Tigercat 235B 245B Loader OPERATOR'S MANUAL - PDF DOWNLOAD

OPERATOR'S MANUAL Tigercat 235B/245B Loader TABLE OF CONTENTS

ISSUE 1.2, MARCH 2003

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

235B-OM00

230B/240B Available Literature Operator's Manual ............................... Part No. 13050A Service Manual .................................... Part No. 13051A Parts Catalog ....................................... Part No. 13048A Hydraulic Adapters Book ....................... Part No. 1472A Hydraulic Hose assemblies Book ......... Part No. 3707A

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

®

ii

Tigercat 235B/245B Loader

INTRODUCTION An Operator's manual, Service manual and a Parts catalog are provided by Tigercat to assist the dealer, customer and operator in becoming familiar with the features of the Tigercat 235B and 245B Loaders.

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

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

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

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

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

Tigercat Industries Inc.

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Tigercat 235B/245B Loader

Introduction

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

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

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

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

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

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

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

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

Tigercat Industries Inc.

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Tigercat 235B/245B Loader

SECTION 1 - SAFETY MARCH 2003

Read and understand this Safety section prior to operating any equipment.

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

Tigercat 235B/245B Loader

Safety

SAFETY SYMBOLS

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

Understanding Signal Words

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

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

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

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

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Tigercat 235B/245B Loader

Safety 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.

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

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

KEEP CLEAR When approaching an operating machine on foot, stay at least 500 feet (150M) away from the machine and all related attachments including the grapple, delimber, topping saw and ground saws until the operator recognizes your presence.

Make sure that all equipment is shut down with grapple resting securely on stable ground before advancing to the machine.

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

Follow all instructions from safety inspector and supervisors.

Always avoid the discharge path of all saws.

Operators of this equipment must be fully trained by a qualified person in safety and operating procedures. The operator must be fully aware of the capabilities and limitations of the equipment and must at no time exceed them. The machine is to be used only for its intended purpose. Learn the most efficient operating techniques.

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

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

Do not let an untrained person operate the machine.

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

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

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

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

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

Tigercat 235B/245B Loader

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

GENERAL SAFETY PRECAUTIONS continued

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

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

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

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

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

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

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

Machine should be washed completely at every major service.

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

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

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

WARNING

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

Do not operate the equipment with anyone in the cab, on platforms, or anywhere else within 500 feet the machine or related equipment. The machine is provided and approved with seating for the operator only.

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

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

WARNING Battery posts, terminals and related accessories contain lead and lead compounds.

Wash hands after handling.

Inspect the machine daily for signs of damage, unusual wear, fluid leaks, or faulty operation.

Repair or replace malfunctioning parts and systems immediately.

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

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

1.4

Tigercat 235B/245B Loader

Safety

OPERATING SAFETY PRECAUTIONS

Start the engine according to the instructions in this manual.

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

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

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

Ensure that the windshield guard is installed and properly secured.

During refuelling do not leave the filler nozzle unattended.

Avoid over filling and immediately clean up spilled fuel.

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

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

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

Make sure that all of the controls are positioned as specified in the pre-start checks instructions in the operator's manual.

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

Sound the machine horn before starting the machine.

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

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

Use only prearranged and approved signalling practices.

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

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Tigercat 235B/245B Loader

Safety

OPERATING SAFETY PRECAUTIONS continued

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

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

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

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

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

Before leaving the operator's cab, stop the circle saw if equipped.

DANGER

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

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

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

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

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

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

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

Serious injury or death or property damage may result.

Before transporting the machine: •

Secure the grapple to the trailer and raise the stabilizers.

•

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

•

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

WARNING Do not not operate slasher circle saw with personnel in the cutting area. Serious injury or death may result.

CAUTION Do not not drop log loads onto slasher circle saw as serious injury or equipment damage may result.

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Tigercat 235B/245B Loader

Safety

SERVICING SAFETY PRECAUTIONS

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

Conduct maintenance inspections at least as frequently as recommended in SECTION 3 of the OPERATOR'S MANUAL. When servicing or repairing equipment, shut the engine down. Turn Master Disconnect switch OFF. Install a “DO NOT START ENGINE” sign on the operator’s cab door when making repairs to the machine.

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.

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

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

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

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

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

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

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

Also, the battery negative terminal must be disconnected.

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

1.7

Tigercat 235B/245B Loader

Safety

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

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

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

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

VERTICAL CENTERLINE

LOWER FRAME

Always be aware of machine pinch points that could cause injury. Never place body parts within the range of motion of the working parts of the machine.

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

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

•

COUNTERBALANCE VALVE

•

STABILIZER UP IN VERTICAL POSITION

• • •

CYLINDER

STABILIZER COUNTERBALANCE/CHECK VALVE CARTRIDGE REMOVAL

230-06A

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

WARNING

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

Work in a ventilated area. If it is necessary to run an engine in an enclosed area, use an exhaust pipe extension to remove toxic exhaust fumes.

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

Plug or cap hydraulic hose end and connections after disconnecting slasher or other remote controlled equipment when installed.

BEFORE PERFORMING ANY SERVICE WORK ON AIR BRAKES: • Block wheels to prevent vehicle from rolling.

• Wear eye protection to prevent eye injury.

• Test vehicle for air leaks • Drain all reservoirs and supply lines to 0 psi.

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Tigercat 235B/245B Loader

Safety

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

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

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

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Tigercat 235B/245B Loader

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

FIRE PREVENTION

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

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.

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

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

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.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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Tigercat 235B/245B Loader

Safety WHAT TO DO IN CASE OF A MACHINE FIRE

FIRE PREVENTION continued

•

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

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.

•

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

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

•

Shut the engine off.

•

Activate the fire suppression system*

•

Radio or call for help (as appropriate).

•

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

•

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

•

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

EQUIPMENT FIRES ADVERSELY EFFECT YOUR ABILITY TO LOG, MAY INCREASE YOUR INSURANCE PREMIUMS DRAMATICALLY OR PREVENT YOU FROM OBTAINING INSURANCE COVERAGE AT ALL. WHAT ELSE TO DO BEFORE YOU EXPERIENCE A FIRE •

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

•

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

•

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

•

Use the PASS method with most extinguishers.

•

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

•

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

•

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

•

•

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

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

•

•

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

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

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

•

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

•

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

Continued on page 12

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

1.11

Tigercat 235B/245B Loader

Safety WHAT TO DO AFTER A FIRE

FIRE PREVENTION continued Continued from page 11

20229A

TYPICAL FIRE EXTINGUISHER ACCESS HOLE

•

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

•

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

•

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

•

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

1.12

•

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

•

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

•

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

•

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

Tigercat 235B/245B Loader

SECTION 2 - CONTROLS & OPERATION APRIL 2001

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

CONTENTS - SECTION 2 AIR BRAKE SYSTEM, SELF PROPELLED .. 2.23 AIR CLEANER .............................................. 2.20 AIR CONDITIONER/HEATER ......................... 2.7 BATTERY DISCONNECT SWITCH .............. 2.14 BREATHER, HYDRAULIC RESERVOIR ....... 2.18 CAB CONTROLS ............................................ 2.2 CARE OF THE MACHINE ............................. 2.33 CIRCLE SAW/DRIVE MODE SWITCH ........... 2.4 CLEANING LEXAN WINDOWS .................... 2.33 CONTROLS, CAB ........................................... 2.2 DRIVE MODE/CIRCLE SAW SWITCH ........... 2.4 ENGINE BLOCK /OIL PAN HEATERS (OPT) 2.15 ENGINE COMPARTMENT ............................ 2.14 ENGINE COMPARTMENT ACCESS ............ 2.14 ENGINE COOLANT TEMPERATURE ............. 2.9 ENGINE, HOT WATER SHUT OFF VALVE ..... 2.7 ENGINE OIL PRESSURE ............................... 2.9 ENGINE OIL PRESSURE LOW ...................... 2.9 ENGINE, STARTING ..................................... 2.27 ENGINE, STOPPING .................................... 2.30 FAN, CAB ...................................................... 2.10 FILTER, HYDRAULIC OIL, PILOT ................. 2.19 FILTERS, A/C AND HEATER .......................... 2.8 FILTERS, HYDRAULIC OIL , RETURN ......... 2.18 FIRE EXTINGUISHER .................................. 2.10 FOOT PEDAL - SWING .................................. 2.3 FOOT PEDAL, BRAKE, SELF PROPELLED .. 2.3 FUEL HEATER ................................................ 2.5 FUEL LINE WATER SEPARATOR. ................ 2.27 FUEL TANK AND FILLER ............................. 2.22 FUSE AND RELAY PANEL ........................... 2.10 HAND FILL PUMP, HYDRAULIC OIL ............ 2.17 HEATER/AIR CONDITIONER ......................... 2.7 HORN .............................................................. 2.4 HOT WATER SHUT OFF VALVE (ENGINE) .... 2.7 HOUR METER ................................................ 2.9 HYDRAULIC OIL RESERVOIR ..................... 2.15 HYDRAULIC OIL TEMPERATURE ................. 2.9 HYDRAULIC RESERVOIR BREATHER ........ 2.18 IGNITION SWITCH ......................................... 2.6

