Service Manual: Tigercat T240B Track Loader

SERVICE MANUAL
Tigercat T240B Track Loader

ISSUE 1.0, AUGUST, 2006
TABLE OF CONTENTS
SECTION
INTRODUCTION .............................................................................................................. iii
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
TRACK DRIVE ................................................................................................................ 11
BOOM FUNCTIONS ....................................................................................................... 12
SWING ............................................................................................................................ 15
GRAPPLE ....................................................................................................................... 17
DELIMBER/SLASHER .................................................................................................... 18
240BT-SM00
Tigercat
T240B Available Literature ®
Operator's Manual ....................................... Part No. 29312A
Service Manual (This Manual) .................... Part No. 29313A
Parts Catalog ............................................... Part No. 13044A P.O. Box 544
Paris, Ontario
Canada N3L 3T6
Tel: (519) 442-1000
Fax: (519) 442-1855
Tigercat T240B Track Loader Introduction
ii
Tigercat T240B
Track Loader Introduction
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 T240B Track Loader.
Serial Number 240T0271 and up.
The operator's manual will assist the operator with the techniques of proper and safe operation of the
T240B Track Loader. There is also important information regarding the safe operation of the saw head.
The service manual contains safety and servicing procedures and a preventive maintenance schedule to
ensure optimum machine performance.
Section 1 in both the operator's manual and the service manual contains safety information that must be
followed. As well, throughout the rest of the manuals, WARNING and CAUTION notices are displayed
where necessary, drawing attention to possible hazards when performing certain procedures.
Only trained personnel should be allowed to operate or work on the machine.
The information contained in this manual is current at time of printing. Improvements to the machine are
on-going and may not be covered, therefore in these cases contact your Tigercat dealer for the
appropriate information.
The phrase “and up” appearing in this manual after the serial number implies that the related information
is current for any machine serial number HIGHER than the serial number preceding the “and up”.
Tigercat reserves the right to make changes to the machine after this manual release date that may not
immediately appear in this manual.
Every effort is made to send out updates on a regular basis. If the machine in question was built after the
release date of this manual and there is a discrepancy, call Tigercat service department. The release date
appears on the first page.
The Company reserves the right to change information contained herein at any time without prior notice.
Tigercat Industries Inc.
iii
Tigercat T240B Track Loader Introduction
NON-APPROVED FIELD PRODUCT CHANGES
The installation of any unauthorized attachment or changes made of any kind to this Tigercat product
could affect the product's ability to perform as originally intended. The product's integrity, stability and
safety could be at serious risk.
IT IS Tigercat POLICY THAT NO CHANGES ARE TO BE MADE TO ITS PRODUCTS INCLUDING
DELETIONS OR ADDITIONS OTHER THAN A Tigercat APPROVED OPTION FITTED IN THE
FACTORY APPROVED MANNER.
Official approval to make changes or install options is only as follows:
i) The relevant options for that product must be shown or listed on current Tigercat documentation or
literature such as a printed specification sheet, price list, parts manual, or product literature issued by
Tigercat .
ii) Approved options or product changes authorized in writing by the Tigercat Engineering Manager.
Authorization by any other person is unacceptable.
Unauthorized changes made or contributed to by a person or organization may result in creating a
dangerous situation and therefore the person or organization will be considered to have assumed the risk
involved or be negligent in creating this situation.
Weight is an important factor when considering the addition of options or an attachment, Refer to your
Tigercat distributor for information on maximum permissible operating weight and the effect the addition
of various options may have on your machine.
Tigercat will not be held responsible for any situation that may arise resulting from Non-approved Field
Product Changes to its product.
Should Tigercat become involved in a suit resulting from changes made to the product without proper
authorization by Tigercat as stated above, Tigercat will take whatever action is appropriate to protect its
interests.
The product warranty policy and the certification on any safety items installed on the modified product will
become NULL and VOID if the above policy is not adhered to as specified.
Non-approved product changes also nullify warranties given to Tigercat by its component manufacturers.
Tigercat Industries Inc.
iv
SECTION 1 - SAFETY
AUGUST, 2006
CONTENTS - SECTION 1
BATTERY DISCONNECT SWITCH ........................................................... 1.6, 1.8

COOLING SYSTEM ........................................................................................... 1.8
EXHAUST FUMES ............................................................................................ 1.9
FIRE PREVENTION ........................................................................................ 1.10
FIRE PREVENTION GUIDELINES .............................................................. 1.10
WHAT ELSE TO DO BEFORE YOU EXPERIENCE A FIRE ......................... 1.11
WHAT TO DO AFTER A FIRE ...................................................................... 1.12
WHAT TO DO IN CASE OF A MACHINE FIRE ............................................. 1.11
FIRST AID ......................................................................................................... 1.4
FLUID LEAKS .................................................................................................... 1.8
LOOSE CLOTHING HAZARD ............................................................................ 1.9
PROTECTIVE CLOTHING ................................................................................. 1.3
SAFETY PRECAUTIONS, OPERATING ........................................................... 1.5
SAFETY PRECAUTIONS, SERVICING ............................................................. 1.7
SAFETY SYMBOLS .......................................................................................... 1.2
SIGNAL WORDS ............................................................................................... 1.2
Tigercat T240B Track Loader Safety
SAFETY SYMBOLS
This safety alert symbol means ATTENTION!

BECOME ALERT! YOUR SAFETY IS INVOLVED!
The safety alert symbol identifies important safety
messages on machines, safety signs, in manuals, or
elsewhere. When you see this symbol, be alert to the
possibility of personal injury or death. Follow the
instructions in the safety message.
Understanding Signal Words
DANGER
DANGER identifies the most serious hazards where

failure to follow listed procedures would result in a
high probability of death or serious injury.
WARNING
WARNING denotes a hazard exists which can result

in serious injury or death if proper precautions are not
taken.
CAUTION
CAUTION is used in areas where failure to follow

listed procedures may cause personal injury,
component damage or subsequent malfunction.
IMPORTANT
IMPORTANT is used to focus attention on items

that should be checked, controlled, adjusted or
cleaned to ensure the efficiency and long term
operation of the machine.
1.2
and adhere to. More specific measures are illustrated
GENERAL with pictograms which may also be attached to the
SAFETY PRECAUTIONS machine in locations pertinent to their respective
message. Keep safety labels in good condition.
Remember that safety is a prime responsibility of all. Repair or replace damaged labels.
To minimize the risks and promote safety at all
times, this section of the operator’s manual details a KEEP CLEAR
number of safety rules which should always be
followed and obeyed. When approaching an operating machine on foot,
stay at least 300 feet (90M) away from the machine
Study all the safety messages in this manual and on
and all related attachments including the grapple,
the labels on the machine carefully.
delimber, topping saw and ground saws until the
Follow all instructions from safety inspector and operator recognizes your presence. Make sure that
supervisors. all equipment is shut down with grapple resting
securely on stable ground before advancing to the
machine.
Always avoid the discharge path of all saws.
Operators of this equipment must be fully trained by

Wear a suitable hearing protective device such as
a qualified person in safety and operating procedures.
earmuffs or earplugs to protect against noise.
The operator must be fully aware of the capabilities
Prolonged exposure to loud noise can cause
and limitations of the equipment and must at no time
impairment or loss of hearing.
exceed them. The machine is to be used only for its
intended purpose. Learn the most efficient operating
techniques.
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
Use recommended protective clothing and safety or leaving the cab.
devices such as gloves, safety boots, safety hat,
When mounting or dismounting the machine always
goggles, and ear protection when necessary.
use the 3 point technique - Use one hand with 2 feet
Fellow workers and other bystanders around the or 2 hands with one foot.
machine must also be provided with the appropriate
safety devices mentioned above.
These safety rules highlight both general and specific
measures that the operator should be familiar with
1.3
When moving the machine, ensure that adequate
GENERAL SAFETY PRECAUTIONS clearance is available on both sides and above the
continued machine or any of its attachments. Extra clearance
may be required particularly where the ground is
uneven.
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
If this is not possible clean up or cover slippery
(10mm) for each addition 1,000 volts above the
surfaces with a non-slip material.
50,000 volt level. If State/Provincial, local or job site
Machines should be completely cleaned of debris at regulations require even greater safety distances
least daily, particularly around the engine exhaust than stated above, adhere strictly to these regulations
components. Hydraulic oil leaks, excess grease, for your own protection.
fuel and oil accumulation (including spillage) should
When the machine is transported, make sure that it
be eliminated immediately. Machine should be
is adequately secured to the transporting vehicle.
washed completely at every major service.
Comply with instructions in this manual and also your
company’s regulations for the operation of this
machine.
Read, understand and follow all general safety
precautions specified by grapple, delimber and saw
manufacturers.
Keep a first aid kit in an easily accessible location on WARNING

the vehicle at all times. Engine exhaust, some of its constituents, and
Do not operate the equipment with anyone in the cab, certain vehicle components contain or emit
on platforms, or anywhere else within 300 feet the chemicals known to the State of California to
machine or related equipment. The machine is cause cancer and birth defects or other
provided and approved with seating for the operator reproductive harm.
only.
Do not allow anyone to operate the machine who may
not be physically fit or who may be under the WARNING
influence of alcohol or drugs. Battery posts, terminals and related accessories
Inspect the machine daily for signs of damage, contain lead and lead compounds. Wash hands
unusual wear, fluid leaks, or faulty operation. Repair after handling.
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
Prior to commencing work, check all equipment
OPERATING controls to ensure that the machine responds
SAFETY PRECAUTIONS correctly.
Ensure that the windshield guard is installed and
properly secured.
Keep the cab door closed when operating the machine

Shut off engine when refuelling - DO NOT refuel the to prevent accidental entry of branches and debris
engine while smoking or when near open flame or into the cab.
sparks.
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 Always rest the grapple on solid ground or trailer
properly and secured. when not operating, regardless if the engine is
running or shut off.
When the engine is running, DO NOT allow anyone
in areas of the machine where they may be injured or
crushed by moving components.
Maintain a safe operating distance between the
machine and other personnel. Never swing the boom
with or without trees, over the heads of bystanders.
Make sure that all of the controls are positioned as Use only prearranged and approved signalling
specified in the starting instructions in the operator's practices.
manual.
Operate the machine only from a seated position in
Check that no other personnel have moved into a the operator’s seat.
hazardous area before starting the machine.
Sound the machine horn before starting the machine.
WARNING
For engine starting and stopping procedures refer

to STARTING ENGINE and STOPPING ENGINE
in SECTION 2 of the THIS MANUAL. For correct
engine speeds, refer to THROTTLE CONTROL in
SECTION 2 of the THIS MANUAL.
Never use a liquid starting aid to start an engine
with a pre-heat device.
1.5
Before transporting the machine:
OPERATING SAFETY PRECAUTIONS
continued • Secure the grapple to the trailer and raise the
stabilizers.
Do not allow other people either in the cab or
anywhere else on the machine. • Shut down the engine and turn the master
disconnect switch off.
• Check to ensure that all doors, panels and access
covers are installed and properly secured.
WARNING
Always lower the boom to the ground and shut
down the engine before leaving the cab.
Before leaving operator's cab, lower the grapple onto

solid ground or the trailer.
WARNING
When leaving the operator's cab for an extended
period shut the engine off. Safe mounting of this loader onto a trailer or
truck is the responsibility of the owner.
Never work alone. Regularly inform other crew
members of your intentions, location and length of
time to perform duties. WARNING
An unstable loader can cause serious injury or
death or equipment damage. Do not operate
the loader without lowering the stabilizers onto
firm ground and with the loader level.
DANGER
A moving stabilizer can cause serious injury
240B-003 BATTERY DISCONNECT SWITCH
or death. Before lowering the stabilizers make
Turn the battery disconnect switch off if the vehicle sure the area is clear of personnel.
is to be idle for an extended period of time (Example
- overnight).
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
Do not allow the driver to remain in the truck
cab during loading operations and do not
move loads over the top of the truck cab.
Serious injury or death or property damage
may result.
1.6
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
Conduct maintenance inspections at least as

•
frequently as recommended in section 3 of the L.H. ARM REST IN
operator's manual. DOWN POSITION AND
LIMIT SWITCH ON
When servicing or repairing equipment, shut the
engine down. Turn Master Disconnect switch OFF. 1
LIMIT SWITCH
Install a “DO NOT START ENGINE” sign on the ACTUATING LEVER
ON SEAT BASE
operator’s cab door when making repairs to the
machine. ••
•
247-25 PILOT SYSTEM SHUT OFF
To operate:
With the engine running and the left arm rest
DOWN, push the pilot reset switch.
Before performing maintenance or repair work on any Once the safety interlock system has been
equipment, consult the manufacturer’s instruction activated, the safety of both the operator and
manual and follow recommended procedures. all persons outside the cab becomes the
responsibility of the operator.
The radiator and the engine cooling system should be
inspected daily and cleaned as necessary to maintain The left arm rest safety interlock switch (pilot
moderate engine temperatures. system shut off limit switch) and the pilot
reset switch are a safety feature and their
function must not be defeated in any way.
WARNING
WARNING, HOT FLUIDS AND HOT MACHINE

SURFACES CAN CAUSE SERIOUS BURNS!
• Before servicing the machine, allow the

engine cooling system, fuel system,
exhaust system, hydraulic system and
machine surfaces to cool down.
• Use a thermometer to check surface and
system temperatures to ensure it is safe to
begin service work.
• DO NOT begin service work until the
surface or system temperature has cooled
down to below 100°F (38°C)!
1.7
SERVICING SAFETY PRECAUTIONS

continued WARNING
Diesel fuel or hydraulic fluid under pressure
Prior to welding on any part of the machine, it can penetrate the skin and cause serious
should be cleaned and a fire extinguisher should personal injury, blindness, or death. If any
be made available at the welding location. Care fluid is injected into the skin, it must be
must be taken in attaching the welding machine surgically removed within a few hours by a
grounding clamp so current does not pass through doctor familiar with treating this type of injury.
pins and bearings, especially the swing bearing.
Turn the battery disconnect switch off. Also,
Disconnect the engine CPU (Central Processing
Unit) by unplugging the two multi-pin connectors
from the left side of the engine.
• •• Never use your bare hand to check for fluid leaks.

