-264

CHARGE AIR COOLER, OIL COOLER, RADIATOR AND A/C CONDENSER CORE ASSEMBLY 10.4

A/C CONDENSER CORE

Tigercat 234 Loader FLOW OF COOLANT WITH ENGINE RUNNING AT OPERATING TEMPERATURE AND THERMOSTAT OPEN

Radiator, Oil and Charge Air Cooler TOP RADIATOR HOSE

SURGE TANK

THERMOSTAT HOUSING

RADIATOR CAP RADIATOR VENT HOSE ENGINE VENT HOSE SHUNT HOSE

ENGINE OIL COOLER

SHUNT HOSE

BOTTOM RADIATOR HOSE

ENGINE COOLING SYSTEM COMPONENTS AND COOLANT FLOW 2340601 TO 2341100

234-266

FLOW OF COOLANT WITH ENGINE RUNNING AT OPERATING TEMPERATURE AND THERMOSTAT OPEN

TOP RADIATOR HOSE

SURGE TANK

THERMOSTAT HOUSING

RADIATOR CAP RADIATOR VENT HOSE ENGINE VENT HOSE SHUNT HOSE

ENGINE OIL COOLER

234-263

SHUNT HOSE

BOTTOM RADIATOR HOSE

ENGINE COOLING SYSTEM COMPONENTS AND COOLANT FLOW 2341101 TO 2342000 10.5

Tigercat 234 Loader FLOW OF AIR WITH ENGINE RUNNING

234-265

FLOW OF AIR WITH ENGINE RUNNING

234-262

Radiator, Oil and Charge Air Cooler OUTLET

INLET

CHARGE AIR COOLER

CHARGE AIR COOLER SYSTEM AND AIR FLOW 2340601 TO 2341100 OUTLET

INLET

CHARGE AIR COOLER SYSTEM AND AIR FLOW 2341101 TO 2342000 10.6

CHARGE AIR COOLER

Tigercat 234 Loader

Radiator, Oil and Charge Air Cooler

ENGINE COMPARTMENT ACCESS Two hinged doors and two removable panels provide access to the engine compartment from all four sides. The front access panel is removed by lifting the latches outwards, tuning them 90° and then lifting the panel up and out.

ENGINE COMPARTMENT ACCESS REAR 2340601 TO 2341100

234E-024

ENGINE COMPARTMENT ACCESS FRONT 2340601 TO 2341100

234E-146

ENGINE COMPARTMENT ACCESS REAR 2341101 TO 2342000

234E-199

ENGINE COMPARTMENT ACCESS FRONT 2341101 TO 2341200

234E-198

ENGINE COMPARTMENT ACCESS FRONT 2341201 TO 2342000

234E-232

234E-016

10.7

ENGINE COMPARTMENT ACCESS LEFT SIDE

Tigercat 234 Loader

Radiator, Oil and Charge Air Cooler

OIL COOLER CIRCUIT DESCRIPTION The oil cooler is situated down stream from the main valve. Approximately half the oil returning to the hydraulic tank is directed to the oil cooler inlet through the cooler to the return filter and on to the hydraulic tank.

Cooling of the oil occurs as air is drawn over the oil cooler cooling fins by the engine fan. Cooled oil then passes through the return filter and into the hydraulic tank.

A 3.5 bar (50 psi) relief valve installed in the line between the cooler inlet and outlet at the filter, provides a bypass route for oil to flow in the event the oil cooler has high resistance.

10.8

Tigercat 234 Loader

Radiator, Oil and Charge Air Cooler CHARGE AIR COOLER

RADIATOR

A/C CONDENSER OIL COOLER

LEGEND PRESSURE LINE DRAIN LINE

234-259

OIL COOLER CIRCUIT DIAGRAM 10.9

Tigercat 234 Loader

Radiator, Oil and Charge Air Cooler

10.10

Tigercat 234 Loader SECTION 12 – BOOM CONTENTS - SECTION 12 B

ISSUE 2.0, JULY 2015

BOOM CIRCUIT DESCRIPTION............................................................................................................. 12.5 BOOM SYSTEM COMPONENTS............................................................................................................ 12.2 ELECTRONIC JOYSTICK CONTROLS, 2340601 TO 2341050.......................................................... 12.2 ELECTRONIC JOYSTICK CONTROLS, 2341051 TO 2342000.......................................................... 12.2 HYDRAULIC PUMPS........................................................................................................................... 12.2 MAIN CONTROL VALVE...................................................................................................................... 12.2 PROXIMITY SENSORS, 2341251 TO 2342000................................................................................... 12.3 BOOM VALVE SPOOL SECTIONS.......................................................................................................... 12.5 C

CIRCUIT DIAGRAMS BOOM ELECTRICAL CIRCUIT, 2340601 TO 2341050........................................................................ 12.9 BOOM ELECTRICAL CIRCUIT, 2341051 TO 2341100...................................................................... 12.10 BOOM ELECTRICAL CIRCUIT, 2341101 TO 2342000...................................................................... 12.12 BOOM HYDRAULIC CIRCUIT.............................................................................................................. 12.8 JOYSTICK ELECTRICAL CIRCUIT, 2341051 TO 2341100............................................................... 12.11 JOYSTICK ELECTRICAL CIRCUIT, 2341101 TO 2342000............................................................... 12.13 E

ELECTRONIC ADJUSTMENT PROCEDURE....................................................................................... 12.17 BOOM FINE CONTROL..................................................................................................................... 12.43 BOOM LIMIT SENSOR ADJUSTMENT.............................................................................................. 12.49 BOOM SPEED ADJUSTMENT........................................................................................................... 12.52 DEFAULT SETTINGS............................................................................................................. 12.32, 12.38 ENABLE BOOM SPEED ADJUSTMENT............................................................................................ 12.52 HOIST ADJUSTMENT........................................................................................................................ 12.27 HOIST AND STICK BAND WIDTH LIMITING..................................................................................... 12.45 HOIST RAMP ADJUSTMENTS.......................................................................................................... 12.33 JOYSTICK DEADBAND ADJUSTMENT............................................................................................ 12.56 MACHINE MODE ADJUSTMENT....................................................................................................... 12.15 MAXIMUM STICK REDUCTION %.................................................................................................... 12.47 RAMP DEFAULT SETTINGS.............................................................................................................. 12.38 RAMPS MODE COPY........................................................................................................................ 12.40 STICK ADJUSTMENT........................................................................................................................ 12.17 STICK RAMP ADJUSTMENTS........................................................................................................... 12.22 ELECTRONIC SETTINGS DESCRIPTION............................................................................................ 12.14 H

HOIST VALVE RELIEF VALVE SETTINGS............................................................................................ 12.59 M

MACHINE MODE................................................................................................................................... 12.15 P

PRESSURE SETTINGS......................................................................................................................... 12.59 CHECKING MAX CURRENT.............................................................................................................. 12.58 PRESSURE SETTINGS, PORT RELIEF VALVES................................................................................. 12.58 S

STICK VALVE RELIEF VALVE SETTINGS............................................................................................ 12.60

Tigercat 234 Loader BOOM SYSTEM COMPONENTS

Boom functions ELECTRONIC JOYSTICK CONTROLS 2340601 to 2341050

HYDRAULIC PUMPS

Electronic joysticks use electrical signals to turn on electric solenoid controls that activate the main control valves for the boom functions.

All hydraulic functions are powered by two pumps.

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

The main valve is supplied with oil from the main pump. The valves receive oil at the inlet section of the main control valve and direct the oil through the spool sections when either of the joysticks are activated.

Moving either of the joysticks will send an electronic CAN signal to the MD3 computer module. The CAN signal is then directed to the XA2 expansion module and from the module an output signal is directed to the solenoid control for the function that is selected.

MAIN PUMP

The electrical signal activates the solenoid and opens a pilot circuit that directs internal pilot oil to the spool actuator of the control valve selected.

This shifts the spool of the control valve directing pump oil flow to the selected function.

234-022

ELECTRONIC JOYSTICK CONTROLS 2341051 to 2342000

SWING PUMP

HYDRAULIC PUMPS

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

HOIST SECTION

Electronic joysticks use electrical signals to turn on electric solenoid controls that activate the main control valves for the boom functions.

The main valve is supplied with oil from the main pump. The valves receive oil at the inlet section of the main control valve and direct the oil through the spool sections when either of the joysticks are activated.

STICK SECTION 175

174

173

172

167

165

164

163

171

170

70

162

160

71

Moving either of the joysticks or pushing the joystick buttons will send an electrical signal to the XS2 cab module. Pushing the buttons will provide a 24V signal to the corresponding input at the XS2 module. Moving the joysticks in either the 'X' or 'Y' axis will provide a variable 5V signal to the corresponding input at the XS2 cab module. This signal will be about 2500 mV when the joystick is in the neutral position, 0 mV when at one end of the axis and about 4800 mV when at the other end of the axis.

MAIN CONTROL VALVE 185 273 the 184 The boom circuit254utilizes main pump to supply hydraulic oil to the HOIST and STICK circuits via two valve sections in the main control valve.

A CAN signal is then directed to the XA2 expansion module and from that module an output signal is directed to the solenoid control for the function that is selected.

For a more detailed description of the main pump, refer to SECTION 4 in THIS SERVICE MANUAL. 40275BUNI R2

The electrical signal activates the solenoid and opens a pilot circuit that directs internal pilot oil to the spool actuator of the control valve selected.

This shifts the spool of the control valve directing pump oil flow to the selected function.

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Boom functions

PROXIMITY SENSORS ( 2341251 to 234200) Two proximity sensors are mounted on the hinge point of the stick and hoist booms to provide cushioning of the cylinders as they approach the end of their stroke.

PROXIMITY SENSOR

END OF CAM PLATE

234-109

Press the menu button MENU.

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to go to the MAIN

PROXIMITY SENSOR, STICK BOOM

When the cylinder is in mid stroke the proximity sensor will detect the cam plate and send a signal to corresponding MD3 module. As the cylinder approaches the end of the stroke the proximity sensor will detect a change in the profile of the stick or hoist cam plate and the signal will be turned off. When the proximity sensor signal is turned off the MD3 computer system will reduce the current to the corresponding solenoid on the main valve and the cylinder will reduce speed.

234-114

The proximity sensor must have a gap clearance from the cam plate of 1/16".

From the Main menu page press the F1 button to access the Adjust menu.

There is an LED indicator built into the proximity sensor to provide feedback for diagnostic purposes. The LED will be on when the proximity sensor signal is on.

This cushioning function can be turned on or off using the MD3 display.

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Tigercat 234 Loader

Boom functions If the limit sensors are enabled the rate at which the cylinders slow down when they approach the end of travel can be controlled through additional adjustments in the MD3 program. See BOOM LIMIT SENSOR ADJUSTMENTS - ELECTRONIC ADJUSTMENT PROCEDURE later in THIS SECTION

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Using the up or down arrow buttons scroll to Machine Parameters and press OK.

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Using the up or down arrow buttons scroll to Hoist Limit Sensor Status and press OK .

234-112

Using the up or down arrow buttons scroll to the selection required and press OK. Repeat for the Stick Limit Sensor Status.

12.4

Tigercat 234 Loader PORT RELIEF ‘B’ SIDE

Boom functions FEED REDUCTION SIDE ‘A’

PORT RELIEF ‘A’ SIDE

24V PROPORTIONAL ELECTRO-HYDRAULIC SPOOL ACTUATORS

FEED REDUCTION SIDE ‘B’

1014-089

SPOOL SECTION

BOOM VALVE SPOOL SECTIONS

PRESSURE COMPENSATOR

SPOOL

All of the main valve spool sections are equipped with 24 volt proportional, electro hydraulic solenoid operated spool actuators. The actuators are spring centered to the neutral position, and are shifted by sending a electrical signal to the appropriate 24 volt electro hydraulic solenoid spool actuator.

also act as anti-cavitation valves, which means they allow oil to flow from the tank gallery in the valve to the service ports in the event of underpressure. The port reliefs cannot be adjusted. Port reliefs installed in each section are specifically designed for use in that section should not be interchanged with port reliefs from other valve sections .

Spools

BOOM CIRCUIT DESCRIPTION

Each of the spools installed in the main valve is selected specifically for the function it is controlling. For example, the hoist boom section spool has different characteristics than the grapple open/close spool. These spools cannot be interchanged

The boom circuit is supplied with oil from the main pump. The two boom valves receive oil at the inlet section of the main control valve and direct the oil through the spool sections when either of the joysticks are activated.

Moving either of the joysticks will send an electronic signal to the MD3 or XS2 computer module. (See ELECTRONIC JOYSTICK CONTROLS earlier in THIS SECTION)

Pressure Compensation The primary purpose of pressure compensation is to maintain a constant flow rate to function (ie: maintain the same speed of movement), regardless of pressure variations in the system.

The pressure compensator also contains a load-hold check valve. An orifice is installed immediately down stream of the pressure compensator to smoothly regulate the response of the compensator.

The signal is then directed to the XA2 expansion module and from the module the signal is directed to the solenoid control for the function that is selected.

The electrical signal activates the solenoid and opens a pilot circuit that directs internal pilot oil to the spool actuator of the control valve selected.

This shifts the spool of the control valve directing pump oil flow to the selected function.

Port Reliefs The main valve is equipped with port reliefs on each side of the stick and hoist spool sections.

The function of the port relief is to protect the valve and the function cylinder or motor from pressure peaks in the system. The port reliefs 12.5

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175

167

174

165

254

173

164

184 273

172

163

185

162

171

160

170

71

70

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MAIN CONTROL VALVE 12.6

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OUT

HOIST DOWN FEED B REDUCER

A

A

B

B IN

A

UP HOIST UP FEED REDUCER

STICK IN/OUT SECTION

DOWN

HOIST UP/DOWN SECTION

Boom functions

STICK OUT FEED A REDUCER

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234-155

STICK IN FEED B REDUCER

HOIST AND STICK CIRCUIT (OTHER SECTIONS REMOVED FOR CLARITY) 12.7

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STICK CYLINDER HOIST CYLINDER

TO OIL COOLER

PUMP CONTROL VALVE

MAIN VALVE

MAIN PUMP

TO TANK

PILOT FILTER

PILOT MANIFOLD

RETURN FILTERS TO TANK

LEGEND PRESSURE LINE PILOT LINE DRAIN LINE

234-213

BOOM HYDRAULIC CIRCUIT 12.8

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Boom functions MD3 DISPLAY

JOYSTICKS

XA2 EXPANSION MODULE

165-GR 177-RD 167-GR 176-RD 175-GR 176A-RD 177A-RD 174-GR

LEGEND CAN WIRE

HOIST SECTION

WIRE

STICK SECTION

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BOOM ELECTRICAL CIRCUIT 2340601 TO 2341050 12.9

Tigercat 234 Loader

Boom functions MD3 DISPLAY

JOYSTICKS

XS2 CAB MODULE

FOR DETAILS OF JOYSTICK INPUTS SEE NEXT PAGE

XA2 EXPANSION MODULE

165-GR 177-RD 167-GR 176-RD 175-GR 176A-RD 177A-RD 174-GR

LEGEND CAN WIRE

HOIST SECTION

WIRE

STICK SECTION

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BOOM ELECTRICAL CIRCUIT 2341051 TO 2341100 12.10

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JOYSTICK ELECTRICAL CIRCUIT 2341051 TO 2341100 12.11

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Boom functions MD3 DISPLAY

JOYSTICKS

XS2 CAB MODULE

FOR DETAILS OF JOYSTICK INPUTS SEE NEXT PAGE HOIST PROXIMITY SENSOR 2341251 AND UP

STICK PROXIMITY SENSOR 2341251 AND UP

336-YL

XA2 EXPANSION MODULE

335-YL

165-GR 177-RD 167-GR 176-RD 175-GR 176A-RD 177A-RD 174-GR

LEGEND CAN WIRE

HOIST SECTION

WIRE

STICK SECTION

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BOOM ELECTRICAL CIRCUIT 2341101 TO 2342000 12.12

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Boom functions

JOYSTICK ELECTRICAL CIRCUIT 2341101 TO 2342000 12.13

Tigercat 234 Loader ELECTRONIC SETTINGS DESCRIPTION Adjustments to the boom controls through the ADJUST MENU of the MD3 control system electronically adjust the performance of the boom to suit operating conditions.