JOYSTICK CONTROL, R.H. 2ND. FOR S.P. ... 2.3 JOYSTICK, L.H. .............................................. 2.2 JOYSTICK R.H. ............................................... 2.2 KEY SWITCH .................................................. 2.6 LIGHT - DOME .............................................. 2.10 LIGHTER ......................................................... 2.5 LIGHTS, SERVICE .......................................... 2.6 LIGHTS, WORK .............................................. 2.6 LOADER MOUNTING/INSTALLATION ......... 2.31 LOW COOLANT .............................................. 2.8 LOW ENGINE OIL PRESSURE ...................... 2.9 LOW HYDRAULIC OIL LEVEL ........................ 2.9 MACHINE OPERATION PRE-START CHECKS ............................... 2.25 PREPARATION .......................................... 2.29 RESTARTING AN ENGINE THAT HAS RUN OUT OF FUEL ....................................... 2.28 STARTING THE ENGINE ........................... 2.27 STOPPING THE ENGINE .......................... 2.30 PARKING BRAKE, SELF PROPELLED .......... 2.3 PILOT RESET ................................................. 2.5 PILOT SUPPLY SHUT OFF VALVE ............... 2.15 PILOT SYSTEM SHUT OFF ........................... 2.5 PRESSURE GAUGE, PNEUMATIC, SELF PROPELLED ................................................... 2.3 PUMP SUCTION SHUT-OFF VALVE ............ 2.16 RADIO, 2-WAY .............................................. 2.10 RELAY BOX, SLASHER/DELIMBER ............. 2.11 SAW SWITCH, AUTO RETRACT .................... 2.4 SEAT ............................................................. 2.12 SERVICE LIGHTS ........................................... 2.6 SETTING THE MACHINE ............................. 2.28 STABILIZER OPERATION .............................. 2.4 STOPPING THE ENGINE ............................. 2.30 SWING ............................................................ 2.3 TAPE DECK .................................................. 2.10 THROTTLE CONTROL ................................... 2.6 TRANSPORTING THE LOADER .................. 2.32 VOLTMETER ................................................... 2.9 WASHER ........................................................ 2.4 WATER DRAIN VALVE, SELF PROPELLED ... 2.3 WINDOWS .................................................... 2.12 WIPER ............................................................ 2.4 WORK LIGHTS ............................................... 2.6

Tigercat 235B/245B Loader

Controls and operation IMPORTANT

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

CAB CONTROLS NOTE 1: Some loaders may not be configured with all controls shown in this manual.

NOTE 2: All joystick and Foot Pedal controls require pilot pressure. Refer to PILOT RESET in THIS SECTION. a 1

•• • •• • •• ••

b

a

• • ••

• c d

f

e

••

•• d

2A

384-8

1.

b c

••

2

••

e

384-9

LEFT HAND JOYSTICK LEVER Hoist Boom

2.

RIGHT HAND JOYSTICK LEVER

Push the joystick lever forward to lower the hoist boom.

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

Pull the joystick lever back to raise the hoist boom.

Pull the joystick lever back to move the stick boom out.

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

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

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

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

LEFT HAND JOYSTICK SWITCHES for machines equipped with circle saw slasher, delimber, self propelled and live heel.

RIGHT HAND JOYSTICK SWITCHES* for machines equipped with circle saw slasher, delimber, self propelled and live heel.

a. Push this push button switch to raise the butt board.

*The right joystick push button switches (a) & (b) perform two separate functions depending on the status of the delimber arms.

b. Push this push button switch to lower the butt board.

With the delimber arms Open:

c. Push this push button switch to retract the live heel (when applicable).

a. Push this push button switch to cut with slasher circle saw.

d. Upper trigger button, Press this push button switch in to open delimber arms.

b. Push this push button switch to retract slasher circle saw. If AUTO SAW RETRACT SWITCH is ON the saw will retract automatically.

e. Lower trigger button, No function.

2.2

Tigercat 235B/245B Loader

Controls and operation

OR With the delimber arms Closed:

4.

FOOT PEDAL - BRAKE, pneumatic Used with air brake option.

Use this brake pedal when travelling to apply brakes and stop machine.

a. Push this push button switch to extend (cut) top saw. b. Push this push button switch to retract top saw.

5A

5

c. Push this push button switch to extend the live heel. (optional)

••

d. Upper trigger button, Press this push button switch in to close delimber arms.

••

e. Lower trigger button, No function.

2A 2ND RIGHT HAND JOYSTICK CONTROL Used with self propel option.

The pilot system must be activated with the pilot reset button pressed and the CIRCLE SAW/DRIVE MODE switch in the drive mode position.

Drive (propel) Push the joystick lever forward to drive vehicle forward.

5.

Pull the joystick lever back to drive vehicle back.

Steer Move the joystick lever to the left to steer vehicle left.

PARKING BRAKE, pneumatic Used with air brake option.

Pull up on knob to apply parking brake and push down to release. DO NOT use to stop machine when travelling.

5A PRESSURE GAUGE, pneumatic A pressure gauge situated beside the parking brake control knob registers the pneumatic air pressure in the air tank. It should show a normal reading of 120 psi. A relief valve on the tank is set at 150 psi.

Move the joystick lever to the right to steer vehicle right.

2ND RIGHT HAND JOYSTICK SWITCH f. Use this rocker switch when travelling to apply brakes, hydraulic braking system only.

AIR COMPRESSOR

4

3 SWING LEFT

SWING RIGHT

••

PARKING BRAKE

384-10

•

•• •• 6

384-11

SWING AND AIR BRAKE FOOT PEDALS 3.

FOOT PEDAL - SWING

235B-12A

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

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

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

2.3

6.

WATER DRAIN VALVE RELEASE CABLE WATER DRAIN VALVE Used with air brake option.

Pull this release cable periodically to open water drain valve on supply tank of air system and drain any water accumulation from tank.

Tigercat 235B/245B Loader 28

7

7A

Controls and operation 7B

8

7C

••

• ••

7D

• ••

•

••

13

14

12

17

••

••

••

••

15

16

••

•

CONTROL PANEL

384-12

7-8. STABILIZER OPERATION The 4 stabilizers are controlled using the buttons located on the instrument panel to the right of the seat.

• First select a direction (up or down) using the Stabilizer Direction selector switch (7).

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.

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

Also see SETTING THE MACHINE in THIS SECTION

circuit.The pilot system must be activated and the pilot reset button pressed to supply power to this switch.

WARNING Ensure that all personnel are clear of the slasher circle saw before turning the saw ON CIRCLE SAW - Place the switch in this position to run the circle saw. Place throttle at HIGH before turning the slasher circle saw on.

DRIVE MODE - Placing the switch in this position will enable the drive and steering controls joystick lever (2A).

BLANK, CENTER POSITION - Slasher circle saw and self propelled drive mode are turned off.

15. WASHER ~ SWITCH This is a two position switch with spring return to OFF. The front window wiper includes a nozzle for spraying washer fluid onto the window. To operate, press and hold the WASHER switch and turn on the WIPER switch. Release the WASHER switch and turn off the WIPER switch when the window is sufficiently clean.

12. HORN ~ SWITCH Depressing the Horn rocker switch (10) will sound the horn.

13. AUTO SAW RETRACT ~ SWITCH This is a two position switch.

In the forward position the slasher circle saw will automatically retract after the saw cut has been made.