Fluid leaks under pressure may not be visible. When
searching for leaks, wear work gloves and use a
wrench or piece of wood to move hydraulic hoses.
Do not grab hold of hydraulic hoses. Wear safety
goggles for eye protection.
DISCONNECT THE
TWO MULTI-PIN
PLUGS FROM THE
ENGINE CPU
240T-021
Explosive release of fluids from the pressurized

cooling system can cause serious burns.
Shut off engine. Only remove engine radiator filler
cap when cool enough to touch with bare hands.
Slowly loosen cap to first stop to relieve pressure
before removing completely.
Do not change any pressure or relief setting unless
authorized instruction has been obtained.
Use the proper tool for the job. Repair or replace worn
or damaged tools including lifting equipment
immediately.
1.8
SERVICING SAFETY PRECAUTIONS

continued
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.
Keep your hands, feet, head, and loose clothing
away from power driven parts. Tie long hair behind Before draining any fluids, know the proper way to
your head. Remove rings and other jewellery to dispose of them.
prevent electrical shorts and entanglement in moving
parts.
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.
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.
1.9
5. Remove debris and blow out dust
regularly from the air intake doors, engine
FIRE PREVENTION radiator, hydraulic oil cooler and A/C
condenser core to prevent overheating of the
engine and hydraulics. Refer to CLEANING
A/C CONDENSER, OIL COOLER AND
RADIATOR in SECTION 2 of the
OPERATOR’S MANUAL.
6. Blow off all debris and dust accumulated
near hot engine exhaust components
(turbocharger and exhaust manifold as well as
When working in a forest environment, it is exhaust pipes and muffler) at the completion
impossible to prevent combustible debris from of each work shift or more frequently
collecting in tight corners of the machine. This depending on logging conditions. Visual
debris, in itself, may cause a fire; however, when inspection after blow off to ensure thorough
mixed with fuel, oil or grease in a hot or confined cleanliness is vital. Engine exhaust systems
place, the danger of fire is greatly increased. provide numerous small pockets where saw
dust, small wood chips and other flammable
The following fire prevention guidelines should be
forest debris can gather. Even small
used to supplement the operator’s fire prevention
accumulations close to hot exhaust
efforts. In no case should the guidelines be used,
components can ignite and smolder. If
or assumed, as replacements for diligent operator
dislodged by vibration this smoldering debris
efforts at preventing fires.
can fall into other areas of the machine and
The following guidelines will help to keep your thereby spread a fire.
equipment up and running efficiently and keep the
7. Clean out all accumulated forest debris
risk of fire damage to a minimum.
(twigs, pine needles, branches, bark, leaves,
1. Maintain a CHARGED fire extinguisher on saw dust, small wood chips) and any other
the machine at all times and KNOW HOW TO combustible materials from inside the
USE IT. machine belly pans or lower machine
structures as well as from areas in proximity
2. Inspect the machine for any signs of fuel or
to the engine, fuel and hydraulic oil systems
hydraulic system leakage and check for worn
no less frequently than at the completion of
or eroded fuel or hydraulic lines before starting
each work shift.
up any equipment.
8. AFTER transporting (trucking) a machine
3. Inspect the EXHAUST SYSTEM DAILY for
from one job sight to the next, open all doors
any signs of LEAKAGE. Check for worn,
and access panels and blow off any debris
cracked, broken, or damaged pipes or muffler.
that may have repositioned itself onto the
Also check for missing or damaged bolts or
engine and exhaust parts due to wind
clamps. Should any exhaust leaks or defective
turbulence caused by the journey.
parts be found, repairs must be made
immediately. Engine exhaust leaks can cause 9. Clean up any grease, diesel fuel, hydraulic
fires, DO NOT OPERATE the machine until and lubricating oil accumulation and
the exhaust leak is repaired. spillage immediately.
4. During daily operation of the machine, the 10. Steam clean the engine, fuel and hydraulic
occurrence of exhaust leaks are usually tank compartments of all equipment at least
accompanied by a change or increase in once a month or more frequently depending
engine exhaust noise levels. These audible on logging conditions.
warnings cannot be ignored. Should any
11. Be cautious when smoking. An open
exhaust leaks occur during operation, the
flame, a lighted cigarette, etc., should not be
machine must be shut down immediately
permitted around any vehicle, especially
and not put back to work until the necessary
during fuelling operations and/or when the fuel
repairs have been completed.
system is open to the atmosphere, and/or
when servicing batteries.
1.10
• Ensure that any hand held fire extinguishers
FIRE PREVENTION are charged and functional.
continued
• Ensure that any stored water systems on the
12. Shut down equipment immediately when a machine are charged and functional.
problem is suspected or smoke is detected. • Ensure that the nozzle of any hand held
13. Park the machine at least 50 feet away extinguishers available at the work site fits
from other equipment at the end of each within the access holes in the doors of the
shift. machine.
14. Turn the battery disconnect switch to OFF • Ensure that you have the proper fire
at shut down to avoid loss by electrical extinguishers on site. Most fires involving
short. mobile equipment will be of the A or B type.
You should have a dry chemical extinguisher
15. Remain with the machine for at least 45 rated ABC and a pressurized water
minutes at the end of operations while the extinguisher rated A.
machine cools.
• Prevent the fire from happening by ensuring
16. Once a fire has started on a machine hoses that the machine is cleaned regularly and all
will quickly burn through causing pressurized systems are well maintained.
fluids (diesel fuel, hydraulic oil, etc.) to fuel
the fire. NEVER leave the machine parked *NOTE: Dry chemical fire suppression
with booms or arches suspended off the systems are offered by Tigercat as an
ground, as they will inject hydraulic oil into optional installation on some of the Tigercat
the fire if a supporting hose burns through. product lines. Please disregard any
17. Remove all keys, lock equipment and fuel references made to fire suppression systems
cap at the end of operations to reduce the if not installed on your machine.
risk of vandalism. WHAT TO DO IN CASE OF A MACHINE FIRE
18. Before starting repair work, such as • At all times ensure your own personal safety
welding, the surrounding area should be and the safety of anyone that may be in the
cleaned and a fire extinguisher should be area. Approach any fire with extreme
close by. caution.
19. Use only nonflammable solutions for • If the machine is in a dangerous position,
cleaning the machine or components. attempt to move to a safe position. Lower
20. Store rags and other combustible working attachment to the ground.
materials in a safe, fireproof location. • Shut the engine off.
21. Do not use the machine on top of or to push • Activate the fire suppression system *
piles of burning timber. A machine fire will
result. • Radio or call for help (as appropriate).
• Exit the machine taking fire extinguisher or
water hose (if applicable) with you.
EQUIPMENT FIRES ADVERSELY EFFECT
YOUR ABILITY TO LOG, MAY INCREASE YOUR • If you can safely open the access panels to
INSURANCE PREMIUMS DRAMATICALLY OR the machine, in the area of the fire, do so.
PREVENT YOU FROM OBTAINING INSURANCE • If you can safely do so, attempt to extinguish
COVERAGE AT ALL. the fire.
• If you can safely do so, turn OFF battery
WHAT ELSE TO DO BEFORE YOU disconnect switch.
EXPERIENCE A FIRE • A dry chemical fire extinguisher should be
• Ensure that you are familiar with emergency used first, if available.
procedure in the event of a fire.
• Ensure that your fire suppression system is * Continued on page 12
charged and functional.
1.11
• Remain with the machine until help arrives to
FIRE PREVENTION ensure that the fire does not re-ignite.
continued
• Ensure that the machine and all components
have cooled down sufficiently after a fire has
Continued from page 11 occurred. Beware of the possibility of coolant
• Use the PASS method with most or hydraulic hoses rupturing after a fire
extinguishers. spraying hot oil or coolant which may result
• Pull the pin. This will allow you to in severe burns.
discharge the extinguisher.
• Aim at the base of the fire. If you aim at WHAT TO DO AFTER A FIRE
the flames (which is frequently the
• Notify your equipment dealer and or Tigercat
temptation), the extinguishing agent will fly
Industries Inc. by completing an incident
right through and do no good. You want to
report, Tigercat form number 5101.
hit the fuel.
• Ensure that the cause of the fire is
• Squeeze the top handle or lever. This
determined and all appropriate repairs are
depresses a button that releases the
completed before returning the machine to
pressurized extinguishing agent in the
work.
extinguisher.
• Sweep from side to side until the fire is • *
Ensure that the fire suppression system is
completely out. Once the fire is out, keep properly serviced and returned to a functional
an eye on the area in case it re-ignites. state (if applicable).
• Ensure that all extinguishers used in fighting
the fire are replaced or recharged as
appropriate.
*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.
TYPICAL FIRE EXTINGUISHER

20229A ACCESS HOLE
• Place the nozzle of the fire extinguisher into
the appropriate fire extinguisher access hole
and discharge the extinguisher.
• Failing all attempts to access the machine
compartment, attempt to discharge the
extinguisher through the mesh or any
available openings on the machine.
• Use the pressurized water hose supplied with
the machine (if applicable) or a pressurized
water extinguisher (if available) after the
discharge of a dry chemical extinguisher or
suppression system* to remove heat build up
from the area. A fire suppressed by a dry
chemical powder may re-ignite with the latent
heat of any debris in the area.
1.12
SECTION 3 - LUBRICATION & MAINTENANCE
AUGUST, 2006
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
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 SETTINGS FOR T240B LOADER ON TRACKS ...................... 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 250 HOURS ................................................................................... 3.5
EVERY 500 HOURS: .................................................................................. 3.5
EVERY 8 HOURS: ...................................................................................... 3.4
GENERAL ................................................................................................... 3.3
TORQUE, FLUID CONNECTIONS .................................................... 3.14, 3.16
TORQUE SETTINGS, RECOMMENDED ..................................................... 3.11
TORQUE SPECIFICATIONS - GENERAL ................................................... 3.13
Tigercat T240B Track Loader Lubrication and Maintenance
PREVENTIVE MAINTENANCE SCHEDULE FOR

T240B TRACK LOADER
NEW MACHINE MAINTENANCE
*INITIAL PRE-DELIVERY INSPECTION:-

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

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

THIS REPORT MUST BE COMPLETED AND RETURNED TO
Tigercat Industries Inc. WARRANTY DEPARTMENT.
Tightening points:~ NOTE: Use of filters other than genuine Tigercat

Check torque on swing bearing replacement filters is not recommended.
retaining bolts
Engine mounting bolts
Pump drive gearbox mounting bolts Refer to diesel engine service manual and
attachment manual for additional required
Pilot pump mounting bolts
maintenance at this scheduled time period.
Swing gearbox mounting bolts
Swing motor mounting bolts
Cab securing bolts
Boom pin nuts IMPORTANT
Track shoe bolts Before driving machine ensure that the track
Track roller retaining bolts tension (sag) is set correctly.
Track sprocket retaining bolts Track sag may be set less than specified for
shipping purposes.
Track drive gearbox mounting bolts
Track drive motor mounting bolts
OIL LOST FROM LEAKAGE
All hydraulic connections LOST 0IL (GALLONS)
Hose clamps PER PER PER
LEAKAGE RATE DAY MONTH YEAR
Pin retainers ONE DROP IN 10 SECONDS 0.112 3.36 40.0
ONE DROP IN 5 SECONDS 0.225 6.75 81.0
Any other loose nut, bolt or fitting ONE DROP SECOND 1.125 33.75 405.0
THREE DROP PER SECOND 3.75 112.5 1,350.0
DROPS BREAK INTO STREAM 24.00 720.0 8,640.0
3.2
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
WARNING adding fluids
Clean around hydraulic fittings before
breaking connection. Plug or cap
immediately
WARNING, HOT FLUIDS AND HOT MACHINE Clean up spills as soon as possible
SURFACES CAN CAUSE SERIOUS BURNS! Always use clean oil and containers
• Before servicing the machine, allow the Drain dirty oil while still warm
engine cooling system, fuel system, exhaust Do not exceed recommended fluid levels
system, hydraulic system and machine
surfaces to cool down. Service all hydraulic filters after the failure of
a pump, motor, cylinder or valve. Failures of
• Use a thermometer to check surface and this nature could contaminate the entire
system temperatures to ensure it is safe to hydraulic system
begin service work.
Top up diesel fuel at each shift to reduce
• DO NOT begin service work until the contamination by condensation
surface or system temperature has cooled Clean up oil spills on walking surfaces in
down to below 100°F (38°C)! 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
EVERY 8 HOURS:~ EVERY 125 HOURS:~
• Check engine coolant level • Perform 8 hour maintenance
• Check engine oil level And in addition replace:~
• Drain fuel/water separator • Return filters restriction indicator with engine
• Check hydraulic oil level running at high idle and oil flow
• Check swing gearbox oil level • Track drive gearbox oil level with both level
plugs in line with the horizontal plane and
Fill reservoir to halfway mark above center
Lubricate:~ • Fluid level in batteries unless maintenance free
• Swing pinion; • Engine rpm.
1-fitting - 10 shots while swinging
• All hydraulic pressures
• Swing bearing;
1-fitting - 10 shots while swinging • Hydraulic pumps and motor securing bolts
• ‡ Boom joints; • Torque tightening points as per new machine
4-fittings - purge maintenance
• ‡ Cylinders; boom, stick & tilt; Visually check for damage to:~
4-fittings total - purge • Main and stick booms and cylinders
‡ Lubricating cylinder pins and boom joints:- • Tracks, track frames and carbody
1. Ensure machine is on level ground • Swing bearing area
2. Fully extend stick boom cylinder • Attachment
3. Lower main boom and rest grapple firmly Make repairs immediately
on ground or stable trailer
Visually inspect for:~
4. While in this position lubricate all cylinder • Frayed electrical wiring and hydraulic hoses
retaining pins and boom joints
• Wear in any other components
NOTE: This procedure will allow grease
to flow to the normally "loaded" side of Clean/replace:~
the pin/bearing surfaces. • Air conditioner re-circulation filter
Clean:~ • Cab fresh air filter