Refer also to COMPUTER ~ (ADJUSTMENT) MENU OPERATION in SECTION 6 of THIS MANUAL. These settings control the operation of the electro-hydraulic spool actuators which control the cylinder tracking and operating speeds by regulating the flow of oil from the main valve to the boom cylinders.

Many types of adjustments can be made to the boom control system and they are described later in THIS SECTION. There are 4 settings that are critical to all the adjustments and it is important that these 4 settings are adjusted correctly to ensure proper boom operation.

Boom functions 3. Start Ramp This is the amount of units/s that are applied to the output as it is turned on and it is proportional to the position of the joystick in its axis. The higher the value the more aggressive the start of the function. The lower the value the smoother the start of the function.

4. Stop Ramp This is the amount of units/s that are applied to the output as it is turned off and it is proportional to the position of the joystick in its axis. The higher the value the more aggressive the stop of the function. The lower the value the smoother the stop of the function.

Below is a typical graph showing the four settings.

The second graph shows the settings after the start ramp setting has been increased resulting in a steeper ramp or more aggressive start.

These 4 settings are: 1. Min Current

INPUT

Current (m/A)

This is the minimum amount of current that causes the function to just begin to creep.

START SLOPE IN UNITS/S

NOTE: An inaccurate adjustment of the Min Current renders the start and stop ramps inaccurate.

STOP SLOPE IN UNITS/S

OUTPUT

MAX CURRENT

2. Max Current MIN CURRENT

This is the current the controls the maximum speed of the function. A higher setting will cause the function to move faster.

Time (m/S)

Current (m/A) INCREASED START SLOPE IN UNITS/S

STOP SLOPE IN UNITS/S

MAX CURRENT

MIN CURRENT Time (m/S)

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MACHINE MODE The machine mode menu enables the machine to be set up quickly to operate under different conditions or with different operators without having to go through various menus to make multiple adjustments to parameters.

The machine modes are M0, M1, M2 and M3. M0 is the least aggressive mode and is intended for training while M3 is the most aggressive mode.

These modes can be personalized through the various adjustment menus described in THIS SECTION. Many of the adjustments will display the active mode, which means that when adjustments are made in these menus where the active mode is displayed then only that mode will be affected by the changes.

Note: When making electronic adjustments it is important to be aware of the active mode so that any changes are applied to the intended machine mode.

The machine mode can be set by using the MD3 display or through the laptop. See MACHINE MODE ADJUSTMENT SELECTION in SECTION 2 of THIS MANUAL to set the machine mode using the MD3.

MACHINE MODE ADJUSTMENT

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From the Adjust menu double click on Machine Mode

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In the Machine Mode menu double click on Mode Select

Click on the mode required and click on Done.

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ELECTRONIC ADJUSTMENT PROCEDURE After logging into the system as "Service" the following adjustments can be made.

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Click on the Adjust Menu to access the Adjust groups.

Double click on Valve Current Settings to access the Boom functions.

STICK ADJUSTMENT

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Double click on Stick to access the Stick current adjustments.

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Click on the + Out Min mA number to highlight this setting. Once in the Min menu only the Min current will be applied to the stick out solenoid. Pull back slowly on the right hand joystick to full travel to activate the stick out function and using the up or down arrows adjust this setting so that the stick is just moving. It is important to use the up or down arrows instead of attempting to type in the value since the stick will react instantly to any value typed and may extend out at full speed unexpectedly.

NOTE: An inaccurate adjustment of the Min Current renders the start and stop ramps inaccurate.

Return the joystick to the neutral position.

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Click on the + Out Max mA number to highlight this setting. This setting determines the stick out cylinder speed. Once in the Max menu only the Max current will be applied to the stick out solenoid. Pull back slowly on the right hand joystick to full travel to activate the stick out function and using the up or down arrows adjust this setting so that the time to extend the stick is within specification.(See PRESSURE AND SPEED SETTINGS in SECTION 3 of THIS MANUAL). It is important to use the up or down arrows instead of attempting to type in the value since the stick will react instantly to any value typed and may extend out at full speed unexpectedly. It may be necessary to toggle between stick in and stick out on the joystick to get an accurate setting of the stick out speed.

Return the joystick to the neutral position.

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Click on the - In Min mA number to highlight this setting. Once in the Min menu only the Min current will be applied to the stick in solenoid. Push forward slowly on the right hand joystick to full travel to activate the stick in function and using the up or down arrows adjust this setting so that the stick is just moving.

It is important to use the up or down arrows instead of attempting to type in the value since the stick will react instantly to any value typed and may retract in at full speed unexpectedly.

NOTE: An inaccurate adjustment of the Min Current renders the start and stop ramps inaccurate.

Return the joystick to the neutral position.

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234-125

Click on the - In Max mA number to highlight this setting. The setting determines the stick in cylinder speed. Once in the Max menu only the Max current will be applied to the stick in solenoid. Push forward slowly on the right hand joystick to full travel to activate the stick in function and using the up or down arrows adjust this setting so that the time to retract the stick is within specification.(See PRESSURE AND SPEED SETTINGS in SECTION 3 of THIS MANUAL). It is important to use the up or down arrows instead of attempting to type in the value since the stick will react instantly to any value typed and may retract in at full speed unexpectedly. It may be necessary to toggle between stick in and stick out on the joystick to get an accurate setting of the stick in speed.

Return the joystick to the neutral position.

Click on Done to confirm the settings.

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STICK RAMP ADJUSTMENTS Before any adjustments are made to the ramps it is important to understand that the adjustments will only apply to the active machine mode. To change the machine mode see MACHINE MODE ADJUSTMENT SELECTION in SECTION 2 of THIS MANUAL or MACHINE MODE ADJUSTMENT in THIS SECTION.

234-126

Double click on Ramps to access the Stick ramp adjustments.

234-127

Double click on Stick Out Start Slope to access the ramp adjustment.

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This setting will determine (along with the Stick Out Min current) how the stick out function will start when activated. Increasing this setting will result in a more aggressive start while decreasing the setting will result in a smoother, less aggressive start. Use the up or down arrows to adjust the setting and then click on Done.

Double click on Stick Out Stop Slope to access the ramp adjustment.

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This setting will determine (along with the Stick Out Min current) how the stick out function will stop when deactivated. Increasing this setting will result in a more aggressive stop while decreasing the setting will result in a smoother, less aggressive stop. Use the up or down arrows to adjust the setting and then click on Done.

Double click on Stick In Start Slope to access the ramp adjustment.

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Boom functions

This setting will determine (along with the Stick In Min current) how the stick in function will start when activated. Increasing this setting will result in a more aggressive start while decreasing the setting will result in a smoother, less aggressive start. Use the up or down arrows to adjust the setting and then click on Done.

Double click on Stick In Stop Slope to access the ramp adjustment.

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Boom functions

This setting will determine (along with the Stick In Min current) how the stick in function will stop when deactivated. Increasing this setting will result in a more aggressive stop while decreasing the setting will result in a smoother, less aggressive stop. Use the up or down arrows to adjust the setting and then click on Done.

The Stick Electronic Min/Max Current and Ramp adjustments are now complete.

Click on the back arrow to navigate back to the Adjust Menu.

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Boom functions

Double click on Valve Current Settings to access the Boom functions.

HOIST ADJUSTMENT

Double click on Hoist to access the Hoist current adjustments.

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Boom functions

234-136

Click on the + Up Min mA number to highlight this setting. Once in the Min menu only the Min current will be applied to the hoist up solenoid. Pull back slowly on the left hand joystick to full travel to activate the hoist up function and using the up or down arrows adjust this setting so that the hoist is just moving. It is important to use the up or down arrows instead of attempting to type in the value since the hoist will react instantly to any value typed and may lift up at full speed unexpectedly.

NOTE: An inaccurate adjustment of the Min Current renders the start and stop ramps inaccurate.

Return the joystick to the neutral position.

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234-137

Click on the + Up Max mA number to highlight this setting. This setting determines the hoist up cylinder speed. Once in the Max menu only the Max current will be applied to the hoist up solenoid. Pull back slowly on the left hand joystick to full travel to activate the hoist up function and using the up or down arrows adjust this setting so that the time to lift up the hoist is within specification.(See PRESSURE AND SPEED SETTINGS in SECTION 3 of THIS MANUAL). It is important to use the up or down arrows instead of attempting to type in the value since the hoist will react instantly to any value typed and may lift up at full speed unexpectedly. It may be necessary to toggle between hoist up and hoist down on the joystick to get an accurate setting of the hoist up speed.

Return the joystick to the neutral position.

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234-138

Click on the - Down Min mA number to highlight this setting. Once in the Min menu only the Min current will be applied to the hoist down solenoid. Push forward slowly on the left hand joystick to full travel to activate the hoist down function and using the up or down arrows adjust this setting so that the hoist is just moving. It is important to use the up or down arrows instead of attempting to type in the value since the hoist will react instantly to any value typed and may move down at full speed unexpectedly.

NOTE: An inaccurate adjustment of the Min Current renders the start and stop ramps inaccurate.

Return the joystick to the neutral position.

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234-139

Click on the - Down Max mA number to highlight this setting. The setting determines the hoist down cylinder speed. Once in the Max menu only the Max current will be applied to the hoist down solenoid.

Push forward slowly on the left hand joystick to full travel to activate the hoist down function and using the up or down arrows adjust this setting so that the time to lower the hoist is within specification.(See PRESSURE AND SPEED SETTINGS in SECTION 3 of THIS MANUAL). It is important to use the up or down arrows instead of attempting to type in the value since the hoist will react instantly to any value typed and may lower at full speed unexpectedly. It may be necessary to toggle between hoist up and hoist down on the joystick to get an accurate setting of the hoist down speed.

Return the joystick to the neutral position.

Click on Done to confirm the settings.

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Boom functions

MIN/MAX DEFAULT SETTINGS

234-148

If during any of the Min/Max adjustments the factory default settings are required click on "Reset Item". A pop up window will appear asking for this action to be confirmed. Click on "Yes" and the factory defaults will be reset.

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Boom functions

HOIST RAMP ADJUSTMENTS Before any adjustments are made to the ramps it is important to understand that the adjustments will only apply to the active machine mode. To change the machine mode see MACHINE MODE ADJUSTMENT SELECTION in SECTION 2 of THIS MANUAL or MACHINE MODE ADJUSTMENT in THIS SECTION.

234-126

Double click on Ramps to access the Hoist ramp adjustments.

234-140

Double click on Hoist Up Start Slope to access the ramp adjustment.

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234-141

This setting will determine (along with the Hoist Up Min current) how the hoist up function will start when activated. Increasing this setting will result in a more aggressive start while decreasing the setting will result in a smoother, less aggressive start. Use the up or down arrows to adjust the setting and then click on Done.

234-142

Double click on Hoist Up Stop Slope to access the ramp adjustment.

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234-143

This setting will determine (along with the Hoist Up Min current) how the hoist up function will stop when deactivated. Increasing this setting will result in a more aggressive stop while decreasing the setting will result in a smoother, less aggressive stop. Use the up or down arrows to adjust the setting and then click on Done.

234-144

Double click on Hoist Down Start Slope to access the ramp adjustment.

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234-145

This setting will determine (along with the Hoist Down Min current) how the hoist down function will start when activated. Increasing this setting will result in a more aggressive start while decreasing the setting will result in a smoother, less aggressive start. Use the up or down arrows to adjust the setting and then click on Done.

234-146

Double click on Hoist Down Stop Slope to access the ramp adjustment.

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234-147

This setting will determine (along with the Hoist Down Min current) how the hoist down function will stop when deactivated. Increasing this setting will result in a more aggressive stop while decreasing the setting will result in a smoother, less aggressive stop. Use the up or down arrows to adjust the setting and then click on Done.

The Hoist Electronic Min/Max Current and Ramp adjustments are now complete.

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RAMP DEFAULT SETTINGS There are 3 ways to reset the factory default settings when in the ramp menu. You can reset an individual ramp setting , all the ramps in the active mode can be reset or all the ramps in all 4 modes can be reset.

234-177

If during any of the individual ramp adjustments the factory default setting is required click on "Reset Item". A pop up window will appear asking for this action to be confirmed. Click on "Yes" and the factory default will be reset.

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234-178

If in the Ramp menu either all the ramps in one mode can be reset or all ramps for all modes. Click on Reset Group. A pop up window will appear asking if all modes or just the active mode are to be reset.

Click on the mode required and click on OK.

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Boom functions

RAMPS MODE COPY In the Ramps menu there is a tab that enables a complete set of ramps to be copied from one machine mode to another. Before copying the set of ramps the MD3 needs to be set in the machine mode that you wish to change. To change the MD3 machine mode see MACHINE MODE ADJUSTMENT SELECTION in SECTION 2 of THIS MANUAL. The example shown below copies the ramps from Machine Mode 0 to Machine Mode 3.

Ensure the MD3 is set to the Machine mode you wish to change. The machine mode is displayed on the main screen.

234-126

In the Adjust menu double click on the Ramps selection to access the Ramps menu.

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234-180

Ensure that the Active mode in this screen is the machine mode you wish to copy to. In this example it is M3. In the Ramps menu screen click on the Copy From Mode tab at the bottom of the screen. A small pop up window will appear and click on the machine mode you want to copy from. In this example it is M0.

234-181

Another pop up window will appear asking for confirmation of the copy of ramp parameters. In this example it is M0 to M3. Click on Yes to confirm the copy.

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234-182

Another window will pop up advising Mode copied successfully. Click OK in this window. The copy is now complete. If the factory defaults are required to be reset after a copy has been made the "All modes" choice must be selected.

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BOOM FINE CONTROL The Boom Fine Control provides an additional adjustment to provide more precise control while making small movements of the joysticks. This can be useful for sorting applications or other applications where small precise movements of the boom are required.

234-119

Double click on Valve Current Settings to access the Boom functions.

234-149

Double click on Boom Fine Control % .

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234-150

Using the up or down arrows adjust this setting to suit. Increasing this value will provide more fine control of the boom movement when using the joysticks. Click on Done once the adjustment has been made.

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HOIST AND STICK BAND WIDTH LIMITING This setting provides more fine tuning of the boom functions by filtering sudden movements of the joysticks.

234-151

Double click on Hoist BWL FP in the Valve Current Settings menu.

234-152

Using the up or down arrows adjust the setting to suit. By decreasing the value the joystick will become more sensitive. Click on Done once the adjustment has been made.