In the back position the slasher circle saw must be retracted manually by using the push button switch on the RIGHT HAND JOYSTICK LEVER.

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

16. WIPER ~ SWITCH This is a three position switch to provide TWO wiper speeds and OFF. OFF, Switch in back position.

NORMAL SPEED, switch in middle position.

14. CIRCLE SAW/DRIVE MODE ~ SWITCH This is a three position switch labelled CIRCLE SAW -BLANK - DRIVE MODE. Power to this switch is via the pilot system shut-off 2.4

FAST SPEED, switch in forward position.

Do Not use WIPER on a dry window, this may result in scratching.

Tigercat 235B/245B Loader

Controls and operation 23

19

20

22

••

ARMREST

••

24

•

•• ••

•

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

21

••

18 LIMIT SWITCH ACTUATING LEVER ON SEAT BASE

384-14 CONTROL PANEL 20. FUEL HEATER ~ SWITCH WITH LIGHT Optional

•

•

IMPORTANT Do not turn fuel heater on more than 2 minutes prior to starting the engine

PILOT SYSTEM SHUT OFF

247-25

17. PILOT RESET ~ SWITCH

This is a two position switch with an integral green warning light.

This function is provided to prevent accidental or improper use of the controls from anywhere but the operators seat.

Placing this switch in the ON position turns on the fuel heater element located on the fuel filter/ water separator. The light in the switch will be ON.

This is a two position switch with spring return.

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

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

When the L.H. arm rest is placed in the DOWN position, the limit switch closes and turns ON the pilot system. But the operating functions are not REACTIVATED until the PILOT RESET switch (item 17) is pressed.

• HEATING ELEMENT

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

••

WATER SEPARATOR BOWL

385-7

FUEL HEATER/FILTER/WATER SEPARATOR The heater is a Positive Temperature Coefficient (PTC) fuel heater to prevent fuel waxing.

2.5

Tigercat 235B/245B Loader 23

19

20

22

••

21

•• ••

•

Controls and operation 24. THROTTLE CONTROL

24

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

•

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

•• 384-14

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

CONTROL PANEL

21. SERVICE LIGHTS ~ SWITCH WITH LIGHT

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

This is a two position switch with an integral green warning light.

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

The light in the switch will be ON when the lights are ON.

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

Low Idle - 950 rpm (No Load)

22. WORK LIGHTS ~ SWITCH WITH LIGHT

High Idle - 2400 rpm Max (No Load)

This is a two position switch with an integral green warning light.

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

This switch controls the work lights located on the front of the cab and on the stick boom. The circuit draws current directly from the battery and is protected by a fuse located in the fuse box. The light in the switch will be ON when the lights are ON.

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

23. KEY SWITCH This is a three position switch labelled OFF/ RUN/START. OFF Position - All electrical power through the Key switch is turned OFF. Electrical power is still available for the horn, lighter, tape deck, 2 way radio, cab dome light, defroster fan, work lights and service light.

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

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

The key will return to RUN position when released.

2.6

Tigercat 235B/245B Loader C

B

••

A

Controls and operation

E

D

•

•• •

SHUT-OFF 26 VALVE ENGINE

HOSE TO A/C HEATER UNIT

• •

•

•

• 356-15

HOT WATER SHUT OFF VALVE - CUMMINS 'B' ENGINE

A/C HEATER CONTROL PANEL 209-7

25. AIR CONDITIONER/HEATER

SHUT-OFF 26 VALVE

ENGINE

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

••

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

HOSE TO A/C HEATER UNIT

• •

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

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

386-12

HOT WATER SHUT OFF VALVE - CUMMINS'C' ENGINE

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

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

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

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

2.7

Tigercat 235B/245B Loader

Controls and operation 28

••

384-18 CONTROL PANEL 28. LOW COOLANT - INDICATOR LIGHT

This light comes ON when the engine coolant drops below a safe operating level. If this light turns on, immediately turn off the engine and correct the fault. The engine coolant sensor is located in the side of the radiator surge tank. The coolant surge tank (reservoir) can be filled through the access panel located on top of the engine

•

RECIRCULATION AIR FILTER

A/C HEATER UNIT

68-7C

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

FILTER

••

FILLER CAP

EXTERNAL AIR FILTER ACCESS PANEL

••

••

248-25

compartment. Ensure that the engine has cooled down sufficiently before removing radiator cap. Prior to removing cap, relieve pressure in radiator by loosening cap slowly to first stop. Use the proper solution of coolant antifreeze when filling the surge tank.

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

CHECK ENGINE COOLANT LEVEL

EXTERNAL AIR FILTER

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

2.8

Tigercat 235B/245B Loader 32

34

33

••

37

35

36

38

•

•• ••

Controls and operation 39

•

••

•

•

247-16

ENGINE OIL PRESS. & COOLANT TEMP. GAUGES 32. LOW HYDRAULIC OIL LEVEL ~ RED LIGHT This light will come on when the hydraulic oil level falls 13 gallons from the full mark. When this light first comes on stop engine and determine cause. Repair leaks and refill the tank to FULL mark on the sight gauge. Restart engine and inspect for leaks.

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

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

Check engine oil pressure every time the engine is started.

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

247-14

GAUGES AND HOUR METER

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

37.

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

If the hydraulic oil temperature rises beyond 180°F, check the following: • Plugged oil cooler • Low hydraulic oil level • Malfunction in a hydraulic circuit • High loads on the hydraulic system

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

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

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

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

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

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

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

39. HOUR METER

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

2.9

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

Tigercat 235B/245B Loader

Controls and operation 41

43

44

42

•

••

•

•

206-13A

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

279-15A

42. LIGHT - DOME Push the switch on the side of the dome to turn the light ON and OFF. 43. TAPE DECK/RADIO Consult the operators manual for the tape deck with two front mounted speakers.

44. 2 WAY RADIO Refer to component manufacturers manual.

11182A

FUSE AND RELAY PANEL 45

40. FUSE AND RELAY PANEL The fuse panel is located below the control panel behind a removable cover.

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

•

247-23

PORTABLE FIRE EXTINGUISHER

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

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

2.10

Tigercat 235B/245B Loader

Controls and operation

•• C = DELAY ON OPERATE 050 = TIME IN SECONDS .1S = 1/10 SECONDS

235B-P02 235B-P01

RELAY BOX

The time delay relay is in the SLASHER SAW AUTO RETRACT circuit. It is turned on or off by a switch on the control panel labelled AUTO SAW RETRACT. When this switch is in the ON position the time delay relay is ready. The relay is triggered by the SAW CUT switch located on the R.H. JOYSTICK LEVER, which when released, causes the time delay relay to energize the SLASHER RETRACT solenoid valve to retract the slasher circle saw. After a preset time period of approximately 5 seconds, the SLASHER RETRACT solenoid valve is deenergized and the relay automatically is reset in readiness for the next cycle.

RELAY BOX

46. RELAY BOX Located under the floor plates in front of the cab door, this relay box contains five standard relays and one time delay relay.

These relays and one located on the cab FUSE AND RELAY PANEL control the slasher circle saw and delimber functions.

2.11

Tigercat 235B/245B Loader

Controls and operation 48

47

••

205-9A

SLIDING WINDOWS HANDLE R.H. WINDOW AND CAB WINDOW

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

206-11A1

SEAT

48. OPERATOR’S SEAT (SEATS INC.)

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

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

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

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

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

2.12

Tigercat 235B/245B Loader

Controls and operation 4-WAY LUMBAR HORIZONTAL ADJUSTMENT

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

•

••

• •

RIDE ADJUSTMENT KNOB

•

• ••

332-6

RIGHT SIDE OF SEAT

ARMREST ADJUSTMENT

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

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

• • FORE/AFT SLIDE LEVER 332-1X

•

SEAT ADJUSTMENTS

BACK ANGLE ADJUSTMENT KNOB HEIGHT ADJUSTMENT LEVER

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

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

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

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

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

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

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

2.13

Tigercat 235B/245B Loader

Controls and operation

ENGINE COMPARTMENT ENGINE COMPARTMENT ACCESS There are 3 hinged doors and one removable panel provided to allow access to the engine compartment from all four sides.

The doors are secured by a retaining knob on each door, unscrew this knob to release the door. The access panel is removed by lifting the latches outwards, tuning them 90° and then lifting the panel up and out.