• Oil cooler, engine radiator and a/c condensor • Refer to diesel engine service manual and
• Remove potentially damaging limbs or sticks attachment manual for additional required
and all debris maintenance at this scheduled time period.
Check:~
• For leakage around hydraulic components and
flexible hoses
• For loose nuts, bolts and fittings
• Condition and tension of fan belts.
• Conduct an overall visual inspection.
• Refer to diesel engine service manual and
Continued on page 5
3.4
Continued from page 4
EVERY 250 HOURS:~ EVERY 1000 HOURS:~
• Perform 8 hour maintenance • Perform 8 hour maintenance
• Perform 125 hour maintenance • Perform 125 hour maintenance
And in addition:~ • Perform 250 hour maintenance
• Replace engine oil and filter • Perform 500 hour maintenance
• Replace engine fuel filter And in addition check:~
• Replace air intake primary element • Fuel intake strainer
• Pump drive gearbox
• Track drive gearboxes
EVERY 2000 HOURS:~
Fill track drive gearbox with both level plugs in
line with the horizontal plane and above center Drain and refill hydraulic oil tank with
recommended hydraulic oil. See APPROVED
HYDRAULIC OILS
EVERY 500 HOURS:~
• Perform 8 hour maintenance
And in addition replace:~
• Air intake safety element
• Hyd. Oil return filters †
• Hyd. Oil pilot pressure filter †
APPROVED HYDRAULIC OILS
• Oil in swing gearbox
Fill reservoir to halfway mark Use only one of the following oils to fill or
replenish the hydraulic system.
Lubricate:~
• Door and cover hinges Chevron Tractor hydraulic fluid (summer)
8 fittings - 1 shot Citgo Tractor hydraulic fluid (33-310)
(summer)
Check:~
• Torque on swing bearing and swing gearbox Imperial Esso hydraul 56 (summer)
retaining bolts Hydraul 50 (low visc) (winter)
• Torque on track drive gearboxes and motor Shell Donax td (summer)
mounting bolts Donax tdl (winter)
• Track rollers and idlers for oil leakage. These Sun Sunfleet th fluid (summer)
components are filled with oil and considered John deere Type j20c (hy-gardtm) (summer)
maintenance free. If oil leakage is detected Type j20d (hy-gardtm) (winter)
repair of component(s) will be necessary.
• Refer to diesel engine service manual and
† NOTE: Use of filters other than genuine Tigercat

replacement filters is not recommended.
3.5
3.6
3.7
DOUBLE FILTER
RETURN FILTER HEADS
MANIFOLD HEAD
•
•• •• •
GASKET
•• • FILTER
ELEMENT
SQUARE SECTION GASKET INSTALLATION

FILTR_SEALS 2
Square Section Gasket

Remove used gasket and clean groove in
head.
Apply clean oil to new gasket surfaces.
358-17HYDRAULIC RETURN FILTERS Install new gasket into groove in filter head.
HYDRAULIC OIL RETURN FILTERS Screw on new filter until gasket makes contact.
Two double filter heads (four 7 micron elements) Tighten filter an additional 3/4 turn.
filter all returning hydraulic oil except pilot, prior to
FILTER
entering the hydraulic reservoir. Each filter head has HEAD
a bypass valve with a 25 psi cracking pressure so •
that oil can bypass the filters if they become
restricted. For service and replacement intervals see •
GASKET
SERVICE AND LUBRICATION CHART in THIS
SECTION. • FILTER
ELEMENT
Changing the filters:
1. Ensure Loader is on level ground with stabilizers FILTR_SEALS 2 'O' RING GASKET INSTALLATION
down. Lower grapple to ground, stop engine, put
parking brake ON.
z 'O' Ring Gasket
Remove used gasket and clean gasket seat in
2. Wipe clean the area around the filter and head. head.
3. Place rags below to catch the spillage of oil. Apply clean oil to new gasket surfaces.
4. Wearing face protection (in case of an oil squirt), Install new gasket on inside lip of filter.
unscrew the old filter. Dispose of old filter and Screw on new filter until gasket makes contact.
any oil properly. Tighten filter until top edge makes metal to
6. The new Tigercat filter is supplied with two metal contact with filter head.
gaskets enclosed, examine the filter head (approximately 1 1/2 additional turns after
closely to determine which gasket should be gasket contact)
used and follow the instructions to ensure 10. Start the engine and check for leaks.
proper installation.
3.8
LOCATED LOWER
LEFT SIDE OF
ENGINE
COMPARTMENT
••
PILOT
FILTER
ELEMENT
205-23A HYDRAULIC PILOT FILTER
PILOT RETURN PRESSURE FILTER

This single full flow filter, is mounted in the output
line between the pilot pump and the pilot manifold.
For service and replacement intervals see
SERVICE AND LUBRICATION CHART in THIS
SECTION.
Changing the filter:
1. Ensure Loader is on level ground. 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 IMPORTANT
contact with the seat in the filter head.
Filters that are an integral part of the
8. Turn filter an additional 1/2 turn by hand to engine (fuel and lubricating oil) should be
tighten. serviced and replaced according to the
9. Start the engine and check for leaks. 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
AIR CONDITIONING - SERVICE
CAUTION
IMPORTANT: It is recommended that during cold
weather when the A/C system is not in use, that it If using compressed air for cleaning filters, use
be run for a period of 5 minutes every two weeks at 30 psi. or less. Always use personal
to circulate oil to all components of the system. protective equipment to guard against flying
PAG OIL A/C CONDENSER CORE

R134a REFRIGERANT
(polyalkylene glycol)
2 LBS. 12 OZ. 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
•
RADIATOR
should be present in the system and must be used
on 'O' rings and fittings during assembly.
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
A/C COMPRESSOR 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
240T-022 A/C COMPRESSOR tension.
b. Check fresh air filter and re-circulating air
filter. Clean or replace as required.
c. Check to see that compressor clutch will
engage.
RECEIVER DRYER d. Check blower operation and air vents.
e. Check the condenser core for dirt and
• debris.
CAUTION
If using water or compressed air for

cleaning, always use personal protective
LOWER FRAME
equipment to guard against flying debris.
••
240T-023 A/C RECEIVER DRYER
3.10
TORQUE CHART
LOCATION THREAD TORQUE (LUBRICATED)
DIAMETER lbf-ft Nm
Cylinders
Piston nut, main boom cylinder 2 1/2"-12 UNF (GC) 3200 4320
Piston nut, stick cylinder 2 1/2"-12 UNF (GC) 3200 4320
Piston nut, heel cylinder 2 1/4"-12 UNF (GC) 2100 2835
Piston nut, grapple cylinder 1 3/4"-12 UNF (GC) 1750 2355
Gland, grapple cylinder 4 1/2" I/D CYLINDER 450 607
Keeper plate bolts, heel cylinder 3/4"-10 UNC (G8) 275-325 370-440
Keeper plate bolts, Main boom cylinder 7/8"-14 UNF (G8) 300-325 405-440
Keeper plate bolts, Stick boom cylinder 3/4"-16 UNF (G8) 240-270 323-363
Boom joint and cylinder pin retaining bolts 3/4"-10 UNC (G8) 282-310 393-420
Main and Stick boom pin retaining nut 2"-12 UNF (G8) 400 540
Heel to Stick boom pin retaining nut 1 3/4"-12 UNF (G8) 400 540
Cab securing bolts 7/8"-9 UNC (G8) 450-500 610-680
Swing bearing bolts 7/8"-9 UNC (G8) 400-450 540-610

Swing gearbox mounting bolts 5/8"-11 UNC (G8) 160-175 215-235
Swing motor mounting bolts M14-2 (10.9) 130 175
Engine mounting
Bolts, bracket/mount to chassis 7/8"-9 UNC (G8) 450-500 610-680
Bolts, bracket to engine M12-1.75 (10.9) 75 100
Engine cooling fan mounting bolts M10-1.5 (12.9) 40 54
Pump drive
Drive plate to flywheel 3/8"-16 UNC (G8) 40 54
Bell housing to engine M10-1.5 (10.5) 45 60
Undercarriage
Track shoe bolts 3/4 UNF T/T* T/T*
Idler bolts M16-2 (10.9) 175 235
Roller mounting bolts 7/8"-9 UNC (G8) 450 610
Sprocket bolts M20-2.5 (10.9) 380 515
Gearbox mounting bolts 3/4"-10UNC (G8) 310 417
Drive motor mounting bolts M12-1.75 (10.9) 80 110
*T/T represents Torque-Turn, this is a method of torquing the track shoe bolts. Refer to SECTION 11 in
the Tigercat SERVICE MANUAL for a complete description on this method of applying torque.
Torque values pertaining to the engine and attachment are provided in the appropriate manuals.
3.11
GENERAL TORQUE SPECIFICATIONS
The torque values listed below are for general use only.
IMPERIAL DO NOT use these values if a different torque value or
tightening procedure is shown for a specific application.
GRADE 8 BOLTS GRADE 5 BOLTS

IMPERIAL BOLT TORQUE SPECIFICATIONS
GRADE 8 BOLTS GRADE 5 BOLTS
COARSE DRY LUBRICATED COARSE DRY LUBRICATED
THREAD lbf-ft Nm lbf-ft Nm THREAD lbf-ft Nm lbf-ft Nm
1/4" - 20 11 - 12 15 - 16 8 - 10 11 - 13 1/4" - 20 7- 8 10 - 11 8 - 10 11 - 13
5/16" - 18 26 - 30 35 - 40 20 - 28 27 - 38 5/16" - 18 14 - 18 19 - 24 10 - 15 13 - 20
3/8" - 16 44 -48 60 - 65 33 - 36 45 - 49 3/8" - 16 31 - 34 42 - 46 23 - 25 31 - 34
7/16" - 14 70 - 77 95 - 104 52 - 57 71 - 77 7/16" - 14 49 - 54 66 - 73 37 - 41 50 - 55
1/2" - 13 106 - 117 144 - 158 80 - 88 109 - 119 1/2" - 13 75 - 83 102 - 112 57 - 63 77 - 85
9/16" - 12 153 - 168 208 - 228 115 - 127 156 - 172 9/16" - 12 109 - 120 148 - 162 82 - 90 111 - 122
5/8" - 11 212 - 233 288 - 316 159 - 175 216 - 237 5/8" - 11 150 - 165 204 - 223 113 - 124 152 - 168
3/4" - 10 376 - 414 510 - 561 282 - 310 393 - 420 3/4" - 10 266 - 293 360 - 397 200 - 220 271 - 298
7/8" - 9 606 - 667 822 - 904 455 - 501 617 - 679 7/8" - 9 394 - 433 535 - 586 296 - 326 402 - 441
1" - 8 909 - 1000 1233 - 1355 682 - 750 925 - 1016 1" - 8 591 - 649 802 - 879 443 - 489 601 - 663
1 1/8" - 7 1288 - 1417 1746 - 1921 966 - 1062 1310 - 1441 1 1/8" - 7 794 - 873 1077 - 1183 596 - 656 808 - 889
1 1/4" - 7 1817 - 1999 2464 - 2710 1360 - 1496 1844 - 2027 1 1/4" - 7 1120 - 1232 1519 - 1670 840 - 924 1139 - 1252
FINE DRY LUBRICATED FINE DRY LUBRICATED
THREAD lbf-ft Nm lbf-ft Nm THREAD lbf-ft Nm lbf-ft Nm
1/4" - 28 13 - 14 18 - 19 10 - 13 14 - 17 1/4" - 28 9 - 10 12 - 13 9 - 10 12 - 13
5/16" - 24 23 - 28 31 - 38 18 - 25 25 - 33 5/16" - 24 17 - 22 23 - 29 16 - 20 21 - 27
3/8" - 24 49 - 54 67 - 73 37 - 41 50 - 55 3/8" - 24 35 - 39 48 - 53 26 - 29 35 - 39
7/16" - 20 78 - 86 106 - 116 58 - 64 79 - 86 7/16" - 20 55 - 61 75 - 83 41 - 45 56 - 61
1/2" - 20 120 - 132 163 - 179 90 - 99 122 - 134 1/2" - 20 85 - 94 116 - 127 64 - 70 87 - 95
9/16" - 18 171 - 188 232 - 255 128 - 141 174 - 191 9/16" - 18 121 - 133 164 - 180 91 - 100 124 - 135
5/8" - 18 240 - 264 326 - 358 180 - 198 244 - 268 5/8" - 18 170 - 187 231 - 253 128 - 141 174 - 191
3/4" - 16 420 - 462 570 - 626 315 - 347 427 - 470 3/4" - 16 297 - 327 403 - 443 223 - 245 303 - 332
7/8" - 14 668 - 735 906 - 996 501 - 550 679 - 745 7/8" - 14 434 - 477 589 - 646 326 - 359 442 - 486
1" - 14 995 - 1096 1359 - 1486 746 - 821 1012 - 1113 1" - 14 646 - 711 876 - 965 484 - 534 657 - 724
1 1/8" - 12 1445 - 1590 1960 - 2155 1083 - 1191 1469 - 1613 1 1/8" - 12 891 - 980 1208 - 1328 668 - 735 906 - 996
1 1/4" - 12 2012 - 2213 2728 - 2997 1509 - 1660 2046 - 2250 1 1/4" - 12 1240 - 1364 1682 - 1849 931 - 1024 1262 - 1387
METRIC
METRIC BOLT TORQUE SPECIFICATIONS