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234-153

Double click on Stick BWL FP in the Valve Current Settings menu.

234-154

Using the up or down arrows adjust the setting to suit. By decreasing the value the joystick will become more sensitive. Click on Done once the adjustment has been made.

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Boom functions

MAXIMUM STICK REDUCTION % When the Hoist Boom is moved up the same time as the Stick Boom is moved out and the pump is saturated, the stick boom will get more oil flow than the hoist boom. To counteract this, this adjustment lowers the flow to the stick boom to match the boom speeds.

234-155

Double click on Maximum Stick Reduction % FP in the Valve Current Settings menu.

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Boom functions

234-156

Using the up or down arrows adjust the setting to suit. Increasing this setting will slow the stick boom while decreasing the setting will increase the stick boom speed under the conditions described. Click on Done once the adjustment has been made.

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BOOM LIMIT SENSOR ADJUSTMENT If the Hoist and Stick Limit Sensors (Proximity Sensors) are enabled the following adjustments are available to control the cushioning effect of the cylinders.

234-157

From the Adjust menu double click on Boom Limit Sensors

234-158

Double click on Hoist Up Stop Cushion.

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234-159

The Hoist Up Stop Cushion is a % reduction adjustment of the Max mA setting. The higher the value of this setting the slower the cylinder will travel when the sensor triggers the lower speed setting to slow the the cylinder down as it approaches the end of its stroke. Use the up or down arrows to adjust this setting and click Done to move to the next setting.

234-160

Double click on Hoist Up Dampen Slope.

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234-160

The Hoist Up Dampen Slope will determine (along with the Hoist Up Stop Cushion setting) how quickly the cylinder changes from full speed to the reduced speed setting. A higher value will reduce the boom speed more quickly. Use the up or down arrows to adjust the setting and click Done.

Repeat these adjustments (Stop Cushion and Dampen Slope settings) for the remaining Hoist Down, Stick Out and Stick In settings as described above.

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BOOM SPEED ADJUSTMENT The Boom Speeds menu allows adjustment of the Stick or Hoist boom speeds within a specific machine mode without affecting the other modes. There is also no requirement to adjust the Max current.

The Boom Speed menu will only appear in the Adjust Menu if this function has been enabled in the Machine Configuration Menu.

ENABLE BOOM SPEED ADJUSTMENT

234-184

In the Adjust menu double click on Machine Configuration.

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234-185

Double click on Boom Speed Adjustment.

234-186

Click on the ON selection and then click on Done to enable the Boom Speed Adjustment.

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234-187

Return to the Adjust menu and double click on Boom Speeds.

234-188

Double click on Hoist Up Speed.

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Tigercat 234 Loader

Boom functions

Note: Before any adjustments are made to the boom speeds it is important to understand that the adjustments will only apply to the active machine mode. To change the machine mode see MACHINE MODE ADJUSTMENT SELECTION in SECTION 2 of THIS MANUAL or MACHINE MODE ADJUSTMENT in THIS SECTION.

234-189

This setting will adjust the Hoist Up boom speed in the machine mode indicated by the Active mode. Use the up or down arrow to adjust the Hoist Up boom speed to the desired setting then click on Done.

Repeat this adjustment for Hoist Down Speed, Stick Out Speed and Stick In Speed.

12.55

Tigercat 234 Loader

Boom functions

JOYSTICK DEADBAND ADJUSTMENT The Joysticks menu allows adjustment of the joystick deadband. The deadband is an adjustable portion of the initial joystick movement where no function will be activated. The adjustment is a % of the joystick movement and can be adjusted between 8 and 30%.

234-190

In the Adjust menu double click on Joysticks.

234-191

Double click on Joystick deadband.

12.56

Tigercat 234 Loader

Boom functions

234-192

Increasing this setting will increase the deadband. Using the up or down arrows adjust the joystick deadband and click on Done.

NOTE: Adjustment of the joystick deadband will affect all functions that are activated by using the axis movement of the joystick.

12.57

Tigercat 234 Loader PRESSURE SETTINGS

Boom functions

Because the hoist and stick valves are controlled electronically by the proportional valves on the main manifold it is important to first check that the maximum current to fully activate each of the valves is applied before attempting any hydraulic testing. The max current can be checked through the MD3 screen.

CHECKING MAX CURRENT

234-115

Using the up or down arrow buttons scroll to Boom Controls and press OK.

234-109

Press the menu button MENU.

to go to the MAIN

234-117

Using the up or down arrow buttons scroll to the Hoist selection. Lower the armrest and press PILOT RESET switch to activate pilot system and activate one of the hoist functions (raise or lower) on the joysticks and ensure that the current reading is more than or 500 mA (+ or - 30 mA) .

234-114

Press F2 to access the Measure menu.

Note: In one direction the reading will be 500 mA or more and in the other direction it will be -500 mA or more.

Repeat this for each hoist function and also for the stick function.

If the reading is less than 500 mA (+ or - 30 mA) the max current setting will need to be adjusted before any hydraulic testing can be done. See ELECTRONIC ADJUSTMENT PROCEDURE in THIS SECTION. If the settings are 500 mA (+ or - 30 mA) turn the pilot off and proceed to the hydraulic tests.

12.58

Tigercat 234 Loader PRESSURE SETTINGS

Boom functions

HOIST VALVE RELIEF VALVE SETTINGS

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

4. Start the engine, and put the throttle control to the FULL position. Lower left arm rest and depress the pilot reset switch to activate the pilot system.

5. While holding the L.H. joystick in the HOIST UP position (fully extended), check gauge pressure reading. Should be 3800 psi.

While holding the L.H. joystick in the HOIST DOWN position (fully retracted), check gauge pressure reading. Should be 3800 psi.

CAUTION

If less than set value in one direction but OK in the other direction the port relief valve for the low reading circuit is malfunctioning, replace the port relief valve.

Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

WARNING

MARGIN PRESSURE ADJUSTING SCREW

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

MAIN PUMP CONTROLLER

PUMP 'POR' VALVE

Main Pump 'POR' relief............ 262 bar/3800 psi

* Main relief................................ 330bar/4785 psi * Hoist up port relief.................. 330bar/4785 psi * Hoist down port relief............. 330bar/4785 psi NOTE: * The main and port relief valves are not adjustable, the following procedure is for checking pressure only.

1. Position machine on flat level ground.

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

234-023

MAIN PUMP CONTROLLER

If less than set value in both directions loosen locknut and turn 'POR' adjusting screw in (the pressure reading should increase if the setting was set too low) until set value is obtained on gauge. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

'PX' TEST PORT

If when adjusting 'POR' valve the pressure does not change then the main relief is malfunctioning and should be replaced.

'PL' TEST PORT

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

234E-191

MAIN VALVE TEST PORTS

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

12.59

Tigercat 234 Loader

Boom functions

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

CAUTION

4. Start the engine, and put the throttle control to the FULL position. Lower left arm rest and depress the pilot reset switch to activate the pilot system.

5. While holding the R.H. joystick in the STICK OUT position (fully extended), check gauge pressure reading. Should be 3800 psi.

While holding the R.H. joystick in the STICK IN position (fully retracted), check gauge pressure reading. Should be 3800 psi.

Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

If less than set value in one direction but OK in the other direction the port relief valve for the low reading circuit is malfunctioning, replace the port relief valve.

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

MARGIN PRESSURE ADJUSTING SCREW

STICK VALVE RELIEF VALVE SETTINGS Main Pump 'POR' relief............. 262bar/3800 psi

MAIN PUMP CONTROLLER

PUMP 'POR' VALVE

* Main relief................................ 330bar/4785 psi * Stick out port relief................. 330bar/4785 psi * Stick in port relief.................... 330bar/4785psi NOTE: * The main and port relief valves are not adjustable, the following procedure is for checking pressure only.

1. Position machine on flat level ground.

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

234-023

MAIN PUMP CONTROLLER

If less than set value in both directions loosen locknut and turn pump 'POR' adjusting screw in (the pressure reading should increase if the setting was set too low) until set value is obtained on gauge. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

'PX' TEST PORT

'PL' TEST PORT

If when adjusting pump 'POR' valve the pressure does not change then the main relief is malfunctioning and should be replaced.

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

234E-191

MAIN VALVE TEST PORTS

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

12.60

Tigercat 234 Loader SECTION 15 – SWING CONTENTS - SECTION 15

ISSUE 2.0, JULY, 2015 CIRCUIT DIAGRAM................................................................................................................................. 15.6 GEARBOX, SWING DRIVE...................................................................................................................... 15.5 HYDROSTATIC DRIVE MOTOR DESCRIPTION..................................................................................................................................... 15.4 PRESSURE SETTINGS SET SWING RELIEF VALVES.............................................................................................................. 15.7 SWING BEARING SEAL KIT..............................................................................................................................................15.9 WEAR LIMITS....................................................................................................................................... 15.8 SWING MOTOR....................................................................................................................................... 15.4 MOTOR REMOVAL NOTE................................................................................................................... 15.4 SWING PUMP.......................................................................................................................................... 15.2

Tigercat 234 Loader

Swing

SWING DRIVE COMPONENTS

ENGINE BELL HOUSING

MAIN PUMP SWING PUMP

234-057

HYDRAULIC PUMPS

SWING PUMP

side of the closed loop is a high pressure supply while the other side is a low pressure return.

The supply and return will alternate from side to side of the closed loop as the direction of swing rotation is changed from left to right.

All hydraulic functions are powered by two pumps mounted one behind the other on the flywheel housing of the engine. The first pump (main pump) is a piston pump with load sensing, pressure compensating and horsepower limiting controls.

The swing drive pump is actually two separate hydraulic pumps mounted in a common case and driven by the same input drive shaft.

Mounted and coupled to the main pump is the swing pump. The primary components of the swing system are the hydraulic pump, hydraulic motor and swing drive gearbox. The hydraulic pump and hydraulic motor are connected together by two hydraulic hoses. The pump converts the mechanical power of the diesel engine into hydraulic power. This high pressure flow of hydraulic oil is then transmitted to the hydraulic motor through a connecting hose. The motor then reconverts the hydraulic power back into mechanical power to drive the swing gearbox used to swing the upper frame. Low pressure hydraulic oil flow then returns from the motor to the pump through the other connecting hose thereby completing a continuous closed loop hydraulic circuit.

The primary pump is a variable displacement, swashplate, in line axial piston type pump. The volume and direction of oil flow from the piston pump is determined by the angle of the tiltable swashplate. When the swashplate is stroked to a maximum displacement angle, the piston pump will produce maximum flow in one direction in the closed loop. As the swashplate is de-stroked, the flow smoothly decreases until there is no flow at an angle of zero (0°). Continuing to angle the swashplate past this neutral position steplessly reverses the direction of flow from the piston pump.

The secondary pump of the drive pump is a fixed displacement, internal gerotor type pump that provides charge oil (cooling, lubricating and make-up oil) for the hydrostatic pump and motor in the closed loop system.

A hydraulic system is termed closed loop when the hydraulic oil returning from the motor is fed straight back to the pump without first returning to tank. When the swing system is operating, one 15.2

Tigercat 234 Loader

Swing

234-055

SWING PUMP CONTROLLER

SWING MOTOR

B A

SWING PUMP

SWING DRIVE GEARBOX

234-051

SWING BEARING

SWING DRIVE CONTINUOUS CLOSED LOOP HYDRAULIC CIRCUIT

FOOT PEDAL CONTROL VALVE

1

The swing function is controlled by the center foot pedal valve which sends proportional pilot signals to the swing pump controller to stroke the pump swashplate producing oil flow to the swing motor.

5

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

3

TANK PORT

4 8 2

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

WORK PORT

The foot pedal control valve will not be active if the pilot is off. For a full description of the pilot circuit see SECTION 5 of THIS MANUAL

AW017

15.3

PRESSURE PORT

WORK PORT

FOOT PEDAL PILOT VALVE

Tigercat 234 Loader

Swing

SWING MOTOR The swing motor is mounted directly onto the input of the swing planetary gearbox. The motor is a fixed displacement, bent axis, axial piston type.

High pressure oil from the swing pump enters the motor via port A or port B depending on the direction of swing required. This oil is then directed to a set of pistons inside the motor rotating group cylinder housing. These pistons push against the back of the output shaft at an angle, causing the shaft to rotate.

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

250BT-018

SWING MOTOR CROSS SECTION

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

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

234-053

15.4

SWING MOTOR AND GEARBOX

Tigercat 234 Loader

Swing

SWING DRIVE GEARBOX Power is transmitted from the motor to a double reduction planetary gearbox. The swing gearbox upper gearing is lubricated by oil stored in a reservoir attached to the side of the gearbox cover. The reservoir must remain half full of oil* at all times. The lower bearing area is lubricated by grease where the cavity is filled with grease at assembly, a grease fitting is not provided since additional greasing is not necessary.

To fill the gearbox with oil, unscrew the air bleed plug located on the motor flange, remove the cap on the reservoir and add oil to the reservoir.

When oil begins to come out of the air bleed hole replace the plug and continue to add oil until the reservoir is half full. Replace the cap on the reservoir.

To drain the gearbox unscrew the drain plug and allow oil to drain into a suitable container. To facilitate draining, the oil should be warm. *For correct oil specification and maintenance schedule, refer to SECTION 3 in THIS MANUAL.

234-035

SWING MOTOR AND GEARBOX

RESERVOIR

CONNECTING HOSE TO GEARBOX

206-16A

15.5

SWING DRIVE LUBRICATION

Tigercat 234 Loader

Swing

SWING DRIVE MOTOR

CCW

B

A

CW SWING FOOT PEDAL

TO TANK

CW

CCW

FE FA

B

A

SWING PUMP (REAR VIEW) SWING DRIVE GEARBOX

TO CASE STRAINER TO TANK CHARGE FILTER

PILOT SHUT OFF VALVE

PILOT MANIFOLD

LEGEND

TO TANK

FROM 'YS' PORT ON MAIN VALVE

PRESSURE LINE PILOT LINE DRAIN LINE 234-221

PILOT FILTER

SWING DRIVE HYDRAULIC CIRCUIT (STANDARD FOOT PEDALS) 15.6

Tigercat 234 Loader

Swing

PRESSURE SETTINGS CAUTION

PUMP 'POR' VALVE

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

A

Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

B

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

CHECK SWING RELIEF VALVES Swing pump POR setting ........ 290 bar/4200 psi Swing ccw pressure relief ...... 310 bar/4500 psi Swing cw pressure relief ....... 310 bar/4500 psi Swing charge pressure relief .... 25 bar/360 psi 1. Position machine on flat level ground.

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

'G' CHARGE PRESSURE TEST PORT

CHARGE PRESSURE RELIEF VALVE

'A' PRESSURE RELIEF VALVE

7. Lower left arm rest and depress the pilot reset switch to activate the pilot system. Lower boom assembly to the ground and restrict boom swing movement in both directions.

8. Observe the gauge on the 'G' test port, charge pressure should be as per set value.

If pressure reading is not within the set value loosen locknut on charge pressure relief valve and turn screw in to increase pressure or out to decrease pressure. When pressure is set, tighten locknut.

9. Press and hold the swing foot pedal in the SWING RIGHT position (CW), check gauge pressure reading on 'MA' gauge port. Loosen locknut on 'A' pressure relief valve, turn screw in to increase pressure or out to decrease pressure. When pressure is set tighten locknut.