SHOWING ADDITIONAL RETURN FILTERS FOR SLASHER CIRCLE SAW OPTION

ENGINE COMPARTMENT ACCESS REAR

385-25

ENGINE COMPARTMENT ACCESS FRONT

385-6

BATTERY DISCONNECT SWITCH

• 385-18

ENGINE COMPARTMENT ACCESS LEFT SIDE RADIATOR

HINGE OUT A/C CONDENSER

••

205-16A

BATTERY DISCONNECT SWITCH

••

OIL COOLER

206-6A

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.).

••

ENGINE COMPARTMENT ACCESS RIGHT SIDE

2.14

Tigercat 235B/245B Loader

Controls and operation

SIGHT GAUGE

ENGINE BLOCK

• ••

ENGINE OIL PAN

•• 386-24

ENGINE BLOCK AND OIL PAN HEATERS

LOW LEVEL SENDING UNIT

ENGINE BLOCK AND OIL PAN HEATERS (OPTIONAL) An engine block heater and an engine oil pan heater are connected to two 120 volt male receptacles.

•• 248-16X

HYDRAULIC OIL SIGHT GAUGE/SENDER

HYDRAULIC OIL FILTERS

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

••

HYDRAULIC OIL SIGHT GAUGE/ SENDER

•

A sight gauge on the front of the reservoir is visible from the left hand access door. The hydraulic oil level must be kept between the HIGH and LOW limits at all times.

Incorporated into the level indicator is a low level switch, when the hydraulic oil reaches this level the switch turns a warning light ON in the operator's cab.

•• ••

RESERVOIR

••

HYDRAULIC PUMPS

•• PILOT PUMP SUCTION LINE SHUT-OFF VALVE

••

•

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 fitting and hydraulic components for leaks. Once the source of the oil loss is located and repaired, oil can be added to the reservoir.

• ••

PILOT SUPPLY SHUT OFF VALVE

SENDER HYD. OIL TEMP.

A ball valve is incorporated into the suction line between the pilot pump inlet and the hydraulic reservoir. This is used to isolate the hydraulic oil in the reservoir when servicing the pilot pump.

• • • HYDRAULIC OIL RESERVOIR

SUCTION TUBES

385-16B

2.15

Tigercat 235B/245B Loader

Controls and operation

••

•

HYDRAULIC RESERVOIR SHUT-OFF VALVE

HYDRAULIC RESERVOIR

PUMP SUCTION TUBES

••

SHUT-OFF VALVE

•

•• •

••

• 373-15A

SHUT-OFF VALVE

••

••

PUMP SUCTION SHUT-OFF VALVE

PILOT FILTER

LIMIT SWITCH

SHUT-OFF VALVE LEVER IN OPEN POSITION

•

PUMP SUCTION HEADER

PUMP SUCTION SHUT-OFF VALVE (VIEWED FROM BELOW)

373-11A

LEVER, SHUT OFF VALVE

• ••

••

•• LIMIT SWITCH LIMIT SWITCH

367-1

373-10A

PUMP SUCTION SHUT-OFF VALVE

PUMP SUCTION SHUT-OFF VALVE One suction header is used to supply all three pumps with hydraulic oil. A shut-off valve is installed between the header and the hydraulic tank to isolate the hydraulic oil in the tank when servicing the pumps. The shut-off valve is operated by a lever on the side of the valve housing. The lever is held in either the CLOSED or OPEN position by a spring loaded locking pin. Pull down on the pin to operate the lever. When the lever is moved to the CLOSED position a limit switch, mounted below the lever is "tripped" disconnecting the power supply to the engine start circuit. This prevents the engine from being started when the hydraulic supply is shut off.

2.16

Tigercat 235B/245B Loader

Controls and operation

AIR VENT

• TOP RIGHT SIDE OF RESERVOIR

OIL FILL SHUT-OFF VALVE

358-24

AIR BREATHER VENT, HYDRAULIC RESERVOIR

HYDRAULIC RESERVOIR BREATHER HAND FILL PUMP

••

SUCTION HOSE IN STORED POSITION

The Hydraulic Reservoir Breather prevents pressure build up in the Hydraulic Reservoir.

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

••

• 385-12

HYDRAULIC HAND FILL PUMP

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

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

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

Operate the pump by moving the handle back and forth at medium speed and a steady motion. The oil passes through the filters on the return lines of the hydraulic system. When the sight gauge reads between LOW and HIGH cease pumping and return handle to upright position. Close the oil fill shut off valve.

2.17

Tigercat 235B/245B Loader

Controls and operation

HYDRAULIC RETURN FILTERS

FILTER RESTRICTION INDICATOR

Three double filter heads (four 7 micron elements) filter all returning hydraulic oil except pilot, prior to entering the hydraulic

•• RETURN MANIFOLD

•• TO HYDRAULIC TANK

CHECK VALVE

386-2

reservoir. 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 two return manifolds. Two filter restriction indicators and one oil sampling connector are mounted onto the manifolds.

OIL SAMPLING CONNECTOR

FILTER RESTRICTION INDICATOR

•

••

•

•

CHECK VALVES

FROM HAND FILL PUMP OIL COOLER BYPASS CHECK VALVE (50 PSI)

••

•• ••

TO OIL COOLER "IN"

•

CHECK VALVE

•• FROM SWING VALVE

362-15

FROM STICK VALVE

HYDRAULIC RETURN FILTERS for slasher circle saw

FROM SAW VALVE

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

HYDRAULIC RETURN FILTERS

FROM OIL COOLER "OUT"

•

DOUBLE FILTER HEAD

••

358-17

•

TO HYDRAULIC TANK

DOUBLE FILTER HEADS

••

FROM HOIST VALVE

HYDRAULIC OIL RETURN MANIFOLD 2.18

Tigercat 235B/245B Loader

Controls and operation

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.

LOCATED LOWER LEFT SIDE OF ENGINE COMPARTMENT

•• 386-20

PILOT FILTER ELEMENT

HYDRAULIC PILOT FILTER

The return filters and the pilot filter should be checked and replaced as per the maintenance schedule in SECTION 3 of THIS MANUAL.

IMPORTANT Contaminated hydraulic fluid can lead to premature failure of hydraulic components and costly repairs. Filters must be replaced at the recommended time intervals, See SECTION 3 in THIS MANUAL. Use of hydraulic oil filters other than the Tigercat brand could lead to severe wear and rapid failure of hydraulic system components.

2.19

Tigercat 235B/245B Loader

Controls and operation

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

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

AIR INTAKE GRILL

INDICATOR

AIR CLEANER UNLOADER VALVE

AIR INTAKE TUBE AIR FILTER

•

••

205-18A

• AIR CLEANER

•• 1/4" HOSE CONNECTION

•• 283-7A

••

FILTER RESTRICTION INDICATOR

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

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

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

205-19A

AIR CLEANER PRIMARY ELEMENT

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

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

205-22A

AIR CLEANER SAFETY ELEMENT

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.

2.20

Tigercat 235B/245B Loader

Controls and operation

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

Looks can be deceiving. A filter that is dirty is actually more efficient than one that is clean. A filter with dust build up on the media reaches nearly 100% dust cleaning efficiency. Only when a filter is so clogged with dirt that air restriction goes beyond the engine manufacturer’s guidelines, should be replaced.

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

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

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

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

4. Always clean the inside of the outlet tube.

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

6. Inspect the new filter for damage.

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

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

2.21

Tigercat 235B/245B Loader

Controls and operation

FUEL TANK AND FILLER

AIR VENT PASSAGE

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

••

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

INNER FILL TUBE

•

FUEL FILL TUBE

248-20

•• FUEL SIGHT GAUGE

248-18

2.22

FILLER TUBE

•

FUEL TANK AND FILLER

Tigercat 235B/245B Loader

Controls and operation

AIR BRAKE SYSTEM FOR SELF PROPELLED CARRIER

WARNING BEFORE PERFORMING ANY SERVICE WORK: • Block wheels to prevent vehicle from rolling.

• Wear eye protection to prevent eye injury.

• Review Test Procedures • Test vehicle for air leaks • Drain all reservoirs and supply lines to 0 psi.

The components of this pneumatic system consist of an air compressor driven off the engine, an air dryer with an integral governor, a purge tank, a supply tank, a foot pedal, hand operated control valve and a pressure gauge.