CLASS 4.8 CLASS 8.8 OR 9.9 CLASS 10.9 CLASS 12.9
SIZE LUBRICATED DRY LUBRICATED DRY LUBRICATED DRY LUBRICATED DRY
Nm lbf-ft Nm lbf-ft Nm lbf-ft Nm lbf-ft Nm lbf-ft Nm lbf-ft Nm lbf-ft Nm lbf-ft
M6 4.8 3.5 6.0 4.5 9.0 6.5 11.0 8.5 13.0 9.5 17.0 12.0 15.0 11.5 19.0 14.5
M8 12.0 8.5 15.0 11.0 22.0 16.0 28.0 20.0 32.0 24.0 40.0 30.0 37.0 28.0 47.0 35.0
M10 23.0 17.0 29.0 21.0 43.0 32.0 55.0 40.0 63.0 47.0 80.0 60.0 75.0 55.0 95.0 70.0
M12 40.0 29.0 50.0 37.0 75.0 55.0 95.0 70.0 110.0 80.0 140.0 105.0 130.0 95.0 165.0 120.0
M14 63.0 47.0 80.0 60.0 120.0 88.0 150.0 110.0 175.0 130.0 225.0 165.0 205.0 150.0 260.0 190.0
M16 100.0 73.0 125.0 92.0 190.0 140.0 240.0 175.0 275.0 200.0 350.0 225.0 320.0 240.0 400.0 300.0
M18 135.0 100.0 175.0 125.0 260.0 195.0 330.0 250.0 375.0 275.0 475.0 350.0 440.0 325.0 560.0 410.0
M20 190.0 140.0 240.0 180.0 375.0 275.0 475.0 350.0 530.0 400.0 675.0 500.0 625.0 460.0 800.0 580.0
M22 260.0 190.0 330.0 250.0 510.0 375.0 650.0 475.0 725.0 540.0 925.0 675.0 850.0 625.0 1,075.0 800.0
M24 330.0 250.0 425.0 310.0 650.0 475.0 825.0 600.0 925.0 675.0 1,150.0 850.0 1,075.0 800.0 1,350.0 1,000.0
M27 490.0 360.0 625.0 450.0 950.0 700.0 1,200.0 875.0 1,350.0 1,000.0 1,700.0 1,250.0 1,600.0 1,150.0 2,000.0 1,500.0
M30 675.0 490.0 850.0 625.0 1,300.0 950.0 1,650.0 1,200.0 1,850.0 1,350.0 2,300.0 1,700.0 2,150.0 1,600.0 2,700.0 2,000.0
M33 900.0 675.0 1,150.0 850.0 1,750.0 1,300.0 2,200.0 1,650.0 2,500.0 1,850.0 3,150.0 2,350.0 2,900.0 2,150.0 3,700.0 2,750.0
M36 1,150.0 850.0 1,450.0 1,075.0 2,250.0 1,650.0 2,850.0 2,100.0 3,200.0 2,350.0 4,050.0 3,000.0 3,750.0 2,750.0 4,750.0 3,500.0
TORQUECHARTGENERAL.XLS
3.12
PRESSURE SETTINGS FOR T240B LOADER ON TRACKS
LOCATION PRESSURE IMPORTANT

1. System to be at operating temperature
Pilot relief valve 450 when setting pressures.
2. All pressures measured in psi.
3. All main and port relief valves to be set at
Main relief stick valve 3000
full engine rpm.
Port relief L. H. track forward Turn In
4. Swing motor crossline relief valves to be set
Port relief L. H. track reverse Turn In
at engine idle and;
Port relief stick out 3500 Using the following procedure:
Port relief stick in 1500 a.Install swing locking device or secure
Port relief grapple saw cut(if equipped) 3500 boom to keep the machine from swinging.
Port relief slasher cut 2500 b.Disconnect and cap the pilot hose running
to the swing motor crossline relief valves.
Main relief hoist valve 3000 c. At idle adjust both swing motor crossline
Port relief grapple open 3500 relief valves to the value given on the
Port relief grapple close 3500 chart.
d.Reconnect the pilot hose and purge the
Port relief hoist up 3500 air out of the lines.
Port relief hoist down 1500 5. Track drive begin of regulation valves to be
Port relief R. H. track forward Turn In set at full engine RPM using the folowing
Port relief R. H. track reverse Turn In procedure:
a. Lower track drive main relief valves to
Main relief swing valve 2500 2500 psi.
Port relief swing ccw 3000
Port relief swing cw 3000 b. Disconnect and plug both motor brake
release lines.
Port relief grapple rotate ccw 1750
Port relief grapple rotate cw 1750 c. Operate track in high speed (track
should not move).
Port relief slasher cut 3000
Port relief slasher retract 1500 d. Adjust begin of regulation valve on each
motor to give pressure between 800-
Crossline reliefs swing motor 2000 1000 psi at motor test port.
SEE NOTE (4)
e. Reset main relief valves and reconnect
Tilt Cab Valve 2000 brake lines.
Tilt Cab C.B. Valve 3000 6. Track drive speeds set at max. RPM to
16.5 rpm LOW and 28 rpm HIGH.
Drive Brake Release Pressure 500
Drive Begin of Regulation 2500 TILT CAB
1. Turn C.B. valve out fully then in 2 turns to
5334B-R1.03-28-06 achieve desired pressure. Valve is pre-set
at 2000 psi.
NOTE:
The above values are for reference purposes only,
SEE SERVICE MANUAL FOR SETTING PROCEDURE
3.13
Par
arkker Assemb
Assemblly Tor que
orque
3.14
Par
arkker Assemb
Assemblly Tor que
orque
JIC 37 Degree Flare NPTF
Tube Connection Swivel or Hose Tube Connection Swivel or Hose
SAE Dash Size Thread Size FFWR Connection FFWR SAE Dash Size Thread Size TFFT Connection TFFT
-2 5/16-24 NA NA -2 1/8-27 2-3 2-3
-3 3/8-24 NA NA -3 NA NA NA
-4 7/16-20 2 2 -4 1/4-18 2-3 2-3
-5 1/2-20 2 2 -5 NA NA NA
-6 9/16-18 1 1/2 1 1/4 -6 3/8-18 2-3 2-3
-8 3/4-16 1 1/2 1 -8 1/2-14 2-3 2-3
-10 7/8-14 1 1/2 1 -10 7/8-14 NA NA
-12 1 1/16-12 1 1/4 1 -12 3/4-14 2-3 2-3
-14 1 3/16-12 1 1 -14 NA NA NA
-16 1 5/16-12 1 1 -16 1-11 1/2 1.5-2.5 1.5-2.5
-20 1 5/8-12 1 1 -20 1 1/4-11 1/2 1.5-2.5 1.5-2.5
-24 1 7/8-12 1 1 -24 1 1/2-11 1/2 1.5-2.5 1.5-2.5
-32 2 1/2-12 1 1 -32 2-11 1/2 1.5-2.5 1.5-2.5
-40 3-12 1 1 -40 NA NA NA
F.F.W.R : Flats From Wrench Resistance T.F.F.T. : Turns from finger tight
All values are for Steel, Stainless Steel and Brass All pipe values are for Steel, Stainless Steel and Brass
O'ring Face Seal / Seal-Lok BSPT

Tube Connection Swivel or Hose Tube Connection Swivel or Hose
SAE Dash Size Thread Size FFWR Connection FFWR SAE Dash Size Thread Size TFFT Connection TFFT
-2 NA NA NA -2 1/8-28 2-3 2-3
-3 NA NA NA -3 NA NA NA
-4 9/16-18 1/4 TO 1/2 1/2 TO 3/4 -4 1/4-19 2-3 2-3
-6 11/16-16 1/4 TO 1/2 1/2 TO 3/4 -6 3/8-19 2-3 2-3
-8 13/16-16 1/4 TO 1/2 1/2 TO 3/4 -8 1/2-14 2-3 2-3
-10 1-14 1/4 TO 1/2 1/2 TO 3/4 -10 NA NA NA
-12 1 3/16-12 1/4 TO 1/2 1/3 TO 1/2 -12 3/4-14 2-3 2-3
-16 1 7/16-12 1/4 TO 1/2 1/3 TO 1/2 -16 1-11 1.5-2.5 1.5-2.5
-20 1 11/16-12 1/4 TO 1/2 1/3 TO 1/2 -20 1 1/4-11 1.5-2.5 1.5-2.5
-24 2-12 1/4 TO 1/2 1/3 TO 1/2 -24 1 1/2-11 1.5-2.5 1.5-2.5
-32 NA NA NA -32 2-11 1.5-2.5 1.5-2.5
F.F.W.R : Flats From Wrench Resistance T.F.F.T. : Turns from finger tight
All values are for Steel, Stainless Steel and Brass All pipe values are for Steel, Stainless Steel and Brass
3.15
EATON Aeroquip Assemb
Assemblly Tor que
orque
Recommended Eaton recommends that a The values listed are for
Parallel Torque wrench be used to steel connections. Contact
Connection assure proper fitting Eaton Aeroquip for torques values for
Assembly torque assembly of these other materials
connections.
Straight Thread O-Ring Straight Thread O-Ring

Boss Low Pressure with Boss High Pressure
37º (SAEJ514) with ORS (J1453)
Jam Nut or Jam Nut or Jam Nut or Jam Nut or
Thread Straight Straight Thread Straight Straight
Dash Size Fitting Torque Fitting Torque Dash Size Fitting Torque Fitting Torque
Size (inches) lb.-ft. Newton Meters Size (inches) lb.-ft. Newton Meters
-03 3/8-24 8-9 12-13 -03 3/8-24 8-10 11-16
-04 7/16-20 13-15 18-20 -04 7/16-20 14-16 20-22
-05 1/2-20 14-15 19-21 -05 1/2-20 18-20 24-27
-06 9/16-18 23-24 32-33 -06 9/16-18 24-26 33-35
-08 3/4-16 40-43 55-57 -08 3/4-16 50-60 68-78
-10 7/8-14 43-48 59-64 -10 7/8-14 72-80 98-110
-12 1 1/16-12 68-75 93-101 -12 1 1/16-12 125-135 170-183
-14 1 3/16-12 83-90 113-122 -14 1 3/16-12 160-180 215-245
-16 1 5/16-12 112-123 152-166 -16 1 5/16-12 200-220 270-300
-20 1 5/8-12 146-161 198-218 -20 1 5/8-12 210-280 285-380
-24 1 7/8-12 154-170 209-230 -24 1 7/8-12 270-360 370-490
-32 2 1/2-12 218-240 296-325
ORS SAE 37º (JIC)

Swivel Swivel
Swivel Swivel Thread Nut Nut
Thread Nut Nut Dash Size Torque Torque
Dash Size Torque Torque Size (inches) lb.-ft. Newton Meters
Size (inches) lb.-ft. Newton Meters -04 7/16-20 11-12 15-16
-04 9/16-18 10-12 14-16 -05 1/2-20 15-16 20-22
-06 11/16-20 18-20 24-27 -06 9/16-18 18-20 24-28
-08 13/16-16 32-35 43-47 -08 3/4-16 38-42 52-58
-10 1-14 46-50 62-68 -10 7/8-14 57-62 77-85
-12 1 3/16-12 65-70 88-95 -12 1 1/16-12 79-87 108-119
-16 1 7/16-12 92-100 125-136 -16 1 5/16-12 108-113 148-154
-20 1 11/16-12 125-140 170-190 -20 1 5/8-12 127-133 173-182
-24 2-12 150-165 204-224 -24 1 7/8-12 158-167 216-227
-32 2 1/2-12 245-258 334-352
Metric BSPP
Thread Size Straight Adapter or Locknut Torque Nominal
mm lb.-ft. Newton Meters Thread Size Straight Adapter or Locknut Torque
M10x1 13-15 18-20 inches** lb.-ft. Newton Meters
M12x1.5 15-19 20-25 G1/8-28 13-15 18-20
M14x1.5 19-23 25-30 G1/4-19 19-23 25-30
M16x1.5 33-40 45-55 G3/8-19 33-40 45-55
M18x1.5 37-44 50-60 G1/2-14 55-70 75-95
M20x1.5 52-66 70-90 G3/4-14 103-118 140-160
M22x1.5 55-70 75-95 G1-11 162-184 220-250
M26x1.5 81-96 110-130 G1 1/4-11 170-192 230-260
M27x2 96-111 130-150 G1 1/2-11 258-347 350-470
M33x2 162-184 220-250 ** "G" denotes parallel threads, other than ISO 6149
M42x2 170-192 230-260 (Port connection only)
M48x2 258-347 350-470
Eaton Aeroquip Fluid Conveyance Products A-HOOV-MC001-E January 2005
3.16
SECTION 5 - PILOT SYSTEM
AUGUST, 2006
CAB TILT ................................................................................................................ 5.6

CIRCUIT DIAGRAM ............................................................................................... 5.7
ELECTRICAL CIRCUIT .......................................................................................... 5.5
PILOT SYSTEM COMPONENTS ........................................................................... 5.2
JOYSTICKS AND FOOT PEDALS ...................................................................... 5.4
PILOT MANIFOLD .............................................................................................. 5.3
PRESSURE SETTINGS ......................................................................................... 5.5
Tigercat T240B Track Loader Pilot system
PILOT SYSTEM COMPONENTS NOTE: Low pilot pressure can influence machine
controls causing slow or sluggish response times,
If this symptom occurs, first check hydraulic oil
LEFT SIDE level in reservoir, if the level is correct, verify that
OF ENGINE
the pilot relief valve setting is 450 psi. Refer to
SET PILOT PRESSURE in THIS SECTION.
A shut-off valve is installed in the pilot suction line
at the hydraulic tank connection. Use this valve to
•• isolate the pilot hydraulic system when
disconnecting any hoses or fittings. A plastic tie is
installed on the shut off valve at the factory to
• prevent the valve from being accidentally turned
to the CLOSED position when the engine is
running, this could cause serious damage to the
pilot pump. The tie should be replaced whenever it
PILOT
PUMP is taken off to operate the shut off valve.
T240B-001
PILOT PUMP
The pilot circuit is supplied with oil from the pilot
pump which is driven by the auxiliary drive off the
left side of the engine.
Oil is first filtered by an in-line pressure filter
before entering the pilot manifold. A pilot relief
valve built into the pilot manifold maintains the FILTER ELEMENT
pilot system pressure at 450 psi. The oil enters
pilot manifold (inlet port) at this reduced pressure ••
and is then distributed by the pilot manifold to the
various pilot actuated functions of the machine.
Solenoid operated pilot valves within the pilot
manifold control the flow of pilot oil to various
functions.
LOCATED
BELOW
PUMPS
HYDRAULIC
TANK
206-5A PILOT FILTER

