PDF Service Manual Tigercat 230B 240B Loader - 918 KB
This comprehensive service manual provides all the information needed to repair and maintain the Tigercat 230B and 240B Loaders.
It contains detailed procedures for diagnostics, disassembly, repair, and reassembly of all major systems.
With clear illustrations and technical specifications, this manual empowers technicians to perform jobs correctly and efficiently.
It is the ultimate resource for keeping these rugged forestry machines in top working order.
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--- Page 1 ---
SERVICE MANUAL
Tigercat 230B/240B Loader
TABLE OF CONTENTS ISSUE 2.1, JUNE, 2005
SECTION
INTRODUCTION ............................................................................................................... ii
NON-APPROVED FIELD PRODUCT CHANGES ............................................................ iv
SAFETY ............................................................................................................................ 1
CONTROLS AND OPERATION ............................. See separate OPERATOR'S MANUAL
LUBRICATION AND MAINTENANCE ............................................................................... 3
PILOT SYSTEM ................................................................................................................ 5
ELECTRICAL, GAUGES AND ALARMS ........................................................................... 6
ENGINE START AND STOP ............................................................................................. 7
BOOM FUNCTIONS ....................................................................................................... 12
SWING ............................................................................................................................ 15
STABILIZERS ................................................................................................................. 16
GRAPPLE ....................................................................................................................... 17
DELIMBER/SLASHER .................................................................................................... 18
230B-SM00
230B/240B Available Literature
Tigercat ®
Operator's Manual .................................................. Part No. 13040A
Service Manual ....................................................... Part No. 13041A
Parts Catalog .......................................................... Part No. 13042A P.O. Box 544
CD - Master Parts Catalog .................................... Part No. 24995A Paris, Ontario
CD - Master Operator's and Service Manual ........ Part No. 24996A Canada N3L 3T6
Hydraulic Adapters Book ........................................ Part No. 1472A
Hydraulic Hose assemblies Book .......................... Part No. 3707A Tel: (519) 442-1000
Fax: (519) 442-1855
--- Page 3 ---
Tigercat 230B/240B Loader Safety
SAFETY INTERLOCK SWITCH ON LEFT ARMREST:
SERVICING The left arm rest is equipped with a safety
SAFETY PRECAUTIONS interlock switch (1) to prevent the machine from
being operated while the armrest is in the raised
position (pilot system is shut off).
NOTE: The engine can be started but the machine
functions cannot be operated with the left arm rest
up.
ARMREST
•
L.H. ARM REST IN
DOWN POSITION AND
Conduct maintenance inspections at least as LIMIT SWITCH ON
frequently as recommended in section 3 of the
operator's manual. 1
When servicing or repairing equipment, shut the LIMIT SWITCH
ACTUATING LEVER
engine down. Turn Master Disconnect switch OFF. ON SEAT BASE
Install a “DO NOT START ENGINE” sign on the
••
operator’s cab door when making repairs to the
machine. •
247-25 PILOT SYSTEM SHUT OFF
To operate:
With the engine running and the left arm rest
DOWN, push the pilot reset switch.
Once the safety interlock system has been
activated, the safety of both the operator and
Before performing maintenance or repair work on any all persons outside the cab becomes the
equipment, consult the manufacturer’s instruction responsibility of the operator.
manual and follow recommended procedures. The left arm rest safety interlock switch (pilot
The radiator and the engine cooling system should be system shut off limit switch) and the pilot
inspected daily and cleaned as necessary to maintain reset switch are a safety feature and their
moderate engine temperatures. function must not be defeated in any way.
1.7
--- Page 4 ---
Tigercat 230B/240B Loader Lubrication and Maintenance
SCHEDULED MAINTENANCE
Clean/replace:~ EVERY 1000 HOURS:~
• Air conditioner re-circulation filter
• Cab fresh air filter • Perform 8 hour maintenance
• Refer to diesel engine service manual and • Perform 24 hour maintenance
attachment manual for additional required • Perform 125 hour maintenance
maintenance at this scheduled time period. • Perform 250 hour maintenance
• Perform 500 hour maintenance
EVERY 250 HOURS:~ And in addition:~
• Check intank fuel strainer. Drain tank, clean or
• Perform 8 hour maintenance
replace as necessary.