PURGE TANK

SUPPLY TANK

•

•• •• WATER DRAIN VALVE

•

RELEASE CABLE

386-15

AIR DRYER

AIR BRAKE PNEUMATIC COMPONENTS Refer to FOOT PEDAL-BRAKE and PARKING BRAKE in SECTION 2 of the OPERATOR'S MANUAL for additional information.

Refer to SECTION 3 of THIS MANUAL for service information.

2.23

Tigercat 235B/245B Loader

Controls and operation

MACHINE OPERATION RESERVOIR

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

•

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

CHECK WINDSHIELD WASHER LEVEL Check windshield washer fluid level.

249-24

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

3.

Read and understand this entire manual prior to operating machine.

PRE-START CHECKS

•

FUEL SIGHT GAUGE

CHECK FUEL LEVEL (later machines) Check fuel level.

248-20

4.

SIGHT GAUGE

356-44

1.

KEY SWITCH - OFF Ensure Key switch is in the OFF position.

CHECK FIRE EXTINGUISHER

• •• LOW LEVEL SENDING UNIT 247-23

2.

PORTABLE FIRE EXTINGUISHER

Check fire extinguisher is sufficiently charged.

• 248-16X

HYDRAULIC OIL SIGHT GAUGE/SENDER 5.

2.24

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

Tigercat 235B/245B Loader

Controls and operation ENGINE OIL LEVEL DIPSTICK AIR CLEANER UNLOADER VALVE

• •• 217-2

9.

CHECK AIR CLEANER UNLOADER VALVE Check air cleaner unloader valve

CHECK ENGINE OIL LEVEL Check that the engine oil level is between the ADD and FULL marks on the dipstick.

381-12A

6.

DIPSTICK

••

385-10

CHECK PUMP DRIVE GEARBOX OIL LEVEL FUEL LINE WATER SEPARATOR

PUMP DRIVE GEARBOX BREATHER AND OIL FILL

•

PUMP DRIVE GEARBOX OIL FILL

287-20

7.

383-18

Check pump drive gearbox oil level with dipstick provided AIR FILTER RESTRICTION INDICATOR

••

•

AIR CLEANER

WATER SEPARATOR BOWL

•

216-2A

10

283-7AA

8.

CHECK AIR FILTER

Check air filter restriction indicator.

2.25

•• DRAIN TAP

Drain water from fuel line water separator at the start of each shift.

Tigercat 235B/245B Loader

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

••

• CONNECTING HOSE TO GEARBOX

•

206-16A

SWING DRIVE GEARBOX OIL RESERVOIR

• A/C COMPRESSOR BELT

FAN BELT

CONNECTING HOSE FROM OIL RESERVOIR

CHECK ENGINE BELTS 11. Check tension and condition of all engine belts.

FILLER CAP

••

••

•• OIL FILL TUBE SWING DRIVE GEARBOX

248-25

••

SWING DRIVE MOTOR

235B-01

CHECK ENGINE COOLANT LEVEL

•

206-15A SWING DRIVE GEARBOX 14. Check swing drive gearbox oil level.

12. Check engine coolant level.

SHUT-OFF VALVE

RADIATOR

SHUT-OFF VALVE LEVER IN OPEN POSITION

••

HINGE OUT A/C CONDENSER

• •

••

••

•• LIMIT SWITCH

367-1

OIL COOLER 206-6A

PUMP SUCTION SHUT-OFF VALVE

15. Ensure that the pump suction shut-off valve is in the OPEN position. Engine will not start if this valve is in the CLOSED position.

CLEAN RADIATOR AND OIL COOLER

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

2.26

Tigercat 235B/245B Loader

Controls and operation STARTING THE ENGINE

16. Perform SCHEDULED MAINTENANCE as shown in SECTION 3 of THIS MANUAL. 17. Inspect machine for leaks, damaged or loose components or any other abnormal conditions.

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

1.

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

2.

Turn key switch to RUN position.

3.

Sound HORN to warn personnel of engine start-up.

4.

Move the throttle control to LOW IDLE position.

5.

Turn key switch to the START position to crank the engine.

NOTE: If engine does not start after three attempts, check the fuel system. Absence of Blue or White smoke coming out of the exhaust pipe indicates that no fuel is being delivered.

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

WARNING Do not attempt to operate any function or accessory while starting the engine. Serious injury or property damage may result.

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

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

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

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

2.27

Tigercat 235B/245B Loader

Controls and operation

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

2.

Ensure key is turn to OFF.

3.

Refill fuel tank completely.

4.

Remove engine fuel filter and fill with clean fuel.

5.

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

6.

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

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.

VERTICAL CENTERLINE

LOWER FRAME

•

COUNTERBALANCE VALVE

•

STABILIZER UP IN VERTICAL POSITION

• • •

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

CYLINDER

Refer to the following steps to ensure safe operation.

STABILIZER COUNTERBALANCE/CHECK CARTRIDGE REMOVAL

(a) Locate the loader on firm level ground only.

230-06A

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

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

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

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

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

2.28

Tigercat 235B/245B Loader

Controls and operation

MACHINE PREPARATION

(l)

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

Warm up the hydraulic system.

•

Test all systems for proper operation.

•

Inspect for hydraulic oil leaks.

NOTE: The right hand joystick button performs two separate functions depending on the status of the delimber arms. With delimber arms closed the button operates the top saw. With the delimber arms open the button operates the slasher saw. (m) Continue testing and operating various functions until engine and hydraulic oil has warmed up to near normal operating temperatures. Never load the machine until it has sufficiently warmed up. Doing so may cause damage to the engine and hydraulic components.

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

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

(b)

Sound horn to warn personnel of machine operation.

(c)

Ensure gauges and warning lights are indicating normal operating conditions.

(d)

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

(e)

Ensure both armrests are in the lowered position and press the PILOT RESET button.

(f)

Raise the throttle control to MID position.

(g)

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

(h)

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

(i)

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

(j)

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

(k)

Operate the swing in both direction to ensure proper operation.

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

(n)

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

(o)

Lower the throttle control to LOW IDLE.

(p)

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

WARNING

Never use your bare hand to check for fluid leaks.

Fluid leaks under pressure may not be visible.

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

Wear safety goggles for eye protection.

2.29

Tigercat 235B/245B Loader

Controls and operation

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

1.

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

2.

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

3.

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

4.

Do not race engine before shut-off

5.

Stop engine by turning Key switch to the OFF position.

6.

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

2.30

Tigercat 235B/245B Loader

Controls and operation

LOADER MOUNTING/INSTALLATION

YOKE

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

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

•

2.

•

4.

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

LOADER LOWER FRAME

•

WASHERS

• • • NUTS

• YOKE STUDS

YOKE 230B-02

5.

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

Ensure that trailer is stable and will not move.

WASHERS

•

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

3.

NUTS

TRAILER

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

1.

• •

TRAILER MOUNTING

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

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

6.

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

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

2.31

7.

Check torque of mounting bolts as specified in maintenance schedule.

8.

Ensure installation conforms to all applicable regulations.

Tigercat 235B/245B Loader

Controls and operation

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

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

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

1.

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

2.

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

3.

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

4.

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

2.32

Tigercat 235B/245B Loader

Controls and operation

CARE OF THE MACHINE

Removing hairline Scratches.

Scratches and minor abrasions can be removed or minimized by using a mid automotive polish. Three such products that tend to polish and fill scratches are Johnson Paste Wax, Novus Plastic Polish #1 & #2 and Mirror Glaze Plastic Polish. It is suggested that a test be made on a sample of LEXAN sheet with the product selected and that the product manufacturers instructions be followed.

1.

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

2.

Follow proper procedure for cleaning windows described in this section.

3.

Lubricate all necessary points as per the maintenance schedule provided.

4.

Never apply a load to a cold engine.

5.

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

6.

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

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

7.

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

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

8.

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

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

Some important Dont’s Don’t use abrasive or highly alkaline cleaners on LEXAN sheet products

Compatible Cleaning Agents Aqueous solutions of soaps and detergents

CLEANING LEXAN WINDOWS (Windshield and Skylight) 1.

Rinse with lukewarm water

2.

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

3.

Rinse with lukewarm water.

4.