10. Press and hold the swing foot pedal in the SWING LEFT position (CCW), check gauge pressure reading on 'MB' gauge port. Loosen locknut on 'B' pressure relief valve, turn screw in to increase pressure or out to decrease pressure. When pressure is set tighten locknut.

'MA' TEST PORT

'MB' TEST PORT

'B' PRESSURE RELIEF VALVE

SWING PUMP

234-075

3. Install a 0-5000 psi pressure gauge on the 'MA' and 'MB' test ports on the swing pump.

4. Install a 0-1000 psi pressure gauge on the 'G' test port on the swing pump.

5. Loosen locknut and turn pump POR valve in fully.

6. Start engine and place throttle control in IDLE.

set POR relief valve: 11. Increase engine speed to FULL throttle.

12. Loosen locknut on swing POR relief and unscrew adjusting screw. Press and hold the swing foot pedal in the SWING RIGHT position, turn adjusting screw in until gauge reads as per set value.

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

14. Shut engine off, remove gauges and wipe up any spilled oil.

15.7

Tigercat 234 Loader

Swing

SWING BEARING WEAR LIMITS

The following procedure will verify the amount of wear in the ball race:

It is important that the swing bearing be periodically inspected for wear. Any significant wear will be noticeable by observing too much "tilting" of the upper frame relative to the lower frame. A small amount of designed-in clearance in the bearing is normal and is present in a new machine.

1. Position machine with boom fully extended as in position 1.

2. Set dial indicator (A) to zero.

3. Lower boom as in position 2.

4. Note tilt reading on dial indicator.

Too much clearance will affect the backlash between the ring gear and the drive pinion and if left unchecked will cause damage to the gear teeth and ultimately the swing drive gearbox.

5. Return machine to position 1.

The main cause of wear in the ball race can be due to a lack of lubricant or not following the proper lubricating procedure. A damaged or missing peripheral seal will also contribute to early wear by allowing dirt particles to enter the ball race.

7. Rotate upper frame 90 deg. and repeat steps 1 thru 6.

6. Check to see if reading on dial indicator has returned to zero, if not repeat steps 1 thru 4.

8. The bearing is considered to be worn when the total play at any one location is 2.7mm (0.105") or greater.

NOTE: Do not add readings of more then one location. When the dial indicator reading of a single loaction is 2.7mm (0.105") or greater the bearing is worn and must be replaced.

Regular inspection of the seal should be carried out and the proper lubricating procedure should be followed. Refer to FILTER AND LUBRICATION SCHEDULE in SECTION 3 of THIS MANUAL.

POSITION 1

POSITION 2

INDICATOR

860C-397

DETAIL A 15.8

Tigercat 234 Loader

Swing

SWING BEARING SEAL KIT

SEAL

INSTALLATION INSTRUCTIONS 1. Remove all traces of former seal and glue from the seal groove.

Groove should then be cleaned with a nonresidue commercial solvent.

2. Wipe the seal with the same solvent.

3. Apply a bead of adhesive (BN157) to the seal groove (avoid the adhesive from being extruded into the bearing cavity as the seal is installed.)

SEAL

4. Insert the seal into the groove ( the length of seal provided is longer than required), trim the excess with a sharp knife or pruning shears in such a manner to smoothly meet the adjoining end. Place a drop of crazy glue (BN158) on the end so that the two ends will be joined.

860C-0004

5. Immediately butt the two ends together, aligning them as quickly as possible. Hold together without movement (motion weakens and may destroy the bond). After 2 minutes the joint will be strong enough.

NOTE: Read the precautions on adhesive container. Avoid getting adhesive on your fingers. It will bond them together.

6. Coat joint with grease from bearing. Moisture or high humidity may weaken bond unless protected with grease.

7. Examine seal for contact withseal surface on race ring.

8. Re-grease the bearing until grease extrudes from under the seal to remove any foreign matter.

15.9

SWING BEARING SEAL

Tigercat 234 Loader

Swing

ADJUST SWING BEARING BACKLASH Make up adjustment tool from a 4" x4" piece of 0.25" thick steel plate.

0.25"

Adjust the hex head bolt to decrease the backlash or swing the upper 180° and adjust the hex head bolt to reposition swing bearing to obtain acceptable backlash of 0.017" to 0.026".

4"

860C-186

4"

Torque four pairs of swing bearing outer race bolts located at 90° to each other to 450 lbs. ft.

ADJUSTMENT TOOL

Weld a 1" nut on the plate as shown.

Position the adjustment tool up against the underside of the turntable 1/2" away from the bearing. Weld the tool to the turntable as shown using 1/4" fillet weld.

Recheck and adjust backlash every 45° of gear rotation to obtain acceptable backlash of 0.017" to 0.026".

Install a 1" x 6" hex head bolt in the nut.

Check the backlash between the pinion gear and swing bearing gear teeth. Should be 0.017" to 0.026".

Apply Loctite 242 to all bolts and torque swing bearing mounting bolts to 400-450 lbs.ft. with sequence shown above.

15.10

Tigercat 234 Loader SECTION 16 – STABILIZERS CONTENTS - SECTION 16 C

ISSUE 2.0, JULY 2015

CIRCUIT COMPONENTS........................................................................................................................ 16.2 CIRCUIT DESCRIPTION, STABILIZER................................................................................................... 16.9 CONTROL VALVE.................................................................................................................................... 16.3 COUNTERBALANCE AND CHECK CARTRIDGES, REMOVAL............................................................. 16.8 COUNTERBALANCE VALVES................................................................................................................ 16.7 CYLINDERS AND COUNTERBALANCE VALVES.................................................................................. 16.7 E

ELECTRICAL CIRCUIT SCHEMATIC, STABILIZER................................................................................ 16.5 H

HYDRAULIC CIRCUIT SCHEMATIC, STABILIZER................................................................................. 16.6 L

LOWERING STABILIZER......................................................................................................................... 16.9 P

PRESSURE SETTINGS......................................................................................................................... 16.11 R

RAISING STABILIZER............................................................................................................................. 16.9

Tigercat 234 Loader

Stabilizers

STABILIZER CIRCUIT COMPONENTS

ENGINE BELL HOUSING

MAIN PUMP

SWING PUMP

HYDRAULIC PUMPS

234-057

MAIN PUMP Supply oil for the stabilizer circuit is provided by the MAIN pump which is an axial-piston, variabledisplacement pump with load sensing and horsepower limiting controls.

For a more detailed description of this pump, refer to SECTION 4 of THIS SERVICE MANUAL. STABILIZER PILOT MANIFOLD

234-085

4-SOLENOID OPERATED PILOT VALVES

STABILIZER MANIFOLD SCHEMATIC

OPERATING DESCRIPTION When any (or ALL) of the four solenoid operated valves are energized (by pressing a switch in the operator's cab), shifts one (or ALL) of the spools and connects either port 'B', 'C', 'D', 'E' (or ALL) with a counterbalance valve mounted to the base end of one of the stabilizer cylinders to raise or lower the stabilizer. When the stabilizers are stationary, the spools in the directional control valves are in the closed position.

SYSTEM PRESSURE SUPPLY 'B' REAR LEFT

234-040

'C' FRONT LEFT

'D' REAR RIGHT

'E' FRONT RIGHT

STABILIZER PILOT MANIFOLD

This stabilizer manifold consists of an aluminium housing containing four solenoid operated valves.

Port 'A' is connected to the stabilizer control valve and supplies oil at system pressure to the four directional valves. Ports 'B', 'C', 'D' and 'E' supply oil at system pressure to the stabilizer cylinders.

16.2

Tigercat 234 Loader

FEED REDUCER

Stabilizers

PORT RELIEF ‘A’ SIDE (PLUG)

24V PROPORTIONAL ELECTRO-HYDRAULIC SPOOL ACTUATORS

PORT RELIEF ‘B’ SIDE (PLUG)

SPOOL

PRESSURE COMPENSATOR

234-068

SPOOL SECTION - STABILIZERS 175

174

173

172

167

165

164

163

171

170

70

162

160

71

40275BUNI R2

STABILIZER CONTROL VALVE The stabilizer UP/DOWN/OFF functions are controlled by one of seven spool sections in the main control valve. The main valve is a load sensing and pressure compensated proportional valve. The control valve is located in the upper frame below the floor plates inside the valve compartment.

RELIEF VALVES AND FEED REDUCERS A main relief valve is installed in the mid-inlet 273to 185 section of 254 the 184 valve protect the hydraulic system against overload pressures. The main relief valve is not adjustable.

The stabilizer valve section has two feed reducers used to set stabilizer circuit system pressure.

40275BUNI R2

For a detailed description of the main control valve, refer to SECTION 4 in THIS MANUAL.

16.3

Tigercat 234 Loader

Stabilizers

STABILIZER OPERATION

49172BUNI

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

1

Select a direction (up or down) using the Stabilizer Direction selector switch (1). 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

3

6

Next use buttons (2), (3), (4) or (5) to control each stabilizer separately or use the ALL button (6) 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.

5

4

STABILIZER CONTROL SWITCHES

16.4

Tigercat 234 Loader

234-145B

Stabilizers

STABILIZER ELECTRICAL CIRCUIT SCHEMATIC 16.5

Tigercat 234 Loader

234-161

Stabilizers

STABILIZER HYDRAULIC CIRCUIT SCHEMATIC 16.6

Tigercat 234 Loader

Stabilizers

STABILIZER CYLINDERS AND COUNTERBALANCE VALVES

234-079

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

COUNTERBALANCE CARTRIDGE

COUNTERBALANCE VALVE SCHEMATIC

234E-192A

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

Return oil from the rod end of the cylinder flows to the 'CR' port and through the open counterbalance valve to the 'VR' port and back to tank via the stabilizer control valve.

STABILIZER CYLINDER COUNTERBALANCE VALVE

Each counterbalance valve assembly includes a counterbalance cartridge and a "pilot-to-open" check valve cartridge.

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

The purpose of the counterbalance valve assembly is to; (a) To prevent the raised stabilizers from falling down when transporting the loader. (b) To prevent the buildup of pressure caused by thermal expansion.

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

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

The purpose of the "pilot-to-open" check valve cartridge is to ensure that the stabilizers remain firmly placed on the ground during the loading/ unloading operation by preventing oil from leaving either end of the cylinders. When the cylinders are in the stationary position this check valve prevents oil from leaving the cylinder base end. The check valve opens when oil is directed to the rod end of the cylinder.

16.7

Tigercat 234 Loader

Stabilizers 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.

LOWER FRAME

VERTICAL CENTERLINE COUNTERBALANCE VALVE

STABILIZER UP IN VERTICAL POSITION CHECK CARTRIDGE

CYLINDER

230-06A

COUNTERBALANCE CARTRIDGE

234-190 234-191

COUNTERBALANCE VALVE & CYLINDER

COUNTERBALANCE/CHECK CARTRIDGE REMOVAL

SAFE REMOVAL OF COUNTERBALANCE AND CHECK CARTRIDGES If it becomes necessary to remove either the counterbalance or check cartridge from the housing; 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.

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.

16.8

Tigercat 234 Loader

Stabilizers

STABILIZER CIRCUIT DESCRIPTION

In this condition, hydraulic oil will flow from the UP side of stabilizer control valve to the rotary manifold and on to the cylinder counterbalance valve where it will be directed to the rod end of all selected cylinders. Return oil from the base end of the cylinders will flow through the pilot operated check valve, the rotary manifold, the stabilizer pilot manifold, to the stabilizer control valve and back to tank.

Refer to CIRCUIT DIAGRAM The stabilizer circuit is supplied with hydraulic oil by the main pump. The stabilizer valve receives oil via the main valve inlet section and directs it to the stabilizer spool section on demand.

During operation of the stabilizers, return oil is directed back to tank via the oil cooler, a check valve to the return manifold and two dual element filters, which are equipped with an internal 25 psi element bypass valve. A 50 psi. relief valve is installed in the oil cooler line to bypass the oil around the oil cooler, usually on cold start ups when the oil is cold and thicker.

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

Electrical current will flow along wire RED 3, through a series of diodes and energize the DOWN solenoid operated pilot valve on the pilot manifold. Pilot oil will then be directed to the stabilizer control valve spool DOWN pilot end cap to shift the spool.

Six switches on the instrument panel control the stabilizers, One 3-position switch OFF/UP/ DOWN and five more switches to operate the stabilizers either ALL at the same time or each one INDIVIDUALLY. For a detailed description of these switches, refer to previous page.

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

Placing the 3-position stabilizer direction switch in the OFF position removes all current from the stabilizer circuit to prevent the stabilizers from operating. The switch should remain in this position when the stabilizers are in the stationary position, either UP or DOWN.

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

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

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

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

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

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

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

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

16.9

Tigercat 234 Loader

234-162

Stabilizers

STABILIZER CIRCUIT 16.10

Tigercat 234 Loader

Stabilizers

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

'PX' TEST PORT

'PL' TEST PORT

CAUTION Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

234E-191

SET STABILIZER PORT RELIEFS VALVES Pump 'POR' Relief setting ....................... 3800 psi

STABILIZER SECTION

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

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

1. Machine must be on level ground with stabilizers properly in place.

STABILIZER DOWN FEED REDUCER

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

STABILIZER FEED REDUCERS 9. With the aid of an assistant, Press ONE of the stabilizer switches to LOWER stabilizer. While holding stabilizer switch in DOWN position, check gauge pressure reading.

4. Start engine and place throttle control in IDLE.

CAUTION

5. Place stabilizer switch in UP position.

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

6. With the aid of an assistant, Press ONE of the stabilizer switches to RAISE stabilizer. While holding stabilizer switch in UP position, check gauge pressure reading.

Adjust UP feed reducer to achieve proper setting. The pressure is increased by turning the screw in. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

8. Place stabilizer switch in DOWN position.

STABILIZER UP FEED REDUCER

234-131

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

7.

MAIN VALVE TEST PORTS

10. Adjust DOWN feed reducer to achieve proper setting. The pressure is increased by turning the screw in. Tighten locknut on adjusting screw taking care not to turn the adjusting screw.