BALL VALVE PRESSURE FILTER
(SHOW OPEN)
This filter is a cartridge filter with a built-in
•• differential pressure relief valve, if the pressure
differential at the oil filter exceeds 50 psi this valve
•• will bypass the pilot oil back to the tank. This will
TO PILOT also result in lower pilot pressure. If a loss of
PUMP controls or slow response is experienced the filter
element may need to be changed.
••
T240B- PILOT SHUT-OFF BALL VALVE
5.2
PILOT SHUT "IN" CONNECTION "PB" POWER BEYOND
PILOT OFF VALVE FROM PILOT FILTER PORT CONNECTIONS
MANIFOLD TO JOYSTICKS AND
FOOT PEDAL VALVES
"T" TANK
CONNECTIONS
•
•
PILOT MANIFOLD
240B-038 •
PILOT MANIFOLD •
The pilot manifold is located below the floor plates
•
in the hydraulic valve compartment. • ••
The pilot manifold distributes oil to the following •
circuits: PILOT
MANIFOLD
• Joysticks (both) (PB) port GAUGE TEST
PORT
• Swing control foot pedal (PB) port CONNECTION
• Gauge test port (G) port
• Slasher saw, cut (1) solenoid valve PILOT RELIEF
VALVE
• Slasher saw, retract (2) solenoid valve
• Top saw, cut (3) solenoid valve 240B-D22 PILOT MANIFOLD
• Delimber, open (4) solenoid valve Two outlet ports ('PB') on each end of the pilot
• Optional Live Heel (5) solenoid valve manifold, feed both joysticks and the swing foot
• Optional Live heel (6) solenoid valve pedal valve. A gauge test port (G) has a quick
• Track Drive Enable (7) solenoid valve connect fitting installed for connecting a pressure
• Travel Speed Low (8) solenoid valve gauge to perform pressure setting procedures.
Pilot oil enters the manifold through the inlet port. Eight solenoid operated pilot valves on the
manifold, when energized, supply "on demand"
The pilot shut off valve, which is an integral part pilot oil to the corresponding functions. These
of the pilot manifold, controls the flow of oil from valves are activated by controls in the cab.
the INLET port to the three outlet ports labelled
(PB and G) and to the eight solenoid operated pilot Two tank ports ('T') drain return oil to the
valves. The pilot shut off valve is activated by reservoir.
pressing the pilot reset switch in cab (with the left
armrest down).
'PB' TO JOYSTICK
DRIVE OPTIONAL OPTIONAL TOP SAW, DELIMBER SLASHER AND SWING FOOT
ENABLE LIVE HEEL LIVE HEEL CUT OPEN SAW, CUT PEDAL
TRAVEL SLASHER SAW,
SPEED LOW • • • RETRACT
PILOT SHUT
OFF VALVE
• • •
• • • GAUGE
TEST PORT
INLET
PILOT
RELIEF
• VALVE •
•
•
• •
•
RETURN OIL FROM
STABILIZER PILOT 'T' RETURN OIL
MANIFOLD TO TANK
230B-04 PILOT MANIFOLD ASSEMBLY
5.3
JOYSTICKS AND FOOT PEDALS OPERATING DESCRIPTION
These pilot valves are manually operated, In the neutral position the joystick lever, or foot
directional control valves and operate on the pedal is held centered by return springs (4).
same principle as a direct operating pressure When the lever (1) is operated, the plunger (5) is
reducing valve. Both the joystick and foot control pushed against its return spring (4). At the same
valves (pedals) use similar spool arrangements. time the regulating spool (2) is moved down
Operated by hand or foot these valves direct pilot against the regulating spring (3). When the
oil to the main control valve pilot end caps. The regulating stroke begins, there is a connection
corresponding spool valve then shifts from its made between the pressure port, via holes (8) in
centre position and directs pump flow to operate a the spool and work ports in the base of the valve.
function.
Pilot pressure is directly proportional to the
operator position of the joystick or foot pedal and
the regulating spring characteristics.
1
•
5
•
•
4
• •
TANK
PORT 8
• •
•
2
• •
WORK PRESSURE WORK
PORT PORT PORT
AW015 JOYSTICK PILOT VALVE (KAWASAKI)
1
•
5
•
3
•
• •
TANK
PORT
4
8
•
•
2
• •
WORK PRESSURE WORK
PORT PORT PORT
FOOT PEDAL PILOT VALVE (KAWASAKI)

AW017
5.4
PILOT SYSTEM ELECTRICAL CIRCUIT PILOT SHUT
OFF VALVE
Refer to circuit diagram;
The pilot shut off valve solenoid is not energized
until the armrest is down and the pilot reset switch
is pushed. Wire 33 connects the armrest switch to
the pilot shut off valve solenoid. Wire 95 connects
the pilot reset switch to the armrest switch. When
the pilot reset switch is pushed ON with the
armrest DOWN, the coil on the pilot shut off relay •
is energized closing the circuit between wires 6
and 11 to energize the coil in the pilot shut off
valve. With the coil energized the valve spool in
the pilot shut off valve is shifted to supply oil to the
pilot circuit. At the same time wire 95A from the
pilot reset switch is connected back to the pilot
•
shut off relay through a diode and thus latches the •
pilot shut off relay in the energized position.
PILOT
The diode in the circuit prevents the flow of
current to the pilot shut off valve solenoid when
MANIFOLD ••
GAUGE TEST
the armrest switch is open (armrest up). Even if PORT
CONNECTION
the pilot reset switch is held down, it will not
operate. Whenever the arm is raised and the PILOT RELIEF
switch opens, the voltage is interrupted to the pilot VALVE
shut off relay coil and the relay contacts open 240B-D22 PILOT RELIEF VALVE
resulting in the pilot shut off valve returning to the
normally closed position. This prevents pilot oil SET PILOT PRESSURE
from reaching the controls. 1. With hydraulic oil at operating temperature,
connect a 0-1000 psi. gauge to the gauge test
fitting on the pilot manifold.
2. Loosen locknut and turn adjusting screw all
the way OUT on pilot relief valve, tighten
locknut on adjusting screw.
3. Start engine and set throttle in FULL position.
4. Loosen locknut on pilot relief valve and turn
adjusting screw IN until pressure gauge at
pilot manifold reads 450 psi.
5. Stop engine, and remove pressure gauge.
PILOT
MANIFOLD
BODY RELIEF VALVE
CARTRIDGE
•
LOCKNUT
ADJUSTING
SCREW
OUT • •
•
IN
240B-01 PILOT RELIEF VALVE

5.5
CAB TILT CIRCUIT
One cylinder is used to tilt the cab forward or
backwards. Operating oil is supplied from the pilot
pump to the inlet section of the cab tilt control
•
CONTROL LEVER
240T2-028A
RELIEF VALVE CAB TILT COUNTERBALANCE VALVES
• ENGINE
START
•• WORK PORT 'B'
SWITCH
• ••
WORK PORT 'A'

BATTERY
DISCONNECT
SWITCH •
BATTERY DISCONNECT AND ENGINE
240T-016 START SWITCHES
T240B-004 CAB TILT VALVE SET CAB TILT RELIEF VALVE
valve. A relief valve is installed in the inlet section 1. Park machine on level ground.
of the tilt control valve to protect the circuit
2. Ensure that the hydraulic oil is at operating
components from abnormally high pressure
temperature.
spikes. A counterbalance valve is installed in the
tilt circuit on the tilt cylinder. The pilot operated 3. "Tee" into work port 'A' on the cab tilt control
counterbalance valve ensures that the cylinders valve and install a 0 - 5000 psi pressure
will remain in any extended supporting position gauge at the "Tee".
should a problem occur with the hydraulic system 4. Loosen the locknut on the relief valve and turn
such as a leaking or broken hose. The cracking the relief adjusting screw out until spring
pressure for each of the two valve cartridges is pressure is relieved, then turn the adjusting
pre-set to 3000 psi. screw one full turn in.
During normal machine operating conditions the 5. Start the engine and put the throttle control to
pilot oil from the pilot pump passes through the the FULL position.
"open center" spool section of the cab tilt valve to
supply the pilot system. 6. With the cab tilt locking bolt still in place, push
and hold the tilt lever in the FORWARD
When the lever on the cab tilt valve is pulled position, check the gauge reading, if less than
forward to tilt the cab, oil is directed from the pilot set value, turn relief valve adjusting screw IN
pump via the control valve and pilot operated until 2000 psi is obtained on gauge.
counterbalance valve to the base end of the cab
tilt cylinder to tilt the cab forward. A 1/32" dia. 7. Tighten locknut on adjusting screw taking
orifice is installed into each elbow at the cylinder care not to turn the adjusting screw.
port connections to control the rate of speed at 8. Stop engine, remove pressure gauge and
which the cab will tilt. "Tee" fitting and reconnect hose to work port
See CAB TILTING PROCEDURE in SECTION 2 'A'. Wipe up any excess oil from the gauge
of the OPERATOR'S MANUAL. connection area.
5.6
240T2-003
PILOT SYSTEM CIRCUIT DIAGRAM
5.7
5.8
SECTION 6 - ELECTRICAL, GAUGES & ALARMS
AUGUST, 2006
CAB WIRING AND ELECTRICAL COMPONENT LOCATIONS .................... 6.6
DISPLAY MODULE ........................................................................................ 6.4
COMPONENT DESCRIPTION ................................................................... 6.4
FAULTS AND WARNINGS ......................................................................... 6.5
KEYPAD FUNCTIONS ............................................................................... 6.4
START-UP OPERATION ............................................................................ 6.4
ELECTRICAL SCHEMATIC DIAGRAM .................................... 6.12, 6.13, 6.14
FUSE AND RELAY PANEL ............................................................................ 6.8
GAUGES AND ALARMS ................................................................................ 6.2
GAUGES AND WARNING LIGHTS ....................................................... 6.6, 6.7
INSTRUMENT PANEL WIRING DIAGRAM ................................. 6.6, 6.9, 6.11
SENSOR LOCATIONS ................................................................................... 6.3
WARNING LIGHTS ................................................................................ 6.6, 6.7
Tigercat T240B Track Loader Electrical, Gauges and Alarms
GAUGES AND ALARMS
The T240B Loaders are monitored for proper
operation by sensors located in the hydraulic
system and on the engine. These sensors are
connected to the PowerView Display and warning
lights.
The operator may sound the warning horn at any
time.
For operation of the PowerView Display and
warning lights listed in the sensor chart below,
refer to SECTION 2 of the OPERATOR'S
MANUAL.
For replacement parts information, refer to
GAUGES AND SENDERS in GROUP 600 of the
PARTS CATALOG.
SENSOR GAUGE LIGHT INFORMATION
FUNCTION RANGE
Engine oil pressure 0 - 100 psi YES RED Light comes ON below 15psi. *
STOP engine below 15 psi
Engine coolant temp. 100°F - 280°F YES 181°F-203°F operating range (Cummins engine)
RED light comes ON above 215°F *
Engine coolant level NONE YES RED light comes ON when level in surge tank is LOW
Hydraulic oil temp. 100°F - 240°F YES RED light comes ON above 205°F *
Hydraulic oil level LOW SIGHT GLASS YES Red light comes ON indicates 13 gallons below FULL *
Wait to start NONE YES YELLOW light turns ON when grid heater elements ON
Water in fuel NONE YES YELLOW light comes ON when fuel/water separator
needs to be drained
Safety Alert HORN NONE NONE Switch on control panel - press to sound horn
*NOTE:
Panel buzzer sounds when engine oil pressure too
low OR engine coolant temperature too high OR
hydraulic oil temperature too high OR hydraulic oil
level too low.
6.2
CONTROL
PANEL
••
• • BACK-UP
PILOT ALARM
MANIFOLD SWITCHES
AND
SOLENOIDS
• •
JOYSTICKS
•• •
PILOT
SHUT-OFF
SWITCH
FUSE & RELAY

ELECTRICAL
BOX
•• A/C
BATTERY PRESSURE
DISCONNECT SWITCH
SWITCH • ••
•• •• COOLANT
ENGINE
REMOTE
START
• • LEVEL PROBE
SWITCH A/C
COMPRESSOR
ENGINE OIL
PRESSURE
SENDER
•• •• 12 VOLT
(RED LIGHT) BATTERIES
(SHOWN
MOVED OUT
•• FROM UNDER
ENGINE)
• •• •• •
••
STARTER ALTERNATOR SAFETY
ALERT
HORN
(SWITCH
ON
CONTROL
SIGHT GAUGE/SWITCH - PANEL)
HYDRAULIC OIL LEVEL SENDER -
(RED LIGHT) COOLANT
SWITCH- HYDRAULIC TEMPERATURE
OIL TEMPERATURE (GAUGE)
SENDER - HYDRAULIC (RED LIGHT)
OIL TEMPERATURE
(GAUGE)
240T2-005 SENSORS AND ELECTRICAL COMPONENT LOCATIONS
6.3
POWERVIEW DISPLAY MODULE
1 7
• ••
2
3
••
•• •• •
•
6
4 5
244-007 POWERVIEW DISPLAY MODULE
COMPONENT DESCRIPTION
1. Amber Warning LED
244-046 POWERVIEW DISPLAY MODULE 2. Display
The PowerView Display Module is the operator 3. Menu Key