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

• Formula 409 • Top Job • Freon T.F. • VM&P grade naphtha • Joy • Windex with Ammonia D • Palmolive Liquid GRAFFITI REMOVAL (A) Butyl Cellosolve (for removal of paints, marking pen inks, etc.) The use of masking tape, adhesive tape or lint removal tools works well for lifting off old weathered paints.

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

To remove wet paint, glazing compound or grease, rub lightly (not in direct sunlight) with a good grade of VM&P naphtha, isopropyl alcohol or butyl cellosolve (2-Butoxy Ethanol), then wash and rinse thoroughly.

DO NOT USE GASOLINE, Gasoline or oil will cause uncoated LEXAN to become opaque. MARGUARD coated LEXAN will start to become opaque around the edges and creep inwards.

2.33

Tigercat 235B/245B Loader

Controls and operation

2.34

Tigercat 235B/245B Loader

SECTION 3 - LUBRICATION & MAINTENANCE APRIL 2001

CONTENTS - SECTION 3 AIR BRAKE SYSTEM FOR SELF PROPELLED CARRIER .......................... 3.11 TROUBLESHOOTING ............................................................................... 3.12 AIR CONDITIONING - SERVICE .................................................................. 3.10 APPROVED HYDRAULIC OILS ...................................................................... 3.5 FILTERS HYDRAULIC OIL RETURN FILTERS .......................................................... 3.8 PILOT RETURN PRESSURE FILTER ........................................................ 3.9 GENERAL MAINTENANCE ............................................................................ 3.3 HYDRAULIC OIL RETURN FILTERS .............................................................. 3.8 HYDRAULIC OILS .......................................................................................... 3.5 LUBRICATING CYLINDER PINS AND BOOM JOINTS ................................. 3.4 LUBRICATION CHART ................................................................................... 3.6 MACHINE OPERATION ............................................................................... 3.11 NEW MACHINE MAINTENANCE ................................................................... 3.2 FIRST 50-100 HOUR INSPECTION AND SERVICE REPORT .................... 3.2 INITIAL PRE-DELIVERY INSPECTION ...................................................... 3.2 TIGHTENING POINTS ................................................................................ 3.2 PILOT RETURN PRESSURE FILTER ............................................................ 3.9 PRESSURE SETTING PROCEDURES. See SERVICE MANUAL PRESSURE SETTINGS ............................................................................... 3.13 PREVENTIVE MAINTENANCE SCHEDULE .................................................. 3.2 SCHEDULED MAINTENANCE EVERY 1000 HOURS: ................................................................................ 3.5 EVERY 125 HOURS ................................................................................... 3.4 EVERY 2000 HOURS: ................................................................................ 3.5 EVERY 24 HOURS: .................................................................................... 3.4 EVERY 250 HOURS ................................................................................... 3.5 EVERY 500 HOURS: .................................................................................. 3.5 EVERY 8 HOURS: ...................................................................................... 3.4 SERVICE AND LUBRICATION POINTS ......................................................... 3.6 TIGHTENING POINTS .................................................................................... 3.2 TORQUE CHART, GENERAL ....................................................................... 3.15 TORQUE SETTINGS, RECOMMENDED ...................................................... 3.14

Tigercat 235B/245B Loader

Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE FOR 235B/245B LOADER NEW MACHINE MAINTENANCE

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

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

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

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

The first 50-100 hour inspection report tightening points:~ All hydraulic connections Hose clamps

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

Pin retainers Check torque on swing bearing retaining bolts Engine mounting bolts Pump mounting bolts Pilot pump mounting bolts Swing gearbox mounting bolts Swing motor mounting bolts

OIL LOST FROM LEAKAGE

Cab securing bolts LEAKAGE RATE ONE DROP IN 10 SECONDS ONE DROP IN 5 SECONDS ONE DROP SECOND THREE DROP PER SECOND DROPS BREAK INTO STREAM

Boom pin nuts Trailer mounting studs Any other loose nut, bolt or fitting

3.2

LOST 0IL (GALLONS) PER PER PER DAY MONTH YEAR 0.112 3.36 40.0 0.225 6.75 81.0 1.125 33.75 405.0 3.75 112.5 1,350.0 24.00 720.0 8,640.0

Tigercat 235B/245B Loader

Lubrication and Maintenance

GENERAL CAUTION All handles, steps and platforms must be kept free of grease, oil, fuel mud, snow ice and forest debris to prevent risk of personal injury Clean around filler caps before checking or adding fluids 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 Top up diesel fuel at each shift to reduce contamination by condensation Clean up oil spills on walking surfaces in engine enclosure immediately Before welding on machine be sure the negative battery terminal is disconnected 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 Always have a fire extinguisher at hand For safety, always lower boom assy. To the ground when leaving cab, leaving machine unattended or during service

3.3

Tigercat 235B/245B Loader

Lubrication and Maintenance

SCHEDULED MAINTENANCE

• Check engine coolant level

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

• Check engine oil level

• For loose nuts, bolts and fittings

• Drain fuel/water separator

• Condition and tension of fan belts.

• Drain water from air supply tank (Self propelled carrier)

• Conduct an overall visual inspection.

EVERY 8 HOURS:~

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

• Check air cleaner unloader valve • Check hydraulic oil level • Check pump drive gearbox oil level

EVERY 24 HOURS:~

• Check swing gearbox oil level Fill reservoir to halfway mark

• Perform 8 hour maintenance

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

And in addition lubricate:~ • Stabilizer arm pins; 8-fittings - purge

• Swing pinion; 1-fitting - 10 shots while swinging

• Stabilizer cylinders; 8-fittings - purge

• ‡ Boom joints; 4-fittings - purge

• Grapple rotator bearing (Tigercat grapple); 1-fitting - 4 shots, rotate 90° after each shot

• ‡ Cylinders; boom and stick; 4-fittings total - purge ‡

EVERY 125 HOURS:~

Lubricating cylinder pins and boom joints:-

1. Ensure machine is on level ground

• Perform 8 hour maintenance

2. Fully extend stick boom cylinder

• Perform 24 hour maintenance

3. Lower main boom and rest grapple firmly on ground or stable trailer

And in addition check:~ • Return filters restriction indicator with engine running at high idle and oil flow

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

• Air cleaner primary element

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

• Fluid level in batteries unless maintenance free • Engine rpm.

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

• All hydraulic pressures

• Grapple arm pins; 6 - fittings - purge

• Torque tightening points as per new machine maintenance

• Grapple cylinder pins; 4 - fittings - purge

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

• Grapple yoke; 2 - fittings, purge

• Lower frame, stabilizer arms and cylinders

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

• Attachment

• Hydraulic pumps and motor securing bolts

• Swing bearing area Make repairs immediately

• Remove potentially damaging limbs or sticks and all debris Continued on page 5

3.4

Tigercat 235B/245B Loader

Lubrication and Maintenance

SCHEDULED MAINTENANCE Continued from page 4

Visually inspect for:~ • Frayed electrical wiring and hydraulic hoses • Wear in any other components

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

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

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

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

EVERY 1000 HOURS:~ • Perform 8 hour maintenance • Perform 24 hour maintenance

EVERY 250 HOURS:~

• Perform 125 hour maintenance

• Perform 8 hour maintenance

• Perform 250 hour maintenance

• Perform 24 hour maintenance

• Perform 500 hour maintenance

• Perform 125 hour maintenance

And in addition:~

And in addition:~

• Replace oil in pump drive gearbox

• Replace engine oil and filter

• Check fuel intake strainer

• Replace engine fuel filter

• Replace air cleaner unloader valve

• Replace fuel/water separator element

EVERY 2000 HOURS:~

• Replace air cleaner primary element

EVERY 2000 HOURS:~

• Check torque on trailer mounting studs

Drain and refill hydraulic oil tank with recommended hydraulic oil. See "approved hydraulic oils"

• Check fire extinguisher

EVERY 500 HOURS:~

______________________________________________

• Perform 8 hour maintenance • Perform 24 hour maintenance

APPROVED HYDRAULIC OILS

• Perform 125 hour maintenance • Perform 250 hour maintenance

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

And in addition replace:~ • Air cleaner safety element

Chevron

Tractor hydraulic fluid (summer)

• Hyd. Oil return filters †

Citgo

Tractor hydraulic fluid (33-310) (summer)