11. Repeat steps 8 and 11 to verify settings.

12. Shut engine off, remove gauge and wipe up any spilled oil.

16.11

Tigercat 234 Loader

Stabilizers

16.12

Tigercat 234 Loader SECTION 17 – GRAPPLE CONTENTS - SECTION 17

ISSUE 2.0, JULY 2015

C

CIRCUIT DESCRIPTION......................................................................................................................... 17.7 CIRCUIT DIAGRAMS GRAPPLE ELECTRICAL CIRCUIT, 2340601 TO 2340930.................................................................. 17.9 GRAPPLE ELECTRICAL CIRCUIT, 2340931 TO 2341050................................................................ 17.11 GRAPPLE ELECTRICAL CIRCUIT, 2341051 TO 2342000................................................................ 17.13 GRAPPLE HYDRAULIC CIRCUIT, 2340601 TO 2340930................................................................... 17.8 GRAPPLE HYDRAULIC CIRCUIT, 2340931 TO 2341050................................................................. 17.10 GRAPPLE HYDRAULIC CIRCUIT, 2341051 TO 2342000................................................................. 17.12 GRAPPLE OPEN/CLOSE CIRCUIT, 2340601 TO 2341050............................................................... 17.4 GRAPPLE OPEN/CLOSE HYDRAULIC CIRCUIT, 2341051 TO 2342000.......................................... 17.3 GRAPPLE ROTATE CIRCUIT.............................................................................................................. 17.4 JOYSTICK ELECTRICAL CIRCUIT, 2341051 TO 2341100............................................................... 17.14 JOYSTICK ELECTRICAL CIRCUIT, 2341101 TO 2342000............................................................... 17.15 E

ELECTRONIC ADJUSTMENT PROCEDURE....................................................................................... 17.19 GRAPPLE OPEN/CLOSE ADJUSTMENT.......................................................................................... 17.19 GRAPPLE OPEN/CLOSE FINE CONTROL....................................................................................... 17.45 GRAPPLE OPEN/CLOSE RAMP ADJUSTMENTS............................................................................ 17.24 GRAPPLE QUICK REVERSAL.......................................................................................................... 17.47 GRAPPLE ROTATE ADJUSTMENT................................................................................................... 17.29 GRAPPLE ROTATE RAMP ADJUSTMENTS..................................................................................... 17.34 JOYSTICK DEADBAND ADJUSTMENT............................................................................................ 17.49 MACHINE MODE ADJUSTMENT....................................................................................................... 17.17 MIN/MAX DEFAULT SETTINGS......................................................................................................... 17.39 RAMP DEFAULT SETTINGS.............................................................................................................. 17.40 RAMPS MODE COPY........................................................................................................................ 17.42 ELECTRONIC SETTINGS DESCRIPTION............................................................................................ 17.16 G

GRAPPLE CONNECTIONS TO BOOM................................................................................................... 17.4 GRAPPLE CONTROL VALVES................................................................................................................ 17.6 GRAPPLE SYSTEM COMPONENTS...................................................................................................... 17.2 ELECTRONIC JOYSTICK CONTROLS, 2340601 TO 2341050.......................................................... 17.2 ELECTRONIC JOYSTICK CONTROLS, 2341051 TO 2342000.......................................................... 17.2 GRAPPLE PILOT VALVE, 2341051 TO 2342000................................................................................. 17.3 GRAPPLE RESPONSE VALVE, 2340931 TO 2342000....................................................................... 17.3 HYDRAULIC PUMPS........................................................................................................................... 17.2 MAIN CONTROL VALVE...................................................................................................................... 17.2 M

MACHINE MODE................................................................................................................................... 17.17 P

PRESSURE SETTINGS CHECKING MAX CURRENT.............................................................................................................. 17.51 GRAPPLE OPEN/CLOSE.................................................................................................................. 17.53 GRAPPLE ROTATE............................................................................................................................ 17.54 PRESSURE SETTINGS, PORT RELIEF VALVES................................................................................. 17.51

Tigercat 234 Loader GRAPPLE SYSTEM COMPONENTS

Grapple ELECTRONIC JOYSTICK CONTROLS 2340601 to 2341050

HYDRAULIC PUMPS

Electronic joysticks use electrical signals to turn on electric solenoid controls that activate the main control valves for the grapple functions.

All hydraulic functions are powered by two pumps.

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

The main valve is supplied with oil from the main pump. The valves receive oil at the inlet section of the main control valve and direct the oil through the spool sections when either of the joysticks are activated.

Moving either of the joysticks will send an electronic CAN signal to the MD3 computer module. The CAN signal is then directed to the XA2 expansion module and from the module an output signal is directed to the solenoid control for the function that is selected.

MAIN PUMP

The electrical signal activates the solenoid and opens a pilot circuit that directs internal pilot oil to the spool actuator of the control valve selected.

This shifts the spool of the control valve directing pump oil flow to the selected function.

234-022

ELECTRONIC JOYSTICK CONTROLS 2341051 to 2342000

SWING PUMP

HYDRAULIC PUMPS

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

GRAPPLE OPEN/ CLOSE SECTION

40275BUNI

Electronic joysticks use electrical signals to turn on electric solenoid controls that activate the main control valves for the grapple functions.

The main valve is supplied with oil from the main pump. The valves receive oil at the inlet section of the main control valve and direct the oil through the spool sections when either of the joysticks are activated.

GRAPPLE ROTATE SECTION

175

174

173

172

167

165

164

163

171

170

70

162

160

71

Moving either of the joysticks or pushing the joystick buttons will send an electrical signal to the XS2 cab module. Pushing the buttons will provide a 24V signal to the corresponding input at the XS2 module. Moving the joysticks in either the 'X' or 'Y' axis will provide a variable 5V signal to the corresponding input at the XS2 cab module. This signal will be about 2500 mV when the joystick is in the neutral position, 0 mV when at one end of the axis and about 4800 mV when at the other end of the axis.

MAIN CONTROL VALVE

185the main pump to 273 184 254 The grapple circuit utilizes supply hydraulic oil to the Grapple open/close and Grapple rotate circuits via two valve sections in the main control valve.

A CAN signal is then directed to the XA2 expansion module and from that module an output signal is directed to the solenoid control for the function that is selected.

For a more detailed description of the main pump, refer to SECTION 4 in THIS SERVICE MANUAL. 40275BUNI R2

The electrical signal activates the solenoid and opens a pilot circuit that directs internal pilot oil to the spool actuator of the control valve selected.

This shifts the spool of the control valve directing pump oil flow to the selected function.

17.2

Tigercat 234 Loader

Grapple

GRAPPLE RESPONSE VALVE 2340931 to 2342000 GRAPPLE RESPONSE VALVE

MAIN PUMP

234-228

HYDRAULIC PUMPS

The grapple response valve is used to assist in the closing of the grapple. When the grapple close function is activated the grapple response valve is also activated through the IQAN system. When this valve is activated a LS signal is sent to the PL port on the main pump and this provides full system pressure to the main valve and grapple close function.

GRAPPLE PILOT VALVE 2341051 to 2342000

GRAPPLE PILOT VALVE

234-193

VALVE COMPARTMENT

The grapple pilot valve provides a rapid response to open or close the grapple when required by the operator. The IQAN system monitors the rate of change in the joystick movement and when a more aggressive joystick activation is recognized either the open or close grapple pilot solenoid is activated. This will direct a pilot signal to the grapple open/close valve section on the main valve which will by-pass the standard electronic ramps.

GRAPPLE OPEN/CLOSE HYDRAULIC CIRCUIT, 2341051 TO 2342000

234-229

17.3

Tigercat 234 Loader

Grapple

234-165

GRAPPLE OPEN/CLOSE CIRCUIT 2340601 TO 2341050

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

277-8 234-164

GRAPPLE ROTATE CIRCUIT 17.4

GRAPPLE CONNECTIONS

Tigercat 234 Loader FEED REDUCTION SIDE ‘B’

Grapple

PORT RELIEF ‘B’ SIDE

FEED REDUCTION SIDE ‘A’

PORT RELIEF ‘A’ SIDE

PRESSURE COMPENSATOR

24V PROPORTIONAL ELECTRO-HYDRAULIC SPOOL ACTUATORS

SPOOL

GRAPPLE OPEN/CLOSE SPOOL SECTION

1014-089.PLT

FEED REDUCER

PORT RELIEF ‘A’ SIDE

PORT RELIEF ‘B’ SIDE

24V PROPORTIONAL ELECTRO-HYDRAULIC SOLENOID CONTROLS

SPOOL

PRESSURE COMPENSATOR

234-068

CROSS SECTION OF ELECTRO-HYDRAULIC OPERATED SPOOL SECTION GRAPPLE ROTATE SPOOL SECTION 17.5

Tigercat 234 Loader

Grapple

175 174

164

173

163

172

273

165

184

167

254 185

171

162

170

160

70

71

234-137

MAIN CONTROL VALVE 17.6

Tigercat 234 Loader

Grapple

234-131

GRAPPLE CLOSE FEED REDUCER

B

B

GRAPPLE OPEN FEED REDUCER

UP

CW

B

A

A

A DOWN

B

B

OPEN

B

B

CCW

CUT

A

RET

CLOSE

A

OPEN

A

IN

A

DOWN

OUT

GRAPPLE ROTATE SECTION

UP

GRAPPLE OPEN/ CLOSE SECTION

GRAPPLE ROTATE FEED REDUCER (BOTH DIRECTIONS)

MAIN CONTROL VALVE Moving either of the joysticks will send an electronic signal to the MD3 or XS2 computer module. (See ELECTRONIC JOYSTICK CONTROLS earlier in THIS SECTION) The signal is then directed to the XA2 expansion module and from the module the signal is directed to the solenoid control for the function that is selected.

The electrical signal activates the solenoid and opens a pilot circuit that directs internal pilot oil to the spool actuator of the control valve selected.

This shifts the spool of the control valve directing pump oil flow to the selected function.

GRAPPLE CONTROL VALVES The grapple open/close function and the grapple rotate motor are controlled by two of the seven spool sections in the main control valve. The main control valve is located in the upper frame below the floor plates inside the valve compartment.

If installed the grapple response valve will be activated when the grapple close function is activated. The electrical signal to the grapple response valve comes from the XA2 expansion module. The grapple response valve provides a LS hydraulic signal to the PL port on the main pump ensuring system pressure when this function is activated.

For a detailed description of the main control valve, refer to SECTION 4 in THIS MANUAL.

If installed and enabled the grapple pilot valve will be activated when an aggressive rate of change in joystick movement is detected. The electrical signals to the open/close grapple pilot valve come from the XS2 cab module. The grapple pilot valve provides a pilot signal to the grapple open/close valve section on the main valve by-passing the standard electronic ramps.

GRAPPLE CIRCUIT DESCRIPTION The grapple circuit is supplied with oil from the main pump. The grapple valves receive oil at the inlet section of the main control valve and direct the oil through the spool sections when either of the grapple functions are activated.

17.7

Tigercat 234 Loader

Grapple

GRAPPLE MOTOR

TO OIL COOLER

PUMP CONTROL VALVE

MAIN VALVE

MAIN PUMP

TO TANK

PILOT FILTER

PILOT MANIFOLD RETURN FILTERS TO TANK

LEGEND PRESSURE LINE PILOT LINE DRAIN LINE

234-222

GRAPPLE HYDRAULIC CIRCUIT 2340601 TO 2340930 17.8

Tigercat 234 Loader

Grapple MD3 DISPLAY

JOYSTICKS

XA2 EXPANSION MODULE

173-GR 178A-RD 164-GR 178-RD 162-GR 180-RD 171-GR 180A-RD

LEGEND CAN WIRE

GRAPPLE ROTATE SECTION

GRAPPLE OPEN/CLOSE SECTION

234-223

GRAPPLE ELECTRICAL CIRCUIT 2340601 TO 2340930 17.9

WIRE

Tigercat 234 Loader

Grapple

GRAPPLE MOTOR

GRAPPLE RESPONSE VALVE (MOUNTED ON PUMP)

TO OIL COOLER

PUMP CONTROL VALVE

MAIN VALVE

MAIN PUMP

TO TANK

PILOT FILTER

PILOT MANIFOLD RETURN FILTERS TO TANK

LEGEND PRESSURE LINE PILOT LINE DRAIN LINE

234-224

GRAPPLE HYDRAULIC CIRCUIT 2340931 TO 2341050 17.10

Tigercat 234 Loader

Grapple MD3 DISPLAY

JOYSTICKS

XA2 EXPANSION MODULE

173-GR 178A-RD 164-GR 178-RD 162-GR 180-RD 171-GR 180A-RD

255-GR

GRAPPLE RESPONSE VALVE (MOUNTED ON PUMP)

LEGEND CAN WIRE

GRAPPLE ROTATE SECTION GRAPPLE OPEN/CLOSE SECTION

234-225

GRAPPLE ELECTRICAL CIRCUIT 2340931 TO 2341050 17.11

WIRE

Tigercat 234 Loader

Grapple

GRAPPLE MOTOR

GRAPPLE RESPONSE VALVE (MOUNTED ON PUMP)

TO OIL COOLER

PUMP CONTROL VALVE

MAIN VALVE

MAIN PUMP

TO TANK

GRAPPLE PILOT VALVE

PILOT FILTER

PILOT MANIFOLD RETURN FILTERS TO TANK

LEGEND PRESSURE LINE PILOT LINE DRAIN LINE

234-226

GRAPPLE HYDRAULIC CIRCUIT 2341051 TO 2342000 17.12

Tigercat 234 Loader

Grapple MD3 DISPLAY

JOYSTICKS

XS2 CAB MODULE

FOR DETAILS OF JOYSTICK INPUTS SEE NEXT 2 PAGES

329-GR 328-GR

GRAPPLE PILOT VALVE

XA2 EXPANSION MODULE

173-GR 178A-RD 164-GR 178-RD 162-GR 180-RD 171-GR 180A-RD

255-GR

GRAPPLE RESPONSE VALVE (MOUNTED ON PUMP)

LEGEND CAN WIRE

GRAPPLE ROTATE SECTION GRAPPLE OPEN/CLOSE SECTION

234-227

GRAPPLE ELECTRICAL CIRCUIT 2341051 TO 2342000 17.13

WIRE

Tigercat 234 Loader

234-216

Grapple

JOYSTICK ELECTRICAL CIRCUIT 2341051 TO 2341100 17.14

Tigercat 234 Loader

234-218

Grapple

JOYSTICK ELECTRICAL CIRCUIT 2341101 TO 2342000 17.15

Tigercat 234 Loader ELECTRONIC SETTINGS DESCRIPTION Adjustments to the grapple controls through the ADJUST MENU of the IQAN control system electronically adjust the performance of the grapple to suit operating conditions.

Refer also to COMPUTER ~ (ADJUSTMENT) MENU OPERATION in SECTION 6 of THIS MANUAL. These settings control the operation of the electro-hydraulic spool actuators which control the cylinder tracking and operating speeds by regulating the flow of oil from the main valve to the grapple cylinders and motor.

Many types of adjustments can be made to the grapple control system and they are described later in THIS SECTION. There are 4 settings that are critical to all the adjustments and it is important that these 4 settings are adjusted correctly to ensure proper grapple operation.

Grapple 3. Start Ramp This is the amount of units/s that are applied to the output as it is turned on and it is proportional to the position of the joystick in its axis. The higher the value the more aggressive the start of the function. The lower the value the smoother the start of the function.

4. Stop Ramp This is the amount of units/s that are applied to the output as it is turned off and it is proportional to the position of the joystick in its axis. The higher the value the more aggressive the stop of the function. The lower the value the smoother the stop of the function.

Below is a typical graph showing the four settings.

The second graph shows the settings after the start ramp setting has been increased resulting in a steeper ramp or more aggressive start.

These 4 settings are: 1. Min Current

INPUT

Current (m/A)

This is the minimum amount of current that causes the function to just begin to creep.

START SLOPE IN UNITS/S

NOTE: An inaccurate adjustment of the Min Current renders the start and stop ramps inaccurate.

STOP SLOPE IN UNITS/S

OUTPUT

MAX CURRENT

2. Max Current MIN CURRENT

This is the current the controls the maximum speed of the function. A higher setting will cause the function to move faster.

Time (m/S)

Current (m/A) INCREASED START SLOPE IN UNITS/S

STOP SLOPE IN UNITS/S

MAX CURRENT

MIN CURRENT Time (m/S)

234-219

17.16

Tigercat 234 Loader

Grapple

MACHINE MODE The machine mode menu enables the machine to be set up quickly to operate under different conditions or with different operators without having to go through various menus to make multiple adjustments to parameters.