• Perform 24 hour maintenance
• Replace air cleaner unloader valve.
• Perform 125 hour maintenance
And in addition:~
• Replace engine oil and filter
EVERY 2000 HOURS:~
• Replace engine fuel filter • Perform 8 hour maintenance
• Replace fuel/water separator filter • Perform 24 hour maintenance
• Replace air cleaner primary element • Perform 125 hour maintenance
• Check fire extinguisher and turn it to mix • Perform 250 hour maintenance
contents • Perform 500 hour maintenance
• Check torque on trailer mounting studs. • Perform 1000 hour maintenance
And in addition:~
EVERY 500 HOURS:~ • Drain and refill hydraulic oil tank with
recommended hydraulic oil. Refer to
• Perform 8 hour maintenance APPROVED HYDRAULIC OILS in THIS
• Perform 24 hour maintenance SECTION.
• Perform 125 hour maintenance ______________________________________________
• Perform 250 hour maintenance
And in addition:~ APPROVED HYDRAULIC OILS
• Replace air cleaner safety element
• Replace hydraulic oil return filters † Use only one of the following oils to fill or
• Replace hydraulic oil pilot pressure filter † replenish the hydraulic system.
• Replace oil in swing gearbox. Fill reservoir to Chevron Mechanism LPS 68 (summer)
half way mark Citgo Mystik HVI-68 (summer)
• Lubricate door and cover hinges; Imperial/ESSO Univis N68 (summer)
8 fittings - 1 shot Univis N22 (winter)
Check:~ Shell Tellus T68 (summer)
• Torque on swing bearing and swing gearbox Tellus T22 (winter)
retaining bolts Texaco Rando HDZ 68 (summer)
• Refer to diesel engine service manual and
attachment manual for additional required
maintenance at this scheduled time period.
† Use of filters other than genuine Tigercat
replacement filters is not recommended.
3.5
--- Page 5 ---
Tigercat 230B/240B Loader Lubrication and Maintenance
PRESSURE SETTINGS
SERIAL NUMBER 2300501 2400501
and up and up
Pilot relief valve 450 450
Main relief stick valve 2500* 2600*
Port relief grapple rotate ccw 1750 1750
Port relief grapple rotate cw 1750 1750
Port relief stick out 3000*** 3000***
Port relief stick in 1500 1500
Port relief saw retract 1500 1500
Port relief slasher cut 3000*** 3000***
Main relief hoist valve 2500* 2600*
Port relief grapple open 3000*** 3000***
Port relief grapple close 3000*** 3000***
Port relief hoist up 3000*** 3000***
Port relief hoist down 1500 1500
Port relief spare 3000*** 3000***
Port relief top saw cut 3000*** 3000***
Main relief swing valve 2500* 2500*
Port relief swing ccw 3000*** 3000***
Port relief swing cw 3000*** 3000***
Port relief stabilizers down 3000*** 3000***
Port relief stabilizers up 2000*** 2000***
Port relief delimber open 3000*** 3000***
Port relief spare 3000*** 3000***
Crossline reliefs swing motor 1650 2000
* Do not adjust pressure over 3000 psi or pump may be damaged.
*** Factory set at 10 gpm.
IMPORTANT
1. System to be at operating temperature when setting pressures.
2. All pressures measured in psi.
3. All main and port relief valves to be set at full engine rpm.
4. Swing motor crossline relief valves to be set at engine idle and;
Using the following procedure:
a. Install swing locking device or secure boom to keep the machine from swinging.
b. Disconnect and cap the pilot hose running to the swing motor crossline relief valves.
c. At idle adjust both swing motor crossline relief valves to the value given on the chart.
d. Reconnect the pilot hose and purge the air out of the lines.