Imperial

Esso hydraul 56 (summer) Hydraul 50 (low visc) (winter)

Shell

Donax TD (summer) Donax TDL (winter)

Sun

Sunfleet TH fluid (summer)

John deere

Type J20C (hy-gardTM) (summer) Type J20C (hy-gardTM) (winter)

• Hyd. Oil pilot pressure filter † • Oil in swing gearbox Fill reservoir to halfway mark Lubricate:~ • Door and cover hinges 8 fittings - 1 shot

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

3.5

LUBRICATION CHART

SERVICE AND LUBRICATION POINTS Tigercat 235B/245B Loader

Lubrication and Maintenance

13

5

15

DOOR HINGES 2 FTG/500

SWING BEARING 1 FTG/8 4 SHOTS WHILE SWINGING

1 2 3 4 9

SWING PINION 1 FTG/8

DOOR HINGES 2 FTG/500

10 SHOTS WHILE SWINGING

6 7 14 8 9

9

STICK JOINT 2 FTG/8

9

BOOM JOINT 2 FTG/8

YOKE PINS 2 FTG/8

11

DOOR HINGES 4 FTG/500

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

10

12

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

GRAPPLE ARM PINS 6 FTG/8

16 FTG/24 STABILIZER ARM JOINTS AND CYLINDERS

CYLINDER PINS 4 FTG/8

10841B

3.6

Tigercat 235B/245B Loader

Lubrication and Maintenance

Tigercat® 235B and 245B Loader SERVICE AND LUBRICATION POINTS REFER TO Tigercat OPERATOR’S MANUAL FOR ADDITIONAL INFORMATION ®

CHK

CHK

3

ENGINE OIL AND FILTER CUMMINS 'B' CUMMINS 'C' FUEL FILTER (ENGINE)

4

FUEL/WATER SEPARATOR

DRN

5

INTANK FUEL STRAINER

2

6

8 9

QTY

2000

30 34

60% ANTIFREEZE, 40% DISTILLEDWATER **

SEE ENGINE MANUFACTURER'S SERVICE MANUAL

REP

REP

1

REP

1 1 DRAIN TANK, CLEAN OR REPLACE AS NECESSARY

CHK

1 CHECK AIR CLEANER FILTER RESTRICTION 1 INDICATOR AT FULL ENGINE RPM

CHK REP

AIR CLEANER SAFETY ELEMENT

REP

7

AIR CLEANER UNLOADER VALVE

CHK

8

HYDRAULIC RESERVOIR

CHK

9

RETURN FILTERS (6 ELEMENTS)

REP D/R 350 92

CHK

10 PRESSURE FILTER, PILOT

12

1000

CHANGE COOLANT EVERY 2 YEARS

DESCRIPTION

15.1 4 24 6.3

AIR CLEANER PRIMARY ELEMENT

11 SWING GEARBOX

500

250

125

8

COOLING SYSTEM CUMMINS 'B' CUMMINS 'C '

US GAL

SERVICE POINT NO.

1

ITEM

LITRE

CAPACITY

SERVICE EVERY

CHK

1 REFER TO OPERATOR'S MANUAL SECTION 2 FOR DETAILS 1 DRAIN AND REFILL AS REQ'D BY SEASONAL OIL CHANGE. REFER TO APPROVED HYD. OILS

REP

6 CHECK FILTER RESTRICTION INDICATOR, ON HYDRAULIC OIL RETURN MANIFOLDS 2-PLACES, WITH ENGINE RUNNING AT HIGH IDLE WITH OIL FLOW

REP

1

D/R

1

HALF FILL RESERVOIR WITH SAE 75W90 EP OIL

GRAPPLE, Tigercat ®

SEE LUBRICATION POINTS DIAGRAM

GRAPPLE, OTHER MANUFACTURERS

SEE MANUFACTURER'S MAINTENANCE SCHEDULE

13 FIRE EXTINGUISHER 14 PUMP DRIVE GEARBOX

CHK CHK

D/R

4

15 COMPRESSED AIR TANK DRAIN (SP) DRN

2 FTG/125

1.1

1 TURN TO MIX CONTENTS 1 CHECK OIL WITH DIPSTICK. FILL WITH: MIL-L-2105C OR API-GL-5 75W FOR BELOW -10˚F (-23˚C) 80W-90 FOR UP TO 100˚F (38˚C) 85W-140 FOR ABOVE 100˚F (38˚C) 1 PULL DRAIN VALVE CABLE TO PURGE WATER

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

…….. HOURS CHK …. CHECK REP …. REPLACE DRN …. DRAIN D/R ….. DRAIN & REFILL (SP) …. SELF PROPELLED 10841B R3

3.7

Tigercat 235B/245B Loader

Lubrication and Maintenance

HYDRAULIC OIL RETURN FILTERS

•

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

FILTER HEAD

• GASKET

•

FILTER ELEMENT

SQUARE SECTION GASKET INSTALLATION

Changing the filters:

FILTR_SEALS 2

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

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

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

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

Apply clean oil to new gasket surfaces.

Install new gasket into groove in filter head.

Screw on new filter until gasket makes contact.

Tighten filter an additional 3/4 turn.

FILTER HEAD

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

• • GASKET

• FILTR_SEALS 2

FILTER ELEMENT

'O' RING GASKET INSTALLATION

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

Apply clean oil to new gasket surfaces.

Install new gasket on inside lip of filter.

Screw on new filter until gasket makes contact.

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

3.8

Tigercat 235B/245B Loader

Lubrication and Maintenance

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

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

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

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

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

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

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

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

9. Start the engine and check for leaks.

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

IMPORTANT Contaminated hydraulic fluid can lead to premature failure of hydraulic components and costly repairs. Filters must be replaced at the recommended time intervals, Refer to SCHEDULED MAINTENANCE in THIS SECTION. Use of hydraulic oil filters other than the Tigercat brand could lead to severe wear and rapid failure of hydraulic system components.

3.9

Tigercat 235B/245B Loader

Lubrication and Maintenance

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

R134a REFRIGERANT 2 LBS. 12 OZ.

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

PAG OIL (polyalkylene glycol)

A/C CONDENSER CORE

2 OZ.

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

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

•

• RADIATOR

A/C COMPRESSOR

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

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

A/C COMPRESSOR

249-17B

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

LEFT FRONT ENGINE MOUNT

c. Check to see that compressor clutch will engage.

•

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

RECEIVER DRYER

••

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

LOWER FRAME

•• 155-2A

A/C RECEIVER DRYER 3.10

Tigercat 235B/245B Loader PURGE TANK

Lubrication and Maintenance

SUPPLY TANK AIR COMPRESSOR

••

•

WATER DRAIN RELEASE CABLE

••

•• WATER DRAIN VALVE

•

••

RELEASE CABLE

•

AIR DRYER

386-15

AIR BRAKE PNEUMATIC COMPONENTS

LINE TO AIR DRYER IN PORT

AIR BRAKE SYSTEM FOR SELF PROPELLED CARRIER

235B-12A

AIR BRAKE PNEUMATIC COMPONENTS

WARNING

moisture, oil, and contaminates from the compressed air system to reduce the risk of freezing or corrosion of the components in the air system.

BEFORE PERFORMING ANY SERVICE WORK: • Block wheels to prevent vehicle from rolling.

• Wear eye protection to prevent eye injury.

• Test vehicle for air leaks • Drain all reservoirs and supply lines to 0 psi.

The components of this pneumatic system consist of an air compressor driven off the engine, an air dryer with an integral governor, a purge tank, a supply tank, a foot pedal, hand operated control valve and a pressure gauge.

OPERATION The air dryer receives air from the compressor at the IN port. The air travels via a copper "cooling line", which helps to lower the temperature of the air before entering the dryer. The air dryer is a desiccant type with an integrated governor and a purge tank attached.

This type of dryer effectively removes TO FOOT PEDAL IN CAB

RELEASE CABLE

•

SUPPLY TANK

EXTENDED COPPER LINE FOR COOLING

•• ••

•

•

FROM AIR DRYER "OUT" PORT TO SUPPLY TANK

• TO AIR DRYER "IN" PORT

386-16B

Connected to the supply tank is a foot pedal a hand control knob and a pressure gauge, all

RELIEF VALVE

FROM COMPRESSOR

••

When the governor "cut-out" setting of approximately 120-130 psi is reached, the Integrated governor senses the system pressure and opens the unloader valve in the dryer and vents compressor air to atmosphere.