interface with the electronic engine controls.The 4. Left Arrow Key
PowerView is a multifunction tool that enables the
operator to view various engine parameters and 5. Right Arrow Key
service codes. The PowerView includes a 6. Enter Key
graphical backlit LCD screen controlled via menu
7. Red Shutdown LED
selection. The display can show either a single
parameter or a quadrant display showing 4 START-UP OPERATION
parameters simultaneously. Diagnostic
capabilities include fault codes with text KEYPAD FUNCTIONS
translation for the most common fault conditions. MENU KEY - This key is pressed to enter or
The PowerView has four buttons used to navigate exit menu screens.
the display with ease. LEFT ARROW KEY - This key is pressed to
DISPLAY PARAMETERS scroll through the screen either moving the
parameter selection toward the left or down.
The following are some of the functions displayed
by the PowerView Display Module: RIGHT ARROW KEY- This key is pressed to
scroll through the screen either moving the
Engine RPM parameter selection toward the right or up.
Engine Hours
Machine Hours ENTER KEY - This key is pressed to select
System Voltage the parameter that is highlighted on the
% Engine Load at the current RPM screen.
Coolant Temperature Refer to manufactures Operations Manual
Oil Pressure (supplied with the machine) for detailed
Fuel Economy information.
Throttle Position
Engine Manifold Air Temperature When power is first applied to the PowerView, the
Current Fuel Consumption “Logo Screen” will be displayed, the “Wait to Start”
Active Service Codes message will be displayed. Once the “Wait to Start”
Stored Service Codes from the engine message is no longer displayed the operator may
Set Units for display (English or Metric) start the engine. When the engine has started the
Engine Configuration Parameters display will show the single engine parameter
display.
6.4
Some of the display and warning functions are:
LOW ENGINE OIL PRESSURE - RED LED
This light will come ON when the engine oil
pressure falls below 15 psi. If this light comes ON
stop the engine and determine cause.
ENGINE COOLANT TEMP. - RED LED
This light will come ON when the engine coolant
SINGLE PARAMETER DISPLAY
244-007
temperature rises above 215°F If this light comes
MAIN MENU NAVIGATION ON stop engine and determine cause. Do not
1. Starting at the single or four engine parameter continue to operate machine.
display, depress the “Menu Button”. TACHOMETER
This display indicates the RPM. of the engine.
HOUR METER
There are two options available for displaying
hours:
TOTAL ENGINE HOURS - displays total hours the
244-047 engine has run as provided by the engine
computer.
2. The first seven items of the “Main Menu” will
be displayed. MACHINE HOURS - displays the total hours the
engine has run as calculated by the display
3. Depressing the “Arrow Buttons” will scroll
module.
through the menu selections.
ENGINE OIL PRESSURE
4. Pressing the right arrow button will scroll
down to reveal the last items of “Main Menu” Oil pressure must be greater than 15 psi at all
screen highlighting the next item down. times. If the oil pressure drops below 15 psi, stop
the engine and determine cause. Check engine oil
5. Use the arrow buttons to scroll to the desired
pressure every time the engine is started.
menu item or press the “Menu Button” to exit
the Main menu and return to the engine The oil pressure at high idle and full load should
parameter display. normally operate between 30 and 60 psi.
FAULTS AND WARNINGS NOTE: At low idle rpm the oil pressure will be low.
This is not an abnormal condition, however it must
During normal operation the single or four
be closely monitored.
parameter screen will be displayed. When the
PowerView receives a fault code from an engine ENGINE COOLANT TEMP.
control unit the single or four parameter screen Normal operating range is between 181°F and
will be replaced with the “Active Fault Codes” 203°F. If the temperature rises beyond 210°F,
message. reduce the load on the engine and check for a
To acknowledge and “Hide” the fault and return to plugged radiator. If the temperature does not
the single or four parameter display press the drop, stop engine and determine cause. Do not
“Enter Button”. The display will return to the single continue to operate machine.
or four parameter screen. Indicates Auxiliary VOLTAGE DISPLAY
Gage Fault. Indicates Fault Warning Indicates
Derate or Shutdown Condition Fault Normal operating range is between 12-13.5 volts.
A reading in excess of 15 volts indicates a possible
Pressing the “Enter Button” will redisplay the faulty voltage regulator. A reading of less than 12
hidden fault. Pressing the “Enter Button” once Volts indicates a possible faulty battery or
again will hide the fault and return the screen to alternator.
the single or four parameter display.
Refer to manufactures Operations Manual
NOTE: The fault can only be cleared by (supplied with the machine) for detailed
correcting the cause of the fault condition. information.
6.5
DEFROSTER CB RADIO DOME LIGHT

FAN
GAUGES AND WARNING LIGHT PANEL
• •
•
DIAGNOSTIC INSTRUMENT
CONNECTOR PANEL
••
••
••
••
FUSE AND RELAY ELECTRICAL CONNECTORS
PANEL (SEE DETAILS (SEE INSTRUMENT PANEL
ON PAGE 6.8) WIRING DIAGRAM ON PAGE
6.9)
CAB WIRING AND ELECTRICAL COMPONENT LOCATIONS
6.6
GAUGES AND WARNING LIGHTS
1 2 3 4 5 6 7 8 9 10
• • •• • •
• ••
••
•• •
240T-005 GAUGES AND WARNING LIGHTS
Component description
1. Windshield Wiper Switch 6. Bulb Test Switch
2. PowerView Display Module 7. Wait To Start Light - Yellow
3. Hydraulic Oil Temperature Gauge 8. Water In Fuel Light - Yellow
4. Low Hydraulic Oil Light - Red 9. Low Coolant Light - Red
5. Hydraulic Oil Temperature Light - Red 10. Not Used
240T-005 REAR VIEW OF GAUGES AND WARNING LIGHT PANEL
6.7
240T-007 FUSE AND RELAY PANEL
21215B FUSE AND RELAY PANEL

FUSE AND RELAY PANEL
The fuse panel is located inside 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.
6.8
240T2-004
INSTRUMENT PANEL WIRING DIAGRAM
6.9
240B-036
240B-035 MAIN FUSE AND RELAY ELECTRICAL BOX
FUSES AND RELAYS - ELECTRICAL BOX

This Main Fuse and Relay electrical box is located in the engine compartment.
6.10
240B-011(23825B)
ELECTRICAL BOX WIRING DIAGRAM
6.11
REFER TO COLOUR
CODE CHART IN
THIS SECTION
240B-007
ELECTRICAL SCHEMATIC DIAGRAM (SHEET 1)
6.12
REFER TO COLOUR
CODE CHART IN
THIS SECTION
240B-008
6.13
REFER TO COLOUR
CODE CHART IN
THIS SECTION
240B-009
6.14
SECTION 7 - ENGINE START AND STOP

AUGUST, 2006
CIRCUIT DESCRIPTION ............................................................................... 7.2
ENGINE START CIRCUIT ............................................................................. 7.2
START CIRCUIT DIAGRAMS ........................................................................ 7.3
Tigercat T240B Track Loader Engine start and stop
ENGINE START CIRCUIT
For detailed engine information, refer to the
engine manufacturer's manual.
For engine starting and stopping procedures refer
to STARTING ENGINE and STOPPING ENGINE
in SECTION 2 of the OPERATOR’S MANUAL.
For correct engine speeds, refer to THROTTLE
CONTROL in SECTION 2 of the OPERATOR'S
MANUAL.
To start engine; Turn battery disconnect switch to
the ON position. Turn ignition key to the START
position and releasing it to the RUN position after
the engine starts.
CIRCUIT DESCRIPTION
With the battery disconnect switch ON, current is
supplied the start solenoid contact, the positive
connection on the alternator and the BATTERY
contact of the key switch (ignition switch).
When the key switch is turned to the START
position, the BATTERY contact is connected to
the RELAY and START contacts. Current
(voltage) then flows through wire (16) to energize
the coils of the start solenoid relay. The start
solenoid relay contacts also close and current
flows from the alternator + RED wire (1) through
wire (12) to the starter solenoid coil to close the
contacts and operate the start motor to start the
engine.
In order to operate the machine functions after
starting the engine, the arm rest must be in the
latched DOWN position and the PILOT RESET
button pushed. This will energize the pilot shut off
relay, close the contacts and allow current to flow
through wires (6) and (11) to energize the pilot
shut off solenoid valve on the pilot manifold. After
the PILOT RESET button is released current will
continue to flow through wire (95) and the diode to
latch the pilot shut off relay in the energized
position and allow current to flow through wires
(6) and (11) to the pilot shut off solenoid valve.
For additional information on the PILOT SYSTEM
refer to SECTION 5 in THIS SERVICE MANUAL.
7.2
240B-012
START CIRCUIT - AT REST
7.3
START CIRCUIT - AT REST

240B-013 BATTERY DISCONNECT SWITCH - ON
7.4
START CIRCUIT - START

IGNITION KEY - START POSITION
240B-014
7.5
START CIRCUIT - RUN

240B-015
IGNITION KEY - RUN POSITION
7.6
START CIRCUIT - RUN

240B-016
PILOT RESET SWITCH - HELD ON
ARM REST DOWN/ARM REST SWITCH - ON
7.7
START CIRCUIT - RUN

240B-017
PILOT RESET SWITCH - RELEASED
ARM REST DOWN/ARM REST SWITCH - ON
7.8
SECTION 11 - TRACK DRIVE
AUGUST, 2006
BRAKE RELEASE PRESSURE .................................................................... 11.15

CIRCUIT DESCRIPTION ................................................................................ 11.6
CIRCUIT DIAGRAM ...................................................................................... 11.11
CONTROL VALVES
FOOT PEDAL CONTROL VALVE ................................................................ 11.3
TRACK CONTROL VALVES ........................................................................ 11.4
TRAVEL AND DRIVE ENABLE SOLENOID VALVES ................................... 11.4
DRIVE MOTOR
DESCRIPTION ............................................................................................ 11.8
DRIVE MOTOR
START-UP PROCEDURE .......................................................................... 11.12
DRIVE MOTOR AND GEARBOX ASSEMBLY ................................................ 11.7
GEARBOX AND DRIVE MOTOR ASSEMBLY ................................................ 11.7
IMPORTANT TRACK DRIVE NOTES
NEW MACHINE ........................................................................................... 11.2
STRAIGHT TRAVEL .................................................................................... 11.2
TRACK SAG ................................................................................................ 11.2
PRESSURE SETTINGS
LEFT TRACK RELIEF VALVE SETTINGS ................................................. 11.13
RIGHT TRACK RELIEF VALVE SETTINGS ............................................... 11.13
SUMMERY, PRESSURE SETTINGS ......................................................... 11.17
PRESSURE SETTINGS, DRIVE SYSTEM
BEGIN OF REGULATION, SET, FOR DRIVE MOTOR .............................. 11.14
SET STRAIGHT TRAVEL .............................................................................. 11.17
SET TRACK SPEED ......................................................................... 11.15, 11.16
TRACK COMPONENTS
MEASURING TRACK SAG ........................................................................ 11.18
TRACK SAG ADJUSTMENT ................................................................. 11.19
OPERATING THE MACHINE ..................................................................... 11.18
ROLLER RETAINING BOLTS .................................................................... 11.20
TORQUING UNDERCARRIAGE BOLTS ................................................... 11.19
TRACK SHOE RETAINING BOLTS ........................................................... 11.19
WEAR LIMITS
BUSHING WEAR, OUTSIDE DIAMETER .............................................. 11.21
IDLER WEAR ......................................................................................... 11.22
PIN AND BUSHING WEAR .................................................................... 11.21
ROLLER WEAR ..................................................................................... 11.21
TRACK LINK WEAR .............................................................................. 11.20
TRACK SHOE GROUSER HEIGHT WEAR ........................................... 11.20
TRACK DRIVE ASSEMBLY ............................................................................ 11.2
TRACK DRIVE BRAKE RELEASE PRESSURE ........................................... 11.15
Tigercat T240B Track Loader Track drive
IMPORTANT TRACK DRIVE NOTES
NEW MACHINE
Before driving a new machine ensure that track
sag is set correctly. Track sag may be set less
than specified for shipping purposes. The correct
SAG
track sag must be adjusted once a machine has UNDERSIDE OF DIMENSION
TRACK GUARD
been delivered to the job sight and operating in •
the accumulated soil buildup in the undercarriage. •
TRACK SAG UPPER SURFACE
OF TRACK SHOE
The track sag dimension is very important and
should be checked regularly. A 50% increase in 853ILL8 MEASURING SAG DIMENSION
the life of the track assembly can be realized,
particularly in bushing O/D wear and 'track pitch'
STRAIGHT TRAVEL
by maintaining the correct amount of track sag. A
track that is too tight will wear out significantly If the machine does not travel straight, the right
faster due to increased tension in the chain. Refer and left track speeds are not set the same. Refer
to MEASURING TRACK SAG in THIS SECTION. to TRACK SPEED SET-UP PROCEDURE in THIS
SECTION.
Check the speed of each track and follow the set-
up procedures closely to obtain straight travel.
UPPER ROLLERS ROTARY MANIFOLD

IDLER
• ASSEMBLY
UNDERCARRIAGE
• LOWER HINGED
ACCESS COVER
UNDERCARRIAGE
• •
LOWER
• • ROLLERS
•
INSPECTION
COVERS
•
DRIVE MOTOR
• •
TRACK DRIVE
GEARBOX
•
•
DRIVE SPROCKET TRACK ASSEMBLY
TRACK ACCESS
COVER
240T-13 TRACK DRIVE ASSEMBLY
11.2
TRACK DRIVE COMPONENTS
HYDRAULIC PUMPS 1
•
LEFT TRACK 5
"STICK" PUMP
SWING PUMP
•
RIGHT TRACK
"HOIST" PUMP
3
•
• •
TANK
• PORT
4
•• •• 8
•
•• •
2
BELL
HOUSING • •
WORK PRESSURE WORK
278-3A GEAR PUMP PORT PORT PORT
FOOT PEDAL PILOT VALVE

The hydraulic pumps used on the T240B track AW017
loader are fixed displacement gear pumps. FOOT PEDAL CONTROL VALVE
The track drive circuit utilizes two of the three gear The drive function is controlled by two center foot
pumps to supply hydraulic oil to both the left and pedal valves which send proportional pilot signals
right track drive motors via a valve section in each to the left and right track drive spool sections in
of the two boom valves. the "hoist" and "stick" valves which supply oil to
For a more detailed description of the triple gear the track drive motors.
pump, refer to SECTION 12 in THIS SERVICE For a detailed description of the foot pedal control
MANUAL. valves, refer to SECTION 5 in THIS MANUAL.
11.3
RELIEF SEAL GROOVES RELIEF

VALVE VALVE
A B PORT 'B'
PORT 'A'
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
TRACK CONTROL VALVES
For a detailed description of the "hoist" and "stick"
The right track forward and reverse function is
control valves, refer to SECTION 12 in THIS
controlled by one of three spool sections in the
MANUAL.
"hoist" valve and the left track forward and reverse
function is controlled by one of three spool
sections in the "stick" valve. The control valves
are located in the upper frame below the floor
plates inside the valve compartment.
RIGHT TRACK 'REVERSE' LEFT TRACK 'FORWARD'
PORT RELIEF (TURN IN) MAIN RELIEF PORT RELIEF (TURN IN)
(3000 PSI) MAIN RELIEF
(3000 PSI)
OUTLET OUTLET
SECTION SECTION
• •
• •
REVERSE
• •
SLASHER
TRACK FORWARD
DOWN
DOWN
GRAPPLE
CLOSE
TRACK
OPEN/
RIGHT
HOIST
STICK
LEFT
• •
REVERSE
SPARE
FORWARD
UP
UP
• •
• GAUGE •
TEST PORT GAUGE
TEST PORT
INLET
SECTION INLET
SECTION
LEFT TRACK 'REVERSE' PORT
RELIEF (TURN IN)
RIGHT TRACK 'FORWARD'
AT047IL PORT RELIEF (TURN IN)
TRACK DRIVE CONTROL VALVES
11.4
TRACK DRIVE
ENABLE
•
TRAVEL, •
HIGH/LOW