NOTE:
The above values are for reference purposes only,
SEE SERVICE MANUAL FOR SETTING PROCEDURE
3.15
--- Page 6 ---
Tigercat 230B/240B Loader Electrical, Gauges and Alarms
SENDER - HYDRAULIC
OIL TEMPERATURE
(GAUGE)
SWITCH- HYDRAULIC BATTERY DELIMBER
OIL TEMPERATURE DISCONNECT 'OPEN'
(RED LIGHT) SWITCH SOLENOID
STABILIZER
SIGHT GAUGE/SWITCH - PILOT
BATTERIES MANIFOLD PILOT MANIFOLD
HYDRAULIC OIL LEVEL
(RED LIGHT)
START SOLENOID
RELAY
•
•
•
•
• •
•
+
•_
• + •
_
SWITCH - ENGINE OIL PRESSURE
(ENGINE HOURS METER)
• (RED WARNING LIGHT)
• • SENDER - BOOM
• • ENGINE OIL PRESSURE LIGHTS
(GAUGE)
LIMIT SWITCH,
•
PILOT SHUT OFF JOYSTICKS
•
•
SAFETY ALERT
HORN (SWITCH
ON CONTROL COOLANT LEVEL
PANEL) PROXIMITY SWITCH
(RED LIGHT)
SWITCH - COOLANT
TEMPERATURE
(RED LIGHT)
SENDER -
COOLANT TEMPERATURE
(GAUGE)
230B-07 SENSOR LOCATIONS - EARLY MACHINES
6.3
--- Page 7 ---
Tigercat 230B/240B Loader Electrical, Gauges and Alarms
240B-029
FUSES AND RELAYS - ELECTRICAL BOX - SN 2300851 TO 2300871 AND 2401001 TO 2401071
6.13
--- Page 9 ---
Tigercat 230B/240B Loader Electrical, Gauges and Alarms
REFER TO COLOUR
CODE CHART IN
THIS SECTION
ELECTRICAL SCHEMATIC DIAGRAM 23057B (SHEET 1)
230B-05A
EARLY MACHINES S/N 2300872 TO 2301020 AND 2401072 TO 2401270
6.23
--- Page 10 ---
Tigercat 230B/240B Loader Engine start and stop
START CIRCUIT - RUN
IGNITION KEY - RUN POSITION
PILOT RESET SWITCH - HELD ON
ARM REST DOWN/ARM REST SWITCH - ON
230B-12
EARLY MACHINES
START CIRCUIT - RUN
IGNITION KEY - RUN POSITION
PILOT RESET SWITCH - RELEASED
ARM REST DOWN/ARM REST SWITCH - ON
230B-13 EARLY MACHINES
7.5
--- Page 11 ---
Tigercat 230B/240B Loader Boom functions
CONTROL VALVE OPERATING DESCRIPTION RETURN DOUBLE
MANIFOLD FILTER HEADS
Oil enters the inlet section and is allowed to pass
through the three spool sections and back to tank
via the outlet section. Each of these spool ••
sections has a self centering 3-position spool
which is open centered. A spring in the spool end
•
cap holds the spool in the center neutral position.
The spool is shifted by pilot pressure being
•
applied to either end of the spool. Shifting the
spool directs oil to operate any one of the three
functions (or all at the same time if required but
with reduced flow to each).
•• •
To protect components and hoses when the valve ••
is closed, each work port in the valve sections
have a port relief valve with an anti-cavitation
function.
1-WATER
ABSORBING
RETURN FILTER
• 3-HYDRAULIC
(COLOUR BLUE) RETURN FILTERS
A main relief valve is installed in the inlet section 358-17 HYDRAULIC RETURN FILTERS
of the valve to protect the hydraulic system Each filter head has a bypass valve with a 25
against overload pressures. psi cracking pressure so that oil can bypass
the filters if they become restricted. The "in"
HYDRAULIC RETURN FILTERS side of the filter heads are connected to a
The majority of return oil entering the return manifold. A filter restriction indicator
hydraulic tank passes through 4 spin-on and an oil sampling connector are mounted
hydraulic oil filters. One of the filters is a onto the manifold. To check the condition of
water absorbing filter (color blue) which is in the filter elements; With the hydraulic oil at
place to assist with the removal of unwanted normal operating temperature, place
moisture from the hydraulic oil (the filters are engine throttle control to FULL and with no
rated 10m abs). machine functions operating, the filter
restriction indicator should be in the GREEN
zone. If the pointer is in the RED zone
replace all four filter elements.