Dry air stored in the purge tank is then allowed to flow back to regenerate the desiccant bed.

This cycle ensures that clean, dry air is always supplied from the OUT port of the dryer to top up the supply tank. The purge tank is then recharge with clean dry air via the newly regenerated desiccant bed.

•• WATER DRAIN VALVE

AIR BRAKE PNEUMATIC COMPONENTS 3.11

Tigercat 235B/245B Loader

Lubrication and Maintenance

located in the operator's cab. Refer to FOOT PEDAL-BRAKE and PARKING BRAKE in SECTION 2 of the OPERATOR'S MANUAL for additional information. Activating either the foot pedal or control knob directs air pressure to the vehicle brakes via the rotary manifold located in the center of the upper frame assembly. A water drain valve is installed on the bottom of the supply tank, this should be opened periodically to drain away any water that may have accumulated in the supply tank due to condensation etc. Pull on the cable provided to open the valve.

The air system is also protected against over pressurization by a relief valve that is installed in the end of the supply tank.

WARNING BEFORE PERFORMING ANY SERVICE WORK: • Block wheels to prevent vehicle from rolling.

• Wear eye protection to prevent eye injury.

• Test vehicle for air leaks • Drain all reservoirs and supply lines to 0 psi.

*NOTE: On dryers with integrated governors it is normal for the compressor to vent air through the dryer when the system is unloaded. To test for system leakage, charge system to cut-out and shut off engine.

TROUBLESHOOTING PNEUMATIC SYSTEM Problem

Cause

Repair

Water in air System

1.Contaminants in desiccant.

2.Excessive dryer inlet temperature.

1. Change desiccant cartridge. Check compressor for excessive oil passage.

2. Dryer inlet temperature must be less than.1500F. This can normally be accomplished with 12' to 16' of compressor discharge line.

3.Duty cycle of compressor does not allow for sufficient time for desiccant regeneration.

3. during normal operation the dryer unloader must remain open for a minimum ot 30 seconds to allow for sufficient purge. Lengthy loading times must be avoided. ~ Check for leaks in system.

1. Leaks in air system.

1. Tighten air connections, soap connection and re-check for leaks. System pressure drop should not exceed 2 PSI per minute with the brake released and 3 PSI per minute with the brake applied. Leaks in the system will shorten the desiccant and compressor life.

2.Defective dryer outlet check valve, 3.Port #4 leaking or plug missing

2. Clean valve seat and replace check valve.

4. Defective governor

4. Check for proper governor cut-in and cut-out.

Adjust or replace valve pack with integrated governor.

1. Desiccant cartridge is plugged.

1. Excessive oil passage from compressor.

Check for worn compressor. Replace desiccant cartridge.

2. Replace or adjust Integrated Governor.

Excessive cycling of dryer * See Note

Safety valve is open

2. Excessive system pressure 3. Defective safety valve.

235B-02

3. Integrated governor requires a plug in this port.

3. Replace safety valve.

BRAKE CIRCUIT FOR SELF PROPELLED LOADER 3.12

Tigercat 235B/245B Loader

Lubrication and Maintenance

PRESSURE SETTINGS LOCATION

ENGINE RPM

235B/245B

FULL

450

Port relief grapple rotate ccw Port relief grapple rotate cw

FULL FULL FULL FULL

2500* 2600* 1750 † 1750 †

Port relief stick out Port relief stick in

IDLE FULL

3000*** 1500

Port relief Port relief

IDLE IDLE

3000*** 3000***

Port relief grapple open Port relief grapple close

FULL FULL IDLE IDLE

2500* 2600* 3000*** 3000***

Port relief hoist up Port relief hoist down

IDLE FULL

3000*** 1500

Port relief delimber open Port relief top saw cut

IDLE IDLE

3000*** 3000***

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

FULL IDLE IDLE

2500* 3000*** 3000***

Port relief stabilizers down Port relief stabilizers up

IDLE FULL

3000*** 2000

Port relief Port relief

IDLE IDLE

3000*** 3000***

Main relief saw/butt valve Port relief butt board up Port relief butt board down

FULL IDLE IDLE

2000* 2700 2700

Port relief slasher cut Port relief slasher retract

IDLE IDLE

2700 2700

Main relief saw valve

FULL IDLE IDLE

2500* 3000*** 3000***

IDLE IDLE

1650 2000

Pilot relief valve Main relief stick valve

- 235B - 245B

Main relief hoist valve

-235B -245B

Port relief circle saw run Port relief

Crossline reliefs swing motor - 235B - 245B

*

Do not adjust pressure over 3000 psi or pump may be damaged. *** Factory set at 10 gpm. † Tigercat grapple set at 1750 psi Rotobec grapple set at 1750 psi Hultdins grapple set at 3000 psi IMPORTANT 1. System to be at operating temperature when setting pressures.

2. All pressures measured in psi.

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

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

3.13

Tigercat 235B/245B Loader

Lubrication and Maintenance

TORQUE CHART LOCATION

THREAD DIAMETER

Cylinders Piston nut, stabilizer cylinders Piston nut, hoist cylinder Piston nut, stick cylinder Piston nut, heel cylinder Piston nut, grapple cylinder Gland, grapple cylinder Gland, stabilizer cylinder Keeper plate bolts, heel cylinder Keeper plate bolts, hoist cylinder Keeper plate bolts, stick cylinder

TORQUE (LUBRICATED) lbf-ft Nm

2 1/4"-12 UNF (GC) 2 1/2"-12 UNF (GC) 2 1/2"-12 UNF (GC) 2 1/4"-12 UNF (GC) 1 3/4"-12 UNF (GC) 4 1/2" I/D CYLINDER 6" I/D CYLINDER 3/4"-10 UNC (G8) 7/8"-14 UNF (G8) 3/4"-16 UNF (G8)

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

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

3/4"-10 UNC (G8)

282-310

393-420

2"-12 UNF (G8)

400

540

Heel to Stick boom pin retaining nut

1 3/4"-12 UNF (G8)

400

540

Cab securing bolts Trailer mounting studs

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

450-500 500

610-680 680

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

400-450 450-500 160-175 130

540-610 610-680 215-235 175

Engine mounting (Cummins 'B' and 'C') Bolts, bracket/mount to chassis Bolts, bracket to engine Engine cooling fan mounting bolts

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

450-500 75 40

610-680 100 54

Pump drive Drive plate to flywheel Bell housing to engine

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

33-36 45

44-48 60

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

*

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

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

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

3.14

Tigercat 235B/245B Loader

Lubrication and Maintenance

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

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

IMPERIAL

GRADE 5 BOLTS

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

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

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

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

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

METRIC

SIZE

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

M6 M8 M10

4.8 12 23

3.5 8.5 17

6 15 29

4.5 11 21

9 22 43

6.5 16 32

11 28 55

8.5 20 40

13 32 63

9.5 24 47

17 40 80

12 30 60

15 37 75

11.5 28 55

19 47 95

14.5 35 70

M12 M14 M16

40 63 100

29 47 73

50 80 125

37 60 92

75 120 190

55 88 140

95 150 240

70 110 175

110 175 275

80 130 200

140 225 350

105 165 225

130 205 320

95 150 240

165 260 400

120 190 300

M18 M20 M22

135 190 260

100 140 190

175 240 330

125 180 250

260 375 510

195 275 375

330 475 650

250 350 475

375 530 725

275 400 540

475 675 925

350 500 675

440 625 850

325 460 625

560 800 1075

410 580 800

M24 M27 M30

330 490 675

250 360 490

425 625 850

310 450 625

650 950 1300

475 700 950

825 1200 1650

600 875 1200

925 1350 1850

675 100 1350

1150 1700 2300

850 1250 1700

1075 1600 2150

800 1150 1600

1350 2000 2700

1000 1500 2000

M33 M36

900 1150

675 850

1150 1450

850 1075

1750 2250

1300 1650

2200 2850

1650 2100

2500 3200

1850 2350

3150 4050

2350 3000

2900 3750

2150 2750

3700 4750

2750 3500

ISSUE 3 800

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

3.15

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

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

Tigercat 235B/245B Loader

Lubrication and Maintenance

3.16