The machine modes are M0, M1, M2 and M3. M0 is the least aggressive mode and is intended for training while M3 is the most aggressive mode.

These modes can be personalized through the various adjustment menus described in THIS SECTION. Many of the adjustments will display the active mode, which means that when adjustments are made in these menus where the active mode is displayed then only that mode will be affected by the changes.

Note: When making electronic adjustments it is important to be aware of the active mode so that any changes are applied to the intended machine mode.

The machine mode can be set by using the MD3 display or through the laptop. See MACHINE MODE ADJUSTMENT SELECTION in SECTION 2 of THIS MANUAL to set the machine mode using the MD3.

MACHINE MODE ADJUSTMENT

234-174

From the Adjust menu double click on Machine Mode

17.17

Tigercat 234 Loader

Grapple

In the Machine Mode menu double click on Mode Select

Click on the mode required and click on Done.

17.18

Tigercat 234 Loader

Grapple

ELECTRONIC ADJUSTMENT PROCEDURE After logging into the system as "Service" the following adjustments can be made.

234-119

Click on the Adjust Menu to access the Adjust groups.

Double click on Valve Current Settings to access the Grapple functions.

GRAPPLE OPEN/CLOSE ADJUSTMENT

234-197

Double click on Grapple Arms to access the Grapple open/close current adjustments.

17.19

Tigercat 234 Loader

Grapple

234-198

Click on the + Close Min mA number to highlight this setting. Once in the Min menu only the Min current will be applied to the grapple close solenoid. Move the left hand joystick fully to the right to activate the grapple close function and using the up or down arrows adjust this setting so that the grapple is just moving. It is important to use the up or down arrows instead of attempting to type in the value since the grapple will react instantly to any value typed and may close at full speed unexpectedly.

NOTE: An inaccurate adjustment of the Min Current renders the start and stop ramps inaccurate.

Return the joystick to the neutral position.

17.20

Tigercat 234 Loader

Grapple

234-199

Click on the + Close Max mA number to highlight this setting. This setting determines the grapple close cylinder speed. Once in the Max menu only the Max current will be applied to the grapple close solenoid.

Move the left hand joystick fully to the right to activate grapple close function and using the up or down arrows adjust this setting to the desired time to close the grapple. It is important to use the up or down arrows instead of attempting to type in the value since the grapple will react instantly to any value typed and may close at full speed unexpectedly. It may be necessary to toggle between grapple open and grapple close on the joystick to get an accurate setting of the grapple close speed.

Return the joystick to the neutral position.

17.21

Tigercat 234 Loader

Grapple

234-200

Click on the - Open Min mA number to highlight this setting. Once in the Min menu only the Min current will be applied to the grapple open solenoid. Move the left hand joystick fully to the left to activate the grapple open function and using the up or down arrows adjust this setting so that the grapple is just moving. It is important to use the up or down arrows instead of attempting to type in the value since the grapple will react instantly to any value typed and may open at full speed unexpectedly.

NOTE: An inaccurate adjustment of the Min Current renders the start and stop ramps inaccurate.

Return the joystick to the neutral position.

17.22

Tigercat 234 Loader

Grapple

234-201

Click on the - Open Max mA number to highlight this setting. This setting determines the grapple open cylinder speed. Once in the Max menu only the Max current will be applied to the grapple open solenoid.

Move the left hand joystick fully to the left to activate grapple open function and using the up or down arrows adjust this setting to the desired time to open the grapple. It is important to use the up or down arrows instead of attempting to type in the value since the grapple will react instantly to any value typed and may open at full speed unexpectedly. It may be necessary to toggle between grapple open and grapple close on the joystick to get an accurate setting of the grapple open speed.

Return the joystick to the neutral position.

17.23

Tigercat 234 Loader

Grapple

GRAPPLE OPEN/CLOSE RAMP ADJUSTMENTS Before any adjustments are made to the ramps it is important to understand that the adjustments will only apply to the active machine mode. To change the machine mode see MACHINE MODE ADJUSTMENT SELECTION in SECTION 2 of THIS MANUAL or MACHINE MODE ADJUSTMENT in THIS SECTION.

234-126

Double click on Ramps to access the Grapple ramp adjustments.

234-202

Double click on Grapple Open Start Slope to access the ramp adjustment.

17.24

Tigercat 234 Loader

Grapple

234-203

This setting will determine (along with the Grapple Open Min current) how the grapple open function will start when activated. Increasing this setting will result in a more aggressive start while decreasing the setting will result in a smoother, less aggressive start. Use the up or down arrows to adjust the setting and then click on Done.

234-204

Double click on Grapple Open Stop Slope to access the ramp adjustment.

17.25

Tigercat 234 Loader

Grapple

234-205

This setting will determine (along with the Grapple Open Min current) how the grapple open function will stop when deactivated. Increasing this setting will result in a more aggressive stop while decreasing the setting will result in a smoother, less aggressive stop. Use the up or down arrows to adjust the setting and then click on Done.

234-206

Double click on Grapple Close Start Slope to access the ramp adjustment.

17.26

Tigercat 234 Loader

Grapple

234-207

This setting will determine (along with the Grapple Close Min current) how the grapple close function will start when activated. Increasing this setting will result in a more aggressive start while decreasing the setting will result in a smoother, less aggressive start. Use the up or down arrows to adjust the setting and then click on Done.

234-208

Double click on Grapple Close Stop Slope to access the ramp adjustment.

17.27

Tigercat 234 Loader

Grapple

234-209

This setting will determine (along with the Grapple Close Min current) how the grapple close function will stop when deactivated. Increasing this setting will result in a more aggressive stop while decreasing the setting will result in a smoother, less aggressive stop. Use the up or down arrows to adjust the setting and then click on Done.

The Grapple Open/Close Electronic Min/Max Current and Ramp adjustments are now complete.

234-208

Click on the back arrow to navigate back to the Adjust Menu.

17.28

Tigercat 234 Loader

Grapple

234-119

Double click on Valve Current Settings to access the Grapple Rotate functions.

GRAPPLE ROTATE ADJUSTMENT

234-210

Double click on Grapple Rotate to access the CW and CCW current adjustments.

17.29

Tigercat 234 Loader

Grapple

234-211

Click on the + CW Min mA number to highlight this setting. Once in the Min menu only the Min current will be applied to the CW rotate solenoid. Move the right hand joystick fully to the right to activate the rotate CW function and using the up or down arrows adjust this setting so that the grapple is just moving.

It is important to use the up or down arrows instead of attempting to type in the value since the grapple will react instantly to any value typed and may rotate at full speed unexpectedly.

NOTE: An inaccurate adjustment of the Min Current renders the start and stop ramps inaccurate.

Return the joystick to the neutral position.

17.30

Tigercat 234 Loader

Grapple

234-212

Click on the + CW Max mA number to highlight this setting. This setting determines the grapple CW rotate speed. Once in the Max menu only the Max current will be applied to the CW rotate solenoid. Move the right hand joystick fully to the right to activate the rotate CW function and using the up or down arrows adjust this setting so that the grapple rotates at the desired speed. It is important to use the up or down arrows instead of attempting to type in the value since the grapple will react instantly to any value typed and may rotate at full speed unexpectedly.

Return the joystick to the neutral position.

17.31

Tigercat 234 Loader

Grapple

234-213

Click on the - CCW Min mA number to highlight this setting. Once in the Min menu only the Min current will be applied to the CCW rotate solenoid. Move the right hand joystick fully to the left to activate the rotate CCW function and using the up or down arrows adjust this setting so that the grapple is just moving. It is important to use the up or down arrows instead of attempting to type in the value since the grapple will react instantly to any value typed and may rotate at full speed unexpectedly.

NOTE: An inaccurate adjustment of the Min Current renders the start and stop ramps inaccurate.

Return the joystick to the neutral position.

17.32

Tigercat 234 Loader

Grapple

234-212

Click on the - CCW Max mA number to highlight this setting. This setting determines the grapple CCW rotate speed. Once in the Max menu only the Max current will be applied to the CCW rotate solenoid.

Move the right hand joystick fully to the left to activate the rotate CCW function and using the up or down arrows adjust this setting so that the grapple rotates at the desired speed. It is important to use the up or down arrows instead of attempting to type in the value since the grapple will react instantly to any value typed and may rotate at full speed unexpectedly.

Return the joystick to the neutral position.

Click on Done to confirm settings.

17.33

Tigercat 234 Loader

Grapple

GRAPPLE ROTATE RAMP ADJUSTMENTS Before any adjustments are made to the ramps it is important to understand that the adjustments will only apply to the active machine mode. To change the machine mode see MACHINE MODE ADJUSTMENT SELECTION in SECTION 2 of THIS MANUAL or MACHINE MODE ADJUSTMENT in THIS SECTION.

234-126

Double click on Ramps to access the Grapple CW and CCW ramp adjustments.

234-216

Double click on Grapple CW Start Slope to access the ramp adjustment.

17.34

Tigercat 234 Loader

Grapple

234-217

This setting will determine (along with the Grapple CW Min current) how the grapple CW rotate function will start when activated. Increasing this setting will result in a more aggressive start while decreasing the setting will result in a smoother, less aggressive start. Use the up or down arrows to adjust the setting and then click on Done.

234-218

Double click on Grapple CW Stop Slope to access the ramp adjustment.

17.35

Tigercat 234 Loader

Grapple

234-219

This setting will determine (along with the Grapple CW Min current) how the grapple CW rotate function will stop when deactivated. Increasing this setting will result in a more aggressive stop while decreasing the setting will result in a smoother, less aggressive stop. Use the up or down arrows to adjust the setting and then click on Done.

234-220

Double click on Grapple CCW Start Slope to access the ramp adjustment.

17.36

Tigercat 234 Loader

Grapple

234-221

This setting will determine (along with the Grapple CCW Min current) how the grapple CCW rotate function will start when activated. Increasing this setting will result in a more aggressive start while decreasing the setting will result in a smoother, less aggressive start. Use the up or down arrows to adjust the setting and then click on Done.

234-222

Double click on Grapple CCW Stop Slope to access the ramp adjustment.

17.37

Tigercat 234 Loader

Grapple

234-223

This setting will determine (along with the Grapple Rotate CCW Min current) how the grapple CCW rotate function will stop when deactivated. Increasing this setting will result in a more aggressive stop while decreasing the setting will result in a smoother, less aggressive stop. Use the up or down arrows to adjust the setting and then click on Done.

The grapple open/close and grapple rotate Electronic Min/Max Current and Ramp adjustments are now complete.

17.38

Tigercat 234 Loader

Grapple

MIN/MAX DEFAULT SETTINGS

234-215

If during any of the grapple open/close or rotate Min/Max adjustments the factory default settings are required click on "Reset Item". A pop up window will appear asking for this action to be confirmed. Click on "Yes" and the factory defaults will be reset.

17.39

Tigercat 234 Loader

Grapple

RAMP DEFAULT SETTINGS There are 3 ways to reset the factory default settings when in the ramp menu. You can reset an individual ramp setting , all the ramps in the active mode can be reset or all the ramps in all 4 modes can be reset.

234-224

If during any of the individual ramp adjustments the factory default setting is required click on "Reset Item". A pop up window will appear asking for this action to be confirmed. Click on "Yes" and the factory default will be reset.

17.40

Tigercat 234 Loader

Grapple

234-178

If in the Ramp menu either all the ramps in one mode can be reset or all ramps for all modes. Click on Reset Group. A pop up window will appear asking if all modes or just the active mode are to be reset.

Click on the mode required and click on OK.

17.41

Tigercat 234 Loader

Grapple

RAMPS MODE COPY In the Ramps menu there is a tab that enables a complete set of ramps to be copied from one machine mode to another. Before copying the set of ramps the MD3 needs to be set in the machine mode that you wish to change. To change the MD3 machine mode see MACHINE MODE ADJUSTMENT SELECTION in SECTION 2 of THIS MANUAL. The example shown below copies the ramps from Machine Mode 0 to Machine Mode 3.

Ensure the MD3 is set to the Machine mode you wish to change. The machine mode is displayed on the main screen.

234-126

In the Adjust menu double click on the Ramps selection to access the Ramps menu.

17.42

Tigercat 234 Loader

Grapple

234-180

Ensure that the Active mode in this screen is the machine mode you wish to copy to. In this example it is M3. In the Ramps menu screen click on the Copy From Mode tab at the bottom of the screen. A small pop up window will appear and click on the machine mode you want to copy from. In this example it is M0.

234-181

Another pop up window will appear asking for confirmation of the copy of ramp parameters. In this example it is M0 to M3. Click on Yes to confirm the copy.

17.43

Tigercat 234 Loader

Grapple

234-182

Another window will pop up advising Mode copied successfully. Click OK in this window. The copy is now complete. If the factory defaults are required to be reset after a copy has been made the "All modes" choice must be selected.

17.44

Tigercat 234 Loader

Grapple

GRAPPLE OPEN/CLOSE FINE CONTROL The Grapple Open/Close Fine Control provides an additional adjustment to provide more precise control while making small movements of the joysticks. This can be useful for sorting applications or other applications where small precise movements of the grapple arms are required.

234-119

Double click on Valve Current Settings to access the Grapple functions.

234-225

Double click on Grapple Open/Close Fine Control % .

17.45

Tigercat 234 Loader

Grapple

234-226

Using the up or down arrows adjust this setting to suit. Increasing this value will provide more fine control of the grapple open/close movement when using the joysticks. Click on Done once the adjustment has been made.

17.46

Tigercat 234 Loader

Grapple

GRAPPLE QUICK REVERSAL The Grapple Quick Reversal provides a way to quickly open or close the grapple arms if required. The IQAN computer system monitors the rate of change of joystick movement from open to close or close to open. When it recognizes a rapid change the IQAN system will activate the appropriate grapple pilot valve to apply pilot pressure to the grapple open/close valve on the main valve and override the existing electronic ramp. This function can be enabled or disabled using the laptop or MD3 display. See ELECTRONIC ADJUSTMENT PROCEDURE - GRAPPLE QUICK REVERSAL in SECTION 2 of THIS MANUAL for MD3 setting.

234-227

From the Adjust menu double click on Machine Parameters.

17.47

Tigercat 234 Loader

Grapple

234-228

Double click on Grapple Quick Reversal Status.

234-229

Click on ON of OFF in the selection box to enable or disable this function and then click on Done.

17.48

Tigercat 234 Loader

Grapple

JOYSTICK DEADBAND ADJUSTMENT The Joysticks menu allows adjustment of the joystick deadband. The deadband is an adjustable portion of the initial joystick movement where no function will be activated. The adjustment is a % of the joystick movement and can be adjusted between 8 and 30%.

234-190

In the Adjust menu double click on Joysticks.

234-191

Double click on Joystick deadband.

17.49

Tigercat 234 Loader

Grapple

234-192

Increasing this setting will increase the deadband. Using the up or down arrows adjust the joystick deadband and click on Done.

NOTE: Adjustment of the joystick deadband will affect all functions that are activated by using the axis movement of the joystick.

17.50

Tigercat 234 Loader PRESSURE SETTINGS

Grapple

Because the grapple open/close and rotate valves are controlled electronically by the proportional valves on the main manifold it is important to first check that the maximum current to fully activate each of the valves is applied before attempting any hydraulic testing. The max current can be checked through the MD3 screen.