RELIEF
VALVE SEAL GROOVES RELIEF
PORT 'A' VALVE
A B PORT 'B'
SPOOL
CENTERING
• • SPRINGS
•
• •
• •
•
• •
• •
• •
•
PILOT
END PILOT
CAP SPOOL END
CAP
TANK PASSAGE PARALLEL LOAD CHECK THRU' WORK TANK
PASSAGE VALVE NEUTRAL PORT PASSAGE
PASSAGE BRIDGE
AT047IL2 CROSS SECTION OF SPOOL SECTIONS
12.3
--- Page 12 ---
Tigercat 230B/240B Loader Swing
SWING DRIVE GEARBOX
Power is transmitted from the motor to a double RESERVOIR
reduction planetary gearbox. The swing gearbox
upper gearing is lubricated by oil stored in a
reservoir attached to the side of the gearbox cover.
•
The reservoir must remain half full of oil* at all CONNECTING
HOSE TO
times. The lower bearing area is lubricated by GEARBOX
grease where the cavity is filled with grease at
assembly, a grease fitting is not provided since
additional greasing is not necessary. •
206-16A SWING DRIVE LUBRICATION
To fill the gearbox with oil, unscrew the air bleed To drain the gearbox unscrew the drain plug and
plug located on the motor flange, remove the cap allow oil to drain into a suitable container. To
on the reservoir and add oil to the reservoir. When facilitate draining, the oil should be warm.
oil begins to come out of the air bleed hole replace
the plug and continue to add oil until the reservoir *For correct oil specification and maintenance
is half full. Replace the cap on the reservoir. schedule, refer to SECTION 3 in THIS MANUAL.
TO OIL RESERVOIR
• MOTOR
MOUNTING
FLANGE
•
• AIR BLEED
PLUG
MOTOR DRIVE
UPPER GEARING SHAFT COUPLING
AREA LUBRICATED
WITH OIL
•
•
TWO STAGE
GEARBOX PLANETARY
MOUNTING GEARING
FLANGE
•
•
OIL DRAIN HOSE •
CONNECTION
LOWER BEARING AREA
FILLED WITH GREASE
•
DRIVE PINION
•
BK0011-5 SWING DRIVE GEARBOX
15.5
--- Page 13 ---
Tigercat 230B/240B Loader Stabilizers
STABILIZER CIRCUIT DESCRIPTION end of the cylinder will be directed back to tank
Refer to STABILIZER CIRCUIT DIAGRAM via the counterbalance valve, through the rotary
manifold, through the stabilizer pilot manifold, to
The stabilizer circuit is supplied with hydraulic oil the stabilizer control valve and the oil cooler.
by a fixed displacement gear pump. The
stabilizer/swing valve receives oil at the inlet LOWERING STABILIZER(S)
section and directs it through the three open Place direction switch in DOWN position. Press
center spool sections, to the outlet section. From and hold one of the stabilizer control switches.
there it is directed back to tank via the oil cooler, a Electrical current will flow along wire RED 3,
check valve to the return manifold and two dual through a series of diodes and energize the
element filters, which are equipped with an DOWN solenoid operated pilot valve on the pilot
internal 25 psi element bypass valve. A 50 psi. manifold. Pilot oil will then be directed to the
relief valve is installed in the oil cooler line to stabilizer control valve spool DOWN pilot end cap
bypass the oil around the oil cooler, usually on to shift the spool.
cold start ups when the oil is cold and thicker.