TRAVEL AND DRIVE ENABLE
SOLENOID VALVES
Pilot oil flows to both track drive foot pedals via
the track drive enable solenoid valve located on
the pilot manifold assembly. A track drive switch in
the operator's cab when in the ON position
energizes this solenoid valve and allows pilot oil to
flow to the 'P' port on the foot pedal control valves.
When the switch is in the 'OFF' position, the valve
is de-energized and pilot oil is blocked from
reaching the foot pedal control valves.
A travel high/low solenoid valve located next to
the drive enable solenoid valve on the pilot
manifold assembly controls the flow of pilot oil to
the drive speed change valve in both track drive
motors (port 'Z'). A track speed switch in the
operator's cab when in the "LOW" position
energizes this solenoid valve and allows pilot oil to
shift the spool in the drive speed change valve
and place the motor at maximum displacement
(slower speed). When the switch is in the "HIGH"
position, the solenoid valve is de-energized
preventing pilot oil from reaching the drive speed
change valve in the motor which places the motor
at minimum displacement (higher speed).
11.5
TRACK DRIVE HYDRAULIC CIRCUIT
LEFT TRACK
DESCRIPTION "STICK" PUMP
The power is transmitted to the tracks by a variable SWING PUMP
displacement piston motor through a triple RIGHT TRACK
"HOIST" PUMP
reduction planetary gearbox on each track frame.
The gearbox has an integral spring apply, hydraulic-
release, multi-disc brake which is automatically
released whenever the drive system is pressurized.
In order to control the vehicle movement in
•
situations where the vehicle may roll down a grade, •• ••
each motor is equipped with a counterbalance
valve. These valves have a spool valve which ••
controls the flow of oil out of the motor, in the motor
schematic diagram it is shown in the centre, closed BELL
HOUSING
position.
278-3A GEAR PUMP
CIRCUIT DESCRIPTION
The types of pumps used on the T240B track loader
are fixed displacement triple gear pumps.
The track drive circuit utilizes the first and second
gear housings from the shaft end of these pumps
to supply hydraulic oil flow to the left and right
hydraulic track motor 'A' and 'B' ports via spool
sections in the "stick" and "hoist" control
valves.Two foot pedal control valves in the cab
when operated in the FORWARD or REVERSE
direction direct pilot oil to each end of the track
spool sections in each of the "stick" and "hoist"
control valves. A drive enable solenoid valve on the
pilot manifold assembly controlled by a DRIVE ON/
OFF switch in the cab, controls the supply of pilot
oil to the drive foot pedals. With the switch ON and
the foot pedals depressed, the track spools in the
"stick" and "hoist" control valves will shift directing
240T2- 015
oil from the pumps to the track drive motors. Return
TRACK DRIVE MOTOR SCHEMATIC oil from the motors is directed back through the
spool sections, to the outlet section, through the
The valve will remain in the closed position as long dual head return oil filter and back to tank.
as there is no oil pressure in the line from the track
control valve. When the track control valve spool is
shifted and oil flows to the motor, a check valve in
the counterbalance valve (G) opens and oil
pressure builds up in the motor pistons.
The motor cannot move until the oil pressure shifts
the counterbalance spool to permit the oil on the
low pressure side of the motor to flow back through
the counterbalance valve to the track control valve
and then to tank.
The hydraulic motor is equipped internally with a
drive speed change valve which is controlled by a
switch in the cab (TRACK DRIVE HIGH/LOW) and
a solenoid operated control valve on the pilot
manifold assembly. For further information refer to
TRAVEL AND DRIVE ENABLE SOLENOID
VALVES in THIS SECTION.
11.6
PLANETARY TRACK • LOWER FRAME

TRACK DRIVE
GEARBOX
SPROCKET
••
• TRACK DRIVE
MOTOR
(AQ019 SHOWN)
••
BRAKE
ASSEMBLY
BK004-822 TRACK DRIVE MOTOR AND GEARBOX ASSEMBLY
11.7
DRIVE MOTOR DESCRIPTION (1) with nine pistons (2) and an output shaft (3)
The drive motor is a variable displacement that is splined to the cylinder block.
swashplate design. The motor is interchangeable Supply oil from the drive control valve enters the
from side to side. motor through the cover (4) to the pistons. During
The motor rotating group consists of a cylinder block operation, high pressure supply oil enters the
SLIPPER RETAINER BALL GUIDE PISTON 2 CYLINDER

BLOCK
6 1
SWASHPLATE PIN
MAXIMUM
5 DISPLACEMENT
SEAL PISTON
8
SPACER
•• •• •• •
9 MINIMUM
DISPLACEMENT
••
ADJUSTMENT
•• • ••
RETAINING
RING STOP
••••• •• • SHIMS
•• 4 COVER
•• •
•• ••
10 MAXIMUM
SHAFT 3 • • •• DISPLACEMENT
ADJUSTMENT
STOP
WEAR
SLEEVE
AQ019-2 CROSS SECTION
BEARING OF DRIVE MOTOR
SHELL
MINIMUM
7 DISPLACEMENT
SPRING
PISTON
MINIMUM CROSSOVER
DISPLACEMENT 11 RELIEF VALVES
ADJUSTMENT
STOP
4 COVER
9
BEGIN OF
REGULATION
ADJUSTMENT
• •
•
••
••
'B' PORT
PRESSURE
PORTS
• 'A' PORT
•
PRESSURE
REGULATOR
VALVE
BLOCK
MAXIMUM
DISPLACEMENT
10 AQ019-1 • DRIVE MOTOR
ADJUSTMENT STOP COUNTERBALANCE VALVE FRONT COVER
11.8
piston bores in the cylinder block (1). This forces NOTE: Swashplate angle (motor displacement) is
the pistons against an angled swashplate (5). limited by the minimum and maximum
Piston sliding action causes the rotating group to displacement pistons contacting the minimum (9)
turn. The cylinder block is splined to the output and maximum (10) displacement adjustment
shaft (3) which causes the output shaft to turn. stops. For minimum displacement, the maximum
During the second half of the motor rotation, low displacement piston contacts the minimum
pressure is discharged as the pistons ride up to a displacement adjustment stop. For maximum
higher position on the swashplate. To reverse displacement, the minimum displacement piston
rotation, oil flow is reversed. During operation a contacts the maximum displacement adjustment
small amount of supply oil flows through the stop.
centre of each piston. This oil lubricates the Refer to front cover illustration;
piston to slipper (6) joint and the slipper to
The drive motor cover (4) consists of several
swashplate area.
components to operate the drive functions.
High pressure supply oil also flows through a tube
The minimum displacement adjustment stop (9)
to lubricate the swashplate to bearing shell area.
limits the minimum angle the swashplate can
Normal leakage and lubrication oil aid in flushing
move. The maximum displacement adjustment
and cooling the motor during drive operation.
stop (10) limits the maximum angle the
The swashplate (5) angle is changed by the swashplate can move. The crossover relief
minimum displacement piston (7) and maximum valve(s) (11) protects the motor circuit from
displacement piston (8). When supply oil acts on pressure spikes.
the minimum displacement piston (7), the motor
runs at its highest speed. When supply oil acts on
the maximum displacement piston (8), the motor
runs at its slowest speed. The maximum
displacement piston is larger than the minimum
piston and will hold the motor in maximum
displacement when equal pressure acts on both
pistons.
BEGIN OF MINIMUM
DISPLACEMENT CROSSOVER CYLINDER PRESSURE
REGULATION RELIEF VALVES 'B' REGULATOR MIN. AND MAX.
ADJUSTMENT ADJUSTMENT BLOCK 'J'
STOP 'A' VALVE BLOCK ADJUSTING
COVER 'L' PISTON 'I' STOPS 'A' & 'E'
PRESSURE
REGULATOR • • SWASHPLATE 'E'
VALVE •
BLOCK • BEARING
SHELL 'R'
• • ••
•
•
•
••
'B' PORT
•
'A' PORT
•
••
'A'
SHAFT 'A' ••
BRAKE • 'A' SLIPPER 'F'
RELEASE
PRESSURE
REDUCING MAXIMUM
VALVE DISPLACEMENT
TUBE •
ADJUSTMENT ADJUSTMENT COUNTERBALANCE
STOP 'E' VALVE
PRESSURE
DRIVE MOTOR CROSS SECTION 'A' 'A' PORTS 'A', 'B'
AQ019
FRONT COVER (AQ019) DRIVE MOTOR (AQ019)
11.9
The drive motor may be operated in two ranges;
MAXIMUM DISPLACEMENT = 105cc/rev.
MINIMUM DISPLACEMENT = app. 50cc/rev.
These two ranges are controlled by a solenoid
pilot valve on the pilot manifold which is operated
by the TRACK (LOW/DRIVE) switch in the cab. In
the LOW position the solenoid on the pilot valve is
energized and the motor is in its maximum
displacement mode which will give the slowest
speed and maximum tractive effort.
For faster travelling modes the TRACK (LOW/
DRIVE) switch can be put in the DRIVE position
and the motor will be in its minimum
displacement position which will give the fastest
speed. When in this high speed mode the motor
will automatically increase motor displacement in
the event that a high load is encountered, e.g. a
short grade or obstacle. This increase in motor
displacement is controlled by the drive speed
240T2- 015
change valve. This valve controls the hydraulic
TRACK DRIVE MOTOR SCHEMATIC
pressure signal to the maximum displacement
piston. The piston increases motor displacement
as the pressure rises above the drive speed
change valve setting.
BEGIN OF MINIMUM
DISPLACEMENT CROSSOVER CYLINDER PRESSURE
REGULATION RELIEF VALVES 'B' REGULATOR MIN. AND MAX.
ADJUSTMENT ADJUSTMENT BLOCK 'J'
STOP 'A' VALVE BLOCK ADJUSTING
COVER 'L' PISTON 'I' STOPS 'A' & 'E'
PRESSURE
REGULATOR • • SWASHPLATE 'E'
VALVE •
BLOCK • BEARING
SHELL 'R'
• • ••
•
•
•
••
'B' PORT
•
'A' PORT
•
••
'A'
SHAFT 'A' ••
BRAKE • 'A' SLIPPER 'F'
RELEASE
PRESSURE
REDUCING MAXIMUM
VALVE DISPLACEMENT
TUBE •
ADJUSTMENT ADJUSTMENT COUNTERBALANCE
STOP 'E' VALVE
PRESSURE
DRIVE MOTOR CROSS SECTION 'A' 'A' PORTS 'A', 'B'
AQ019
FRONT COVER (AQ019) DRIVE MOTOR (AQ019)
11.10
240T2-011 TRACK DRIVE CIRCUIT DIAGRAM

11.11
DRIVE MOTOR START-UP PROCEDURE
DRAIN LINE
IMPORTANT:
The minimum displacement adjusting screws on • 'U' PORT
DRAIN
the track drive motors must be turned in 2 full CONNECTION
turns before running the track. The preset speed
of a new motor is too fast and the motor will GAUGE
TEST
immediately fail if this adjustment is not PORT 'Y1'
performed. ••
IMPORTANT: ••
The drive motor will be damaged if is not filled
with oil before operating the drive function. This
822-D61 DRIVE MOTOR TOP VIEW
procedure must be performed whenever a new
drive motor or drive pump is installed or whenever
oil has been drained from the motor.
1. Disconnect drive motor drain line on top of
motor.
2. Install plug in line to minimize loss of oil.
3. Remove port adapter from motor drain port.
4. Fill motor with oil through the drain port. Add
oil slowly until level is to the top of drain port.
5. Re-connect drain line.
6. Run each drive motor slowly with track off the
ground for three track revolutions to remove
air from the drive circuit.
GAUGE TEST PRESSURE

PORT Y1 REGULATOR
VALVE BLOCK
SYSTEM
PRESSURE
PORT 'A' •
MAXIMUM
DISPLACEMENT
ADJUSTMENT STOP ••
6mm ALLEN KEY
19mm WRENCH
SYSTEM
PRESSURE
PORT 'B'
•
MINIMUM
DISPLACEMENT
ADJUSTMENT STOP
6mm ALLEN KEY
19mm WRENCH
•
COUNTERBALANCE
VALVE
•• 'B'
SIDE
'A'
BEGIN OF
REGULATION
ADJUSTING
SIDE
SCREW ••
•• 6mm WRENCH
13mm WRENCH
CROSSOVER •
RELIEF VALVES
5mm ALLEN KEY
'L' PORT DRAIN
CONNECTION
•
17mm WRENCH (FOR L.H. SIDE)
822-D62 DRIVE MOTOR (AQ019) - R.H. SIDE SHOWN

11.12
10. Slowly depress the L.H. drive foot pedal to
CAUTION ensure brake holds. While holding the LEFT
Use caution when in the cab as a slight drive foot pedal in the FORWARD position,
touch of the controls can cause check gauge pressure reading.
sudden rotation of the upper frame and 11. If less than set value, loosen locknut on stick
booms or movement of the tracks main relief valve and turn relief valve adjusting
screw in or out until 3000 psi. is obtained on
CAUTION gauge.
Be aware of other personnel in the area. 12. Tighten locknut on the main relief adjusting
Operator is responsible for the safe screw taking care not to turn the adjusting
operation of the machine. screw. Verify setting.
RIGHT TRACK RELIEF VALVE SETTINGS

WARNING
Right track/"Hoist" valve main relief setting ....... 3000 psi
Ensure that no one is standing near the
Right track port relief setting .......................... Turn in Fully
grapple during this procedure.
Follow pressure setting procedure for LEFT TRACK
RELIEF VALVE SETTINGS - use "hoist" control
IMPORTANT valve.
Avoid blowing oil over relief for longer
than five seconds, as this will cause 13. Stop engine, reconnect the brake release
excessive heating of the hydraulic fluid. line(s) at the brake port on the track drive
gearbox
LEFT TRACK RELIEF VALVE SETTINGS 14. Replace inspection covers.
Left track/"Stick" valve main relief setting ........... 3000 psi
15. Remove pressure gauge and wipe up any
Left track port relief setting ............................. Turn in Fully excess oil from test port area.
1. Park machine on level ground.
2. Ensure hydraulic oil is at operating
temperature.
3. Remove final drive inspection covers.
4. Disconnect brake release lines at brake port
on final drive gearboxes. Plug hoses with size
06 JIC plug and cap port adapters on gearbox.
SET LEFT TRACK MAIN RELIEF VALVE