CHECKING MAX CURRENT

234-195

Using the up or down arrow buttons scroll to Grapple Controls and press OK.

234-109

Press the menu button MENU.

to go to the MAIN

234-196

Using the up or down arrow buttons scroll to the Grapple Arms selection. Lower the armrest and press PILOT RESET switch to activate pilot system and activate one of the grapple functions (open or close) on the joysticks and ensure that the current reading is 700 mA (+ or - 30 mA) .

234-114

Press F2 to access the Measure menu.

Note: In one direction the reading will be around 700 mA and in the other direction it will be -700 mA .

Repeat this for each grapple open/close function.

If the reading is less than 700 mA (+ or - 30 mA) the max current setting will need to be adjusted before any hydraulic testing can be done. See ELECTRONIC ADJUSTMENT PROCEDURE in THIS SECTION.

17.51

Tigercat 234 Loader

Grapple

234-194

Using the up or down arrow buttons scroll to the Grapple Rotate selection. Lower the armrest and press PILOT RESET switch to activate pilot system and activate one of the grapple rotate functions (CW or CCW) on the joysticks and ensure that the current reading is 450 mA (+ or 30 mA).

Note: In one direction the reading will be around 450 mA and in the other direction it will be -450 mA .

If the reading is less than 450 mA (+ or - 30 mA) the max current setting will need to be adjusted before any hydraulic testing can be done. See ELECTRONIC ADJUSTMENT PROCEDURE in THIS SECTION. If the settings for the Grapple Arms and Grapple Rotate functions are OK, turn the pilot off and proceed to the hydraulic tests.

17.52

Tigercat 234 Loader

Grapple

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

CAUTION

4. Start the engine, and set the throttle control to the IDLE position. Lower left arm rest and depress the pilot reset switch to activate the pilot system.

5. While holding the L.H. joystick in the GRAPPLE OPEN position (cylinders fully retracted), check gauge pressure reading.

GRAPPLE OPEN CLOSE VALVE

Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

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

PRESSURE SETTINGS GRAPPLE OPEN/CLOSE RELIEF VALVE SETTINGS Pump 'POR'............................... 262 bar/3800 psi Grapple open feed reducer ...... 172 bar/2500 psi

CLOSE FEED REDUCER

Grapple close feed reducer ..... 172 bar/2500 psi 1. Position machine on flat level ground .

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

OPEN FEED REDUCER

234-131

GRAPPLE OPEN CLOSE FEED REDUCERS 6. If Less than set value adjust feed reducer.

Turn adjusting screw in to increase pressure or turn screw out to decrease pressure.

7. While holding the L.H. joystick in the GRAPPLE CLOSE position (cylinders fully extended), check gauge pressure reading.

'PX' TEST PORT

8. If Less than set value adjust feed reducer.

Turn adjusting screw in to increase pressure or turn screw out to decrease pressure.

'PL' TEST PORT

NOTE: Relief valves are not adjustable. If less than set value in one direction but OK in the other direction the relief valve for the low pressure circuit must be replaced.

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

234E-191

MAIN VALVE TEST PORTS

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

17.53

Tigercat 234 Loader

Grapple

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

CAUTION Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

6. Start the engine, and set the throttle control to the IDLE position. Lower left arm rest and depress the pilot reset switch to activate the pilot system.

7. Move the R.H. joystick to the right to the ROTATE CLOCKWISE position, check gauge pressure reading.

8. If Less than set value adjust feed reducer.

Turn adjusting screw in to increase pressure or turn screw out to decrease pressure.

GRAPPLE ROTATE VALVE

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

GRAPPLE ROTATE RELIEF VALVE SETTINGS Pump 'POR'............................... 262 bar/3800 psi Rotate CW feed reducer .......... 121 bar/1750 psi Rotate CCW feed reducer........ 121 bar/1750 psi 1. Position machine on flat level ground.

FEED REDUCER (BOTH DIRECTIONS)

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

234-131

GRAPPLE ROTATE FEED REDUCERS

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

'PX' TEST PORT

'PL' TEST PORT

NOTE: This feed reducer is used for both CW and CCW circuits.

9. Move the R.H. joystick to the left to the ROTATE COUNTERCLOCKWISE position, check gauge pressure reading.

10. If the feed reducer was adjusted for the CW direction no further adjustment should be required.

NOTE: Port relief valves are not adjustable. If less than set value in one direction but OK in the other direction the relief valve for the low pressure circuit must be replaced.

234E-191

MAIN VALVE TEST PORTS

4. Connect a 0 - 5000 p.s.i. pressure gauge to the main control valve 'PL' test port on the inlet section of the main control valve.

11. Release grapple from it's secured position.

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

17.54

Tigercat 234 Loader SECTION 18 – DELIMBER/SLASHER CONTENTS - SECTION 18 C

ISSUE 2.0, JULY 2015

CIRCUIT DESCRIPTION, 2340601 TO 2341050.................................................................................... 18.7 CIRCUIT DESCRIPTION, 2341051 TO 2342000.................................................................................... 18.8 CIRCUIT DIAGRAMS DELIMBER/SLASHER HYDRAULIC CIRCUIT.................................................................................... 18.9 JOYSTICK ELECTRICAL CIRCUIT, 2341051 TO 2341100............................................................... 18.14 JOYSTICK ELECTRICAL CIRCUIT, 2341101 TO 2342000............................................................... 18.15 CONTROL VALVE DELIMBER................................................................................................................. 18.2 CONTROL VALVE SAWS RETRACT SLASHER CUT............................................................................ 18.2 D

DELIMBER/SLASHER CIRCUIT COMPONENTS................................................................................... 18.2 DELIMBER OPEN/DUMP VALVE......................................................................................................... 18.3 ELECTRONIC JOYSTICK CONTROLS, 2340601 TO 2341050.......................................................... 18.4 ELECTRONIC JOYSTICK CONTROLS, 2341051 TO 2342000.......................................................... 18.4 MAIN CONTROL VALVE...................................................................................................................... 18.2 PILOT DELIMBER OPEN/HOLD VALVE.............................................................................................. 18.3 DELIMBER/SLASHER CONNECTIONS.................................................................................................. 18.4 DELIMBER/SLASHER ELECTRICAL...................................................................................................... 18.2 DELIMBER/SLASHER PUMP.................................................................................................................. 18.2 E

ELECTRONIC ADJUSTMENT PROCEDURE....................................................................................... 18.18 DELIMBER CLOSE DELAY ADJUSTMENT....................................................................................... 18.19 DELIMBER OPEN DELAY ADJUSTMENT......................................................................................... 18.18 MACHINE MODE ADJUSTMENT....................................................................................................... 18.16 M

MACHINE MODE................................................................................................................................... 18.16 P

PRESSURE SETTINGS......................................................................................................................... 18.23 CHECKING MAX CURRENT.............................................................................................................. 18.21 PRESSURE SETTINGS FOR TOP SAW CUT, SLASHER CUT AND DELIMBER............................ 18.23

Tigercat 234 Loader

Delimber/Slasher

DELIMBER/SLASHER CIRCUIT COMPONENTS

ENGINE BELL HOUSING

MAIN PUMP SWING PUMP

234-057

HYDRAULIC PUMPS

PUMP

SAW CUT RETRACT SECTION

The main pump is an axial-piston, variabledisplacement pump with load sensing and horsepower limiting controls.

The delimber and slasher circuits utilize the main pump to supply hydraulic oil to the delimber and slasher control valve spool sections in the "main" control valve.

DELIMBER OPEN SECTION

175

174

173

172

167

165

164

163

171

170

70

162

160

71

For a more detailed description of the main pump, refer to SECTION 4 in THIS SERVICE MANUAL. DELIMBER CONTROL VALVE

40275BUNI R2

The delimber arms OPEN/CLOSE functions are controlled by one of seven spool sections in the main control valve and the pilot delimber open/ hold valve in the pilot manifold.

MAIN CONTROL VALVE SAWS CUT/TOP SAW RETRACT CONTROL 185 273 184 254 VALVE The slasher saw cutting function and the retraction of both the slasher saw and the top saw are controlled by one of seven spool sections in the main control valve.

40275BUNI R2

For a detailed description of the main control valve, refer to SECTION 4 in THIS MANUAL. 18.2

Tigercat 234 Loader DELIMBER OPEN/DUMP VALVE The delimber open/dump valve is a pilot operated three way directional valve consisting of an aluminum valve body, a screw-in poppet type, pilot operated valve cartridge and a screw-in check valve cartridge. This valve is located on the lower frame.

Delimber/Slasher PILOT DELIMBER OPEN/HOLD VALVE DELIMBER OPEN/HOLD SOLENOID

DELIMBER OPEN

234-082

234E-195

DELIMBER OPEN DUMP VALVE

PILOT MANIFOLD

When the LH. joystick switch is pressed to OPEN the delimber arms, the delimber open/hold solenoid on the pilot valve is activated and directs pilot oil to the valve cartridge on the open/dump valve shifting the valve cartridge to block the connection between ports 'D' and 'T' and instead allow system oil to flow from port 'V', "through" the check valve to port 'D' to the base end of the cylinder to open the delimber arms.

When the open switch on the joystick is released this valve remains on or "latched" to hold the delimber arms open.

240B-027

DELIMBER OPEN/DUMP VALVE SCHEMATIC

When the LH. joystick switch is pressed to CLOSE the delimber arms the the delimber open/hold solenoid on the pilot valve is deactivated and opens the connection between 'D' and 'T' allowing oil from the base end of the cylinder back to tank to close the delimber arms.

In the neutral position with the pilot de-activated, port 'D' is open to tank port 'T', allowing oil to flow from the base end of the delimber arms cylinder and "dump" to tank. An orifice in the connecting port controls the flow of this return oil so that the delimber arms do not CLOSE too fast.

When the LH. joystick switch is pressed to OPEN the delimber arms, the delimber open/close solenoid on the pilot valve is activated and directs pilot oil to the valve cartridge on the open/dump valve shifting the valve cartridge to block the connection between ports 'D' and 'T' and instead allow system oil to flow from port 'V', "through" the check valve to port 'D' to the base end of the cylinder to open the delimber arms.

18.3

Tigercat 234 Loader

Delimber/Slasher DELIMBER/SLASHER CONNECTIONS

ELECTRONIC JOYSTICK CONTROLS 2340601 to 2341050 Electronic joysticks use electrical signals to turn on electric solenoid controls that activate the main control valves for the delimber/slasher functions.

Hydraulic connections for the delimber and the slasher are located on the lower frame. The delimber connections, located at the front of the lower frame and accessed from below, consist of one No.8 JIC elbow, one No.12 JIC elbow and two No. 16 JIC elbow. The slasher connections, located at the front of the lower frame consist of two No. 16 JIC fittings and one No. 8 JIC fitting. All fittings are capped when not in use with special steel caps to prevent leakage. Always ensure caps are tightly in place when not operating a delimber or slasher.

When making the hydraulic connection to either the delimber or the slasher, it is very important to clean around the fittings before disconnecting them to prevent dirt from entering the system.

The main valve is supplied with oil from the main pump. The valves receive oil at the inlet section of the main control valve and direct the oil through the spool sections when either of the joysticks are activated.

Moving either of the joysticks will send an electronic CAN signal to the MD3 computer module. The CAN signal is then directed to the XA2 expansion module and from the module an output signal is directed to the solenoid control for the function that is selected.

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

The electrical signal activates the solenoid and opens a pilot circuit that directs internal pilot oil to the spool actuator of the control valve selected.

This shifts the spool of the control valve directing pump oil flow to the selected function.

DELIMBER OPEN

ELECTRONIC JOYSTICK CONTROLS 2341051 to 2342000 TANK

Electronic joysticks use electrical signals to turn on electric solenoid controls that activate the main control valves for the delimber/slasher functions.

TOP SAW CUT

The main valve is supplied with oil from the main pump. The valves receive oil at the inlet section of the main control valve and direct the oil through the spool sections when either of the joysticks are activated.

TOP SAW RETRACT

DELIMBER CONNECTIONS

234E-195

Moving either of the joysticks or pushing the joystick buttons will send an electrical signal to the XS2 cab module. Pushing the buttons will provide a 24V signal to the corresponding input at the XS2 module. Moving the joysticks in either the 'X' or 'Y' axis will provide a variable 5V signal to the corresponding input at the XS2 cab module. This signal will be about 2500 mV when the joystick is in the neutral position, 0 mV when at one end of the axis and about 4800 mV when at the other end of the axis.

A CAN signal is then directed to the XA2 expansion module and from that module an output signal is directed to the solenoid control for the function that is selected.

SLASHER RETRACT SLASHER CUT

234E-194

TANK

SLASHER CONNECTIONS

For information on the DELIMBER or SLASHER, please refer to the MANUFACTURERS MANUAL.

The electrical signal activates the solenoid and opens a pilot circuit that directs internal pilot oil to the spool actuator of the control valve selected.

This shifts the spool of the control valve directing pump oil flow to the selected function.

18.4

Tigercat 234 Loader

Delimber/Slasher

175

167

174

165

254

173

164

184 273

172

163

185

171

162

170

160

70

71

40275BUNI R2

234-137

MAIN CONTROL VALVE 18.5

Tigercat 234 Loader FEED REDUCER

Delimber/Slasher PORT RELIEF ‘A’ SIDE

PORT RELIEF ‘B’ SIDE

24V PROPORTIONAL ELECTRO-HYDRAULIC SPOOL ACTUATORS

SPOOL

SPOOL SECTION - DELIMBER OPEN GRAPPLE SAW OPTION

PORT RELIEF ‘B’ SIDE FEED REDUCTION SIDE ‘B’

FEED REDUCTION SIDE ‘A’

PRESSURE COMPENSATOR

PORT RELIEF ‘A’ SIDE 24V PROPORTIONAL ELECTRO-HYDRAULIC SPOOL ACTUATORS

SPOOL 234-068 234-131 234-158

PRESSURE COMPENSATOR

SPOOL SECTION - SAW CUT/RETRACT 18.6

Tigercat 234 Loader

Delimber/Slasher

DELIMBER/SLASHER CIRCUIT DESCRIPTION 2340601 TO 2341050

Cut with delimber top saw; Push RIGHT side of L.H. Joystick switch, Push LEFT side of R.H. joystick switch, an electronic CAN signal is sent to the MD3 computer which then sends a CAN signal on to the XA2 expansion module. The signal is then sent to energize the SAW SOLENOID on SAW valve.

REFER TO CIRCUIT DIAGRAMS The delimber/slasher circuit is supplied with hydraulic oil by an axial-piston, variabledisplacement pump. Two spool sections in the main control valve hydraulically control the delimber or slasher functions.

Two 3-position joystick switches, the MD3 computer module and the XA2 expansion module electrically control the delimber and slasher functions via proportional electro hydraulic solenoid controls on the main control valve and pilot valve on the pilot manifold :Open delimber arms; Push LEFT side of L.H. Joystick switch, an electronic CAN signal is sent to the MD3 computer which then sends a CAN signal on to the XA2 expansion module. The signal is then sent to energize the DELIMBER OPEN/ HOLD SOLENOID valve on the pilot manifold and allow pilot oil to shift the valves in the DELIMBER OPEN DUMP VALVE and the THREE-WAY VALVE. At the same time, a signal is also sent to energize the DELIMBER OPEN SOLENOID on the main valve and allow internal pilot oil to shift the spool in the delimber spool section of the main valve and direct system oil to flow through the ROTARY MANIFOLD to the base end of the DELIMBER ARM CYLINDERS to open the arms.