Current will also flow to energize a solenoid pilot
Six switches on the instrument panel control the valve(s) on the stabilizer pilot manifold to allow
stabilizers, One 3-position switch OFF/UP/DOWN pilot oil, via internal porting, to shift a spool in a
and five more switches to operate the stabilizers directional valve in the manifold.
either ALL at the same time or each one
In this condition, hydraulic oil will flow from the
INDIVIDUALLY. For a detailed description of
DOWN side of stabilizer control valve, through the
these switches, refer to SECTION 2 in the
stabilizer pilot manifold to the rotary manifold and
OPERATOR'S MANUAL.
on to the cylinder counterbalance valve where it
Placing the 3-position stabilizer direction switch in will be directed to the BASE end of the selected
the OFF position removes all current from the cylinder. Return oil from the ROD end of the
stabilizer circuit to prevent the stabilizers from cylinder will be directed back to tank via the
operating. The switch should remain in this counterbalance valve, through the rotary manifold
position when the stabilizers are in the stationary to the stabilizer control valve and the oil cooler.
position, either UP or DOWN.
To raise or lower all of the stabilizers at the same
time; Press direction switch, Press and hold the
CAUTION center 'ALL' switch, Electrical current will flow
When loading/unloading, the Operator must through all of the diodes to supply electrical
always ensure that all four stabilizers are current to all four solenoid operated pilot valves
firmly placed on the ground. Soft ground on the stabilizer pilot manifold and also through
conditions can cause instability. the direction switch and energize the solenoid
operated pilot valve on the pilot manifold.
RAISING STABILIZER(S) Hydraulic oil will then flow as described above for
either UP or DOWN except that all cylinders will
Place direction switch in UP position. Press and operate at the same time.
hold one of the stabilizer control switches.
Electrical current will flow along wire RED 3,
through a series of diodes and energize the UP
solenoid operated pilot valve on the pilot manifold.
Pilot oil will then be directed to the stabilizer
control valve spool UP pilot end cap to shift the
spool.
Current will also flow to energize a solenoid pilot
valve(s) on the stabilizer pilot manifold and allow
pilot oil, via internal porting, to shift a spool in a
directional valve in the manifold.
In this condition, hydraulic oil will flow from the UP
side of stabilizer control valve to the rotary
manifold and on to the cylinder counterbalance
valve where it will be directed to the rod end of
ALL selected cylinders. Return oil from the base
16.5
--- Page 14 ---
Tigercat 230B/240B Loader Grapple
8. While holding the R.H. joystick in the
CAUTION ROTATE CLOCKWISE position, check gauge
Use caution when in the cab as a slight pressure reading. If less than set value, turn
touch of the controls can cause relief valve adjusting screw in until set value
sudden rotation of the upper frame and is obtained on gauge.
booms or movement of the stabilizers
IMPORTANT
CAUTION Approach the gauge reading slowly and
deliberately by turning the adjusting screw in
Be aware of other personnel in the area.
a little at a time. The pressure setting must
Operator is responsible for the safe
not exceed the above value.
operation of the machine.
9. Tighten locknut on adjusting screw taking
care not to turn the adjusting screw.
IMPORTANT
10. While holding the R.H. joystick in the
Avoid blowing oil over relief for longer
ROTATE COUNTERCLOCKWISE position,
than five seconds, as this will cause
check gauge pressure reading. If less than
excessive heating of the hydraulic fluid.
set value, turn relief valve adjusting screw in
GRAPPLE ROTATE RELIEF VALVE SETTINGS until set value is obtained on gauge.
Grapple rotate/"Stick" main relief setting:- 11. Tighten locknut on adjusting screw taking
care not to turn the adjusting screw.
S/N 2300501 and up ........................ 2500 psi
S/N 2400501 and up ........................ 2600 psi 12. Release grapple from it's secured position.
Rotate clockwise port relief setting .... 1750 psi reset main relief valve:
Rotate counterclockwise 13. Loosen locknut on "stick" main relief and
port relief setting .................................. 1750 psi unscrew adjusting screw 3 full turns.
1. Position machine on flat level ground with 14. While holding the R.H. joystick in the STICK
stabilizers down. OUT position (fully extended), check gauge