5. Loosen the locknut on both port relief valve
adjusting screws for the TRACK FORWARD/
REVERSE spool section of the "stick" valve
and check that the adjusting screws are
turned in fully. Tighten locknuts.
6. Connect a 0-5000 psi pressure gauge to the
"stick" control valve test port on the inlet
section of the valve.
7. Start engine and place throttle control to full.
8. Set pilot pressure to 450 psi at full throttle.
9. Place engine throttle control to full throttle.
11.13
SET BEGIN OF REGULATION 8. Activate LEFT track drive foot pedal in both
(DRIVE SPEED CHANGE VALVE) FORWARD and REVERSE directions to
ensure that the track does not move. At this
Note: Begin of regulation adjustment is made with
time ADJUST BOTH TRACK DRIVE MAIN
both track drive main relief valves set at 2500 psi.
RELIEF VALVES TO 2500 psi.
9. With the aid of an assistant, activate LEFT
temperature.
track drive foot pedal in the FORWARD
2. Remove both LEFT and RIGHT drive motor direction and check pressure reading on
inspection covers. gauge at motor gauge test port 'Y1' it should
3. Disconnect LEFT and RIGHT brake line at show between 800 and 1,000 psi.
port on final drive gearbox. Plug hose with If adjustment is required, loosen locknut on
size 06 JIC plug and cap port adapter on begin of regulation adjusting screw and turn
gearbox. screw in to increase pressure or out to
4. Install a 0 to 5,000 psi gauge on drive motor decrease pressure. Tighten locknut.
gauge test ports 'Y1', size 04JIC quick 10. Repeat steps (4) through (9) for the right drive
connect. motor.
5. Start engine and set throttle to FULL ... 11. Reset track drive main releif valve pressure to
3000 psi.
6. Lower left arm rest and depress the pilot reset 12. Re-connect brake line(s) to both gearboxes.
switch to activate the pilot system.
13. Remove pressure gauge and wipe up any
7. Place HIGH/LOW switch to HIGH position. spills.
14. Replace both LEFT and RIGHT drive motor
inspection covers.
GAUGE TEST PRESSURE

PORT Y1 REGULATOR
VALVE BLOCK
SYSTEM
PRESSURE
PORT 'A' ••
MAXIMUM
DISPLACEMENT
ADJUSTMENT STOP •
6mm ALLEN KEY
19mm WRENCH
SYSTEM
PRESSURE
PORT 'B'
••
MINIMUM
DISPLACEMENT
ADJUSTMENT STOP
6mm ALLEN KEY
19mm WRENCH
••
COUNTERBALANCE
VALVE
•• 'B'
SIDE
'A'
BEGIN OF
REGULATION
ADJUSTING
SIDE
SCREW ••
• 6mm WRENCH
13mm WRENCH •
CROSSOVER ••
RELIEF VALVES
5mm ALLEN KEY
'L' PORT DRAIN
CONNECTION
• BRAKE
RELEASE
17mm WRENCH (FOR L.H. SIDE) PRESSURE
REDUCING
VALVE
DRIVE MOTOR (AQ019) - R.H. SIDE SHOWN ADJUSTMENT
822-D62
11.14
TRACK DRIVE BRAKE RELEASE
PRESSURE
temperature.
2. Remove both LEFT and RIGHT drive motor
inspection covers.
3. Disconnect LEFT and RIGHT brake line at port
on final drive gearbox. Install a test hose and
tee fitting between the brake lines and ports on
final drive gearboxes.
4. Install a 0 to 1,000 psi gauge on both tee
fittings.
5. Start engine and set throttle to FULL ...
6. Lower left arm rest and depress the pilot reset

switch to activate the pilot system. •• BRAKE
RELEASE
7. With the aid of an assistant, activate LEFT track PRESSURE
REDUCING
drive foot pedal in the FORWARD direction and VALVE
ADJUSTMENT
check brake pressure reading on gauge at
brake line it should show 500 psi.
822-D62 RIGHT TRACK DRIVE MOTOR
If adjustment is required, loosen locknut on
brake pressure reducing valve and turn screw
in to increase pressure or out to decrease BRAKE
RELEASE
pressure. Tighten locknut. PRESSURE
REDUCING
VALVE
8. Repeat step (7) for the right track drive brake ADJUSTMENT
pressure adjustment. ••
9. Set engine speed to low idle, shut engine off
and remove test gauges, hoses and fittings.
10. Reinstall LEFT and RIGHT brake line at port on
final drive gearbox. Wipe up any spilled oil.
11. Reinstall both LEFT and RIGHT drive motor
inspection covers.
822-D60 LEFT TRACK DRIVE MOTOR
11.15
TRACK SPEED SET-UP PROCEDURE 7. With an assistant depressing the LEFT TRACK
drive pedal FORWARD, record the track drive
IMPORTANT:
sprocket speed. A reading of 17 rpm is desired.
• Ensure hydraulic oil is up to operating
temperature. 8. Turn the maximum displacement adjustment
screw on the left drive motor IN to speed up or
1. Remove both left and right final drive OUT to slow down the final drive. Continue
inspection covers to access track drive adjusting the motor and checking the track drive
motors. sprocket speed until 17 rpm is obtained.
LEFT TRACK ADJUSTMENT
MINIMUM
POSITION MACHINE: DISPLACEMENT
ADJUSTING SCREW
2. Swing boom to LEFT side of machine. 6mm ALLEN KEY
19mm WRENCH
3. Place grapple on solid ground and by
forcing down with boom controls, lift track
clear of ground. (Hoist down and stick out) •
HARD
SURFACE
SUPPORT
•• MAXIMUM
DISPLACEMENT
BLOCK ADJUSTING SCREW
6mm ALLEN KEY
19mm WRENCH
• 822-D60 LEFT TRACK DRIVE MOTOR

•
240T-17
LIFTING TRACK MAXIMUM
DISPLACEMENT
ADJUSTING SCREW
4. Use blocks to firmly support track frame in 6mm ALLEN KEY
raised position. DO NOT place arms, legs 19mm WRENCH
or body under track while in the raised

position.
SET LOW SPEED (motor maximum displacement)
••
MINIMUM
NOTE: Turn the maximum displacement DISPLACEMENT
adjusting screw either IN (clockwise) to speed

ADJUSTING SCREW
6mm ALLEN KEY
••
up or OUT (counterclockwise) to slow down the 19mm WRENCH
final drive. 822-D61 RIGHT TRACK DRIVE MOTOR

5. Set TRACK HIGH/LOW switch to LOW. SET HIGH SPEED
6. Set throttle to FULL. (motor minimum displacement)
9. Turn HIGH/LOW switch to HIGH.
10. Set engine to full throttle.
A TIMING MARK,
VISIBLE FROM THE 11. With an assistant depressing the left track drive
CAB CAN ALSO BE
PLACED ON THE pedal forward record the track drive sprocket
TRACK speed. A reading of 28 rpm is desired.
12. Turn the minimum displacement adjustment
screw on the left drive motor OUT to speed up
or IN to slow down the final drive. Continue
adjusting the motor and checking the track drive
ROTATION
sprocket speed until 28 rpm is obtained.
IMPORTANT: DO NOT exceed 30 rpm since
TO RECORD TRACK
SPEED, PLACE TIMING over speeding will damage the drive motor.
MARKS ON TRACK FRAME
AND GEARBOX HOUSING
84-18
SET TRACK SPEED
11.16
RIGHT TRACK ADJUSTMENT SUMMERY OF PRESSURE SETTINGS
13. Lower the left track onto the ground, swing LEFT TRACK ADJUSTMENT
the boom around to the right side of the • Park machine on level ground.
machine and proceed to raise the right track • Ensure hydraulic oil is at operating
clear of the ground. temperature.
14. Use blocks to firmly support track frame in • Remove final drive inspection covers.
raised position. DO NOT place arms, legs or • Disconnect and plug brake lines.
body under track while in the raised position. • Turn TRACK FORWARD and REVERSE port
15. Follow steps 5 through 12 from LEFT TRACK relief valves on "stick" valve fully in..
ADJUSTMENT. • Connect pressure gauge to "stick" valve.
• Start engine and place throttle control to full.
16. Lower machine down onto the ground, stop
the engine and replace the final drive • Set PILOT PRESSURE.
inspection covers. • Place throttle control to 1/4 throttle.
• Set stick main relief.
SET STRAIGHT TRAVEL • Stop engine, re-connect brake lines.
Following completion of TRACK SPEED SET- • Replace inspection covers.
UP PROCEDURE, try driving machine in both RIGHT TRACK ADJUSTMENT
forward and reverse directions with the
Follow LEFT TRACK ADJUSTMENT
‘DRIVE/LOW’ switch in both ‘HIGH’ and ‘LOW’
procedure above but use "hoist" control valve.
positions.
If machine does not travel straight, the right
and left track speeds are not set the same, SUMMERY OF TRACK SPEED SET-UP
therefore the above set-up procedures need PROCEDURE
to be rechecked. • Park machine on level ground.
• Ensure hydraulic oil is at operating
temperature.
• Remove final drive inspection covers.
• Raise LEFT track off ground.
• Set LEFT track low speed.
• Set LEFT track high speed.
• Raise RIGHT track off ground.
• Set RIGHT track low speed.
• Set RIGHT track high speed.
• Lower machine onto ground.
• Set straight travel.
• Replace inspection covers.
11.17
TRACK COMPONENTS
IMPORTANT:
New machine: Before driving a new machine HARD
ensure that track sag is set correctly. Track sag may SURFACE
SUPPORT
be set less than specified for shipping purposes. BLOCK
The correct track sag must be adjusted once a

machine has been delivered to the job sight and •
operating in the accumulated soil build-up in the •
undercarriage. 240T-17
LIFTING TRACK
TRACK SAG NOTE: MEASURING TRACK SAG
The track sag dimension is very important and
1. Swing boom to side of machine.
should be checked regularly, 50% increase in the
life of the track assembly can be realized, 2. Place grapple on ground as shown and by
particularly bushing O/D wear and track pitch by forcing down with boom controls, lift track
maintaining the correct amount of track sag. A track clear of ground.
that is too tight will wear out significantly faster due 3. Rotate track in forward and reverse several
to increased tension in the chain. times. Stop the track while in reverse. Do not
Track components operate under varying terrain clean the track.
conditions, most of which cause excessive wear. 4. Stop engine.
Wear to one component can quickly spread to the
rest of the track assembly. 5. Measure distance between top surface of
track shoe at centre of lower surface of track
To ensure that the track components are always in frame.
good running order, a periodic inspection should be
made to ensure that components have not come
loose, that bolts are at the correct torque, that
components are within the specified wear limits
(discussed further in this section) and where
applicable, check lubrication points.
For a guide on inspection, refer to the PERIODIC UNDERSIDE OF
SAG
DIMENSION
MAINTENANCE SCHEDULE in SECTION 3 OF TRACK GUARD
THIS MANUAL. •
•
UPPER SURFACE
OF TRACK SHOE
853ILL8 MEASURING SAG DIMENSION

DRIVE
SPROCKET
6. This dimension should be between 6" and 8"
for normal operations.
IDLER
NOTE: If track sag is less than specified, track
chain wear will be accelerated. If track sag is
• • excessive, it is possible for the track to jump off
the sprocket.
OPERATE MACHINE WITH
240T-16 GRAPPLE OVER IDLERS
OPERATING THE MACHINE
Whenever possible the machine should always be
operated with the felling head over the IDLERS and
not over the SPROCKETS.
Operating over the sprockets will result in
overloading of the contact surfaces between the
sprocket and the track bushings. Bushings could
crack during sprocket impact.
11.18
IDLER
TORQUING UNDERCARRIAGE BOLTS
ADJUSTING 4 •
CYLINDER It is important to check the torque values of the
track shoe retaining bolts and the bottom roller
retaining bolts at the NEW MACHINE
MAINTENANCE time period (first 100 hours) and
3 the EVERY 125 HOURS SCHEDULED
MAINTENANCE time period.
DO NOT
REMOVE
•
When installing new components, all traces of
paint and dirt must be removed from all mating
• surfaces including the contact area under the bolt
• •
head and nut.
CW001-3 1 2
Both the bolt and the nut on the track shoes
CW001-2 TRACK ADJUSTMENT
should be lightly lubricated with SAE 30 oil and
TRACK SAG ADJUSTMENT tightened using the Torque-turn method.
To tighten track, attach adjustment fitting adapter The torque-turn method involves torquing the
(3) onto valve body (1). Connect a grease gun to bolt to an initial predetermined value, plus an
the grease fitting (2) on the adjustment fitting additional 1/3 turn (not the value shown in the
adapter (3). Add grease until track sag dimension torque charts). This ensures a more accurate and
is within recommended limits. Remove adjustment consistent torquing of the bolts, with less
fitting adapter. likelihood of the bolt/nut coming loose later.
CAUTION: The grease is under very high When checking the torque values at the first 100
pressure, DO NOT REMOVE the adjustment hours and every 125 hours thereafter use the
fitting valve body (1) from the idler adjusting CHECKING TORQUE values listed in the
cylinder (4). following paragraphs.
To loosen track, slowly loosen valve body (1) until If loose shoes or under torqued bolts are
grease begins to escape via a relief passage in discovered during the FIRST 100 HOUR check,
the valve body housing, grease will be seen they should be removed, surfaces cleaned, and
escaping from around valve body threads. When reused using the torque-turn method. If the shoe
track sag is correct, tighten valve body. is not loose but a single bolt is low on torque,
loosen the bolt and re torque-turn.
If loose or under torqued bolts are discovered any
time after the 100 HOUR check, the bolts and
nuts must be replaced with NEW ones, surfaces
cleaned, and re torque-turned.
TRACK SHOE RETAINING BOLTS

Track shoes must be fastened together applying
the exact torque values shown below and using
the Torque-turn method described in TORQUING
UNDER CARRIAGE BOLTS earlier in this section.
TORQUE