When the LEFT side of the L.H. joystick switch is released the DELEIMBER OPEN solenoid on the main valve is de-energized, stopping the flow of oil (but the DELIMBER OPEN/HOLD solenoid on the pilot manifold remains energized or "latched" to hold the delimber arms open).

Close delimber arms; Push RIGHT side of L.H. Joystick switch, an electronic CAN signal is sent to the MD3 computer which then sends a CAN signal on to the XA2 expansion module. The XA2 module then de-energizes the DELIMBER OPEN/HOLD solenoid valve on the pilot manifold, removing pilot pressure from the DELIMBER OPEN DUMP VALVE. In this condition oil from the base end of the DELIMBER ARMS CYLINDER is returned to tank via the DELIMBER OPEN/DUMP VALVE, due to oil entering the rod end of the cylinders forced from the DELIMBER ACCUMULATOR to close the arms.

Pilot oil flows through the SAW CUT solenoid pilot valve to shift the spool in the SAW CUT valve to allow system oil to flow through the ROTARY MANIFOLD to the pilot operated three-way valve.

Because the delimber knives are closed there is no pressure to shift the three-way valve and the system oil flows to the TOP SAW MOTOR and the rod end of the TOP SAW CYLINDER to run the saw motor and cut with the saw bar.

Cut with slasher saw; Push LEFT side of L.H. Joystick switch, Push LEFT side of R.H. joystick switch, an electronic CAN signal is sent to the MD3 computer which then sends a CAN signal on to the XA2 expansion module. The signal is then sent to open delimber knives and to energize SLASHER CUT solenoid on SAW valve.

The SLASHER CUT solenoid allows pilot oil to shift the spool in the SLASHER CUT valve to allow system oil to flow through the ROTARY MANIFOLD to the pilot operated three-way valve. Because the delimber knives are open there is pressure to shift the three-way valve and the system oil flows to SLASHER SAW MOTOR and the rod end of the BAR CYLINDER to run the saw motor and cut with the saw bar.

Retract delimber top saw and/or slasher saw; Push RIGHT side of R.H. joystick switch, an electronic CAN signal is sent to the MD3 computer which then sends a CAN signal on to the XA2 expansion module. The signal is then sent to energize the TOP SAW/SLASHER SAW RETRACT solenoid on SAW valve.

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

18.7

Tigercat 234 Loader

Delimber/Slasher

DELIMBER/SLASHER CIRCUIT DESCRIPTION 2341051 TO 2342000

Cut with delimber top saw; Push RIGHT side of L.H. Joystick switch, Push LEFT side of R.H. joystick switch, an electrical signal is sent to the XS2 cab module which then sends a CAN signal on to the XA2 expansion module. The signal is then sent to energize the SAW SOLENOID on SAW valve.

REFER TO CIRCUIT DIAGRAMS The delimber/slasher circuit is supplied with hydraulic oil by an axial-piston, variabledisplacement pump. Two spool sections in the main control valve hydraulically control the delimber or slasher functions.

Two 3-position joystick switches, the MD3 computer module, the XS2 cab module and the XA2 expansion module electrically control the delimber and slasher functions via proportional electro hydraulic solenoid controls on the main control valves:Open delimber arms; Push LEFT side of L.H. Joystick switch, an electrical signal is sent to the XS2 cab module which then sends a CAN signal on to the XA2 expansion module. The signal is then sent to energize the DELIMBER OPEN/ HOLD SOLENOID valve on the pilot manifold and allow pilot oil to shift the valves in the DELIMBER OPEN DUMP VALVE and the THREE-WAY VALVE. At the same time, a signal is also sent to energize the DELIMBER OPEN SOLENOID on the main valve and allow internal pilot oil to shift the spool in the delimber spool section of the main valve and direct system oil to flow through the ROTARY MANIFOLD to the base end of the DELIMBER ARM CYLINDERS to open the arms.

When the LEFT side of the L.H. joystick switch is released the DELEIMBER OPEN solenoid on the main valve is de-energized, stopping the flow of oil (but the DELIMBER OPEN/HOLD solenoid on the pilot manifold remains energized or "latched" to hold the delimber arms open).

Close delimber arms; Push RIGHT side of L.H. Joystick switch, an electrical signal is sent to the XS2 cab module which then sends a CAN signal on to the XA2 expansion module. The XA2 module then de-energizes the DELIMBER OPEN/HOLD solenoid valve on the pilot manifold, removing pilot pressure from the DELIMBER OPEN DUMP VALVE. In this condition oil from the base end of the DELIMBER ARMS CYLINDER is returned to tank via the DELIMBER OPEN/DUMP VALVE, due to oil entering the rod end of the cylinders forced from the DELIMBER ACCUMULATOR to close the arms.

Pilot oil flows through the SAW CUT solenoid pilot valve to shift the spool in the SAW CUT valve to allow system oil to flow through the ROTARY MANIFOLD to the pilot operated three-way valve.

Because the delimber knives are closed there is no pressure to shift the three-way valve and the system oil flows to the TOP SAW MOTOR and the rod end of the TOP SAW CYLINDER to run the saw motor and cut with the saw bar.

Cut with slasher saw; Push LEFT side of L.H. Joystick switch, Push LEFT side of R.H. joystick switch, an electrical signal is sent to the XS2 cab module which then sends a signal on to the XA2 expansion module. The signal is then sent to open delimber knives and to energize SLASHER CUT solenoid on SAW valve.

The SLASHER CUT solenoid allows pilot oil to shift the spool in the SLASHER CUT valve to allow system oil to flow through the ROTARY MANIFOLD to the pilot operated three-way valve. Because the delimber knives are open there is pressure to shift the three-way valve and the system oil flows to SLASHER SAW MOTOR and the rod end of the BAR CYLINDER to run the saw motor and cut with the saw bar.

Retract delimber top saw and/or slasher saw; Push RIGHT side of R.H. joystick switch, an electrical signal is sent to the XS2 cab module which then sends a CAN signal on to the XA2 expansion module. The signal is then sent to energize the TOP SAW/SLASHER SAW RETRACT solenoid on SAW valve.

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

18.8

Tigercat 234 Loader

Delimber/Slasher

PILOT OPERATED 3-WAY VALVE

DELIMBER OPEN /DUMP VALVE

TO TOP SAW MOTOR AND BAR CYLINDER ROD END (OPEN) TO SLASHER MOTOR AND BAR CYLINDER ROD END (OPEN) TO DELIMBER ARMS CYLINDER BASE END (OPEN) TO TOP SAW BAR CYLINDER BASE END (RETRACT)

ROTARY MANIFOLD

LEGEND TO SLASHER SAW CYLINDER BASE END (RETRACT)

PRESSURE LINE PILOT LINE DRAIN LINE

RETURN LINE

RETURN LINE

MAIN PUMP

MAIN VALVE

TO OIL COOLER

TO TANK

INTAKE FROM HYDRAULIC TANK

PILOT FILTER

PILOT MANIFOLD RETURN FILTERS TO TANK

234-230

DELIMBER/SLASHER HYDRAULIC CIRCUIT 18.9

Tigercat 234 Loader

234-169

Delimber/Slasher

DELIMBER/SLASHER HYDRAULIC SCHEMATIC 18.10

Tigercat 234 Loader

234-168

Delimber/Slasher

DELIMBER/SLASHER CIRCUIT

18.11

Tigercat 234 Loader

Delimber/Slasher

MD3 DISPLAY

JOYSTICKS

XA2 EXPANSION MODULE

LEGEND CAN WIRE WIRE

172-GR 179A-RD 163-GR 179-RD 160-GR

MAIN VALVE

DELIMBER OPEN/HOLD SOLENOID

184-GR

SAW CUT RETRACT SECTION

234-231

DELIMBER OPEN SECTION

DELIMBER/SLASHER ELECTRICAL CIRCUIT 2340601 TO 2341050 18.12

PILOT MANIFOLD

Tigercat 234 Loader

Delimber/Slasher

JOYSTICKS

MD3 DISPLAY XS2 CAB MODULE

FOR DETAILS OF JOYSTICK INPUTS SEE NEXT 2 PAGES

XA2 EXPANSION MODULE

LEGEND CAN WIRE WIRE

172-GR 179A-RD 163-GR 179-RD 160-GR

MAIN VALVE

DELIMBER OPEN/HOLD SOLENOID

184-GR

SAW CUT RETRACT SECTION

234-232

DELIMBER OPEN SECTION PILOT MANIFOLD

DELIMBER/SLASHER ELECTRICAL CIRCUIT 2341051 TO 2342000 18.13

Tigercat 234 Loader

234-216

Delimber/Slasher

JOYSTICK ELECTRICAL CIRCUIT 2341051 TO 2341100 18.14

Tigercat 234 Loader

234-218

Delimber/Slasher

JOYSTICK ELECTRICAL CIRCUIT 2341101 TO 2342000 18.15

Tigercat 234 Loader

Delimber/Slasher

MACHINE MODE The machine mode menu enables the machine to be set up quickly to operate under different conditions or with different operators without having to go through various menus to make multiple adjustments to parameters.

The machine modes are M0, M1, M2 and M3. M0 is the least aggressive mode and is intended for training while M3 is the most aggressive mode.

These modes can be personalized through the various adjustment menus described in THIS SECTION. Many of the adjustments will display the active mode, which means that when adjustments are made in these menus where the active mode is displayed then only that mode will be affected by the changes.

Note: When making electronic adjustments it is important to be aware of the active mode so that any changes are applied to the intended machine mode.

The machine mode can be set by using the MD3 display or through the laptop. See MACHINE MODE ADJUSTMENT SELECTION in SECTION 2 of THIS MANUAL to set the machine mode using the MD3.

MACHINE MODE ADJUSTMENT

234-174

From the Adjust menu double click on Machine Mode

18.16

Tigercat 234 Loader

Delimber/Slasher

In the Machine Mode menu double click on Mode Select

Click on the mode required and click on Done.

18.17

Tigercat 234 Loader

Delimber/Slasher

ELECTRONIC ADJUSTMENT PROCEDURE After logging into the system as "Service" the following adjustments can be made.

234-271

Click on the Adjust Menu to access the Adjust groups.

Double click on Delimber Delays to access the Delimber functions.

DELIMBER OPEN DELAY ADJUSTMENT

234-272

Double click on Delimber Open Delay to access the delay adjustment.

18.18

Tigercat 234 Loader

Delimber/Slasher

234-273

This setting will determine how much of a delay is applied to open the delimber arms when this function is selected. Increasing this setting will result in a longer delay.

Using the up or down arrows to adjust the setting and then click on Done.

DELIMBER CLOSE DELAY ADJUSTMENT

234-274

Double click on Delimber Close Delay to access the delay adjustment.

18.19

Tigercat 234 Loader

Delimber/Slasher

234-275

This setting will determine how much of a delay is applied to close the delimber arms when this function is selected. Increasing this setting will result in a longer delay.

Using the up or down arrows to adjust the setting and then click on Done.

The Delimber Delay adjustments are now complete.

18.20

Tigercat 234 Loader

Delimber/Slasher

PRESSURE SETTINGS

Because the delimber/saw valves are controlled electronically by the proportional valves on the main manifold it is important to first check that the maximum current to fully activate each of the valves is applied before attempting any hydraulic testing. The max current can be checked through the MD3 screen.

CHECKING MAX CURRENT

234-230

Using the up or down arrow buttons scroll to Saw/ Delimber and press OK.

234-109

Press the menu button MENU.

to go to the MAIN

234-231

Using the up or down arrow buttons scroll to the Gr.Saw/Str Right selection. Lower the armrest and press PILOT RESET switch to activate pilot system and activate and hold the R.H. joystick switch in the Saw Extend position and ensure that the reading is 'True'.

Release joystick switch.

234-114

Press F2 to access the Measure menu.

18.21

Tigercat 234 Loader

Delimber/Slasher

234-233

Using the up or down arrow buttons scroll to the Saw Coil selection. Activate and hold the R.H. joystick switch in the Saw Retract position and ensure that the reading is -600mA (+ or - 30mA).

Release joystick switch.

234-232

Using the up or down arrow buttons scroll to the Delimber Open selection. Activate and hold the L.H. joystick switch in the Delimber Open position and ensure that the reading is 'True'.

Release the joystick button. If the above readings are OK, turn the pilot off and proceed to the hydraulic tests.

18.22

Tigercat 234 Loader

Delimber/Slasher

PRESSURE SETTINGS FOR TOP SAW CUT, SLASHER CUT AND DELIMBER 'PX' TEST PORT

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

'PL' TEST PORT

CAUTION Be aware of other personnel in the area.

Operator is responsible for the safe operation of the machine.

234E-191

234-131

WARNING

MAIN VALVE TEST PORTS SAW CUT RETRACT SECTION

DELIMBER OPEN SECTION

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

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

RELIEF VALVE SETTING - SAW CUT Main Pump 'POR' setting ......................3800 psi

SAW CUT REDUCER

SAW CUT/RETRACT FEED REDUCERS

Saw cut feed reducer setting ...............2500 psi

5. While holding the R.H. joystick switch in the SAW EXTEND position, check gauge pressure reading at "PL" connection.

1. Position machine on level ground.

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

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

4. Start the engine, and set the throttle control to the IDLE position. Lower left arm rest and depress the pilot reset switch to activate the pilot system.

SAW RETRACT REDUCER

6. If Less than set value adjust feed reducer. Turn adjusting screw in to increase pressure or turn screw out to decrease pressure.

7. Stop engine, remove pressure gauges and wipe up any excess oil from test port area.

18.23

Tigercat 234 Loader

Delimber/Slasher

RELIEF VALVE SETTING SAW RETRACT Main Pump 'POR' setting ......................3800 psi

234-131

SAW CUT RETRACT SECTION

DELIMBER OPEN SECTION

Saw retract feed reducer setting ..........2500 psi 1. Position machine on level ground.

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

'PX' TEST PORT

'PL' TEST PORT

DELIMBER OPEN REDUCER

GRAPPLE SAW REDUCER

SAW CUT/RETRACT FEED REDUCERS RELIEF VALVE SETTINGS - DELIMBER ARMS Main Pump 'POR' setting ......................3800 psi Delimber open feed reducer setting:-...2500 psi 234E-191

Grapple Saw feed reducer setting:-.....3000 psi

MAIN VALVE TEST PORTS

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

4. Start the engine, and set the throttle control to the IDLE position. Lower left arm rest and depress the pilot reset switch to activate the pilot system.

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

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

4. Start the engine, and set the throttle control to the IDLE position. Lower left arm rest and depress the pilot reset switch to activate the pilot system.

5. While holding the R.H. joystick switch in the SAW RETRACT position, check gauge pressure reading at "PL" test connection.

6. If Less than set value adjust feed reducer. Turn adjusting screw in to increase pressure or turn screw out to decrease pressure.

7. Stop engine, remove pressure gauges and wipe up any excess oil from test port area.

1. Position machine on level ground.

5. While holding the L.H. joystick switch in the DELIMBER OPEN position, check gauge pressure reading at "PL" test connection.

6. If Less than set value adjust feed reducer. Turn adjusting screw in to increase pressure or turn screw out to decrease pressure.

7. Stop engine, remove pressure gauges and wipe up any excess oil from test port area.

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

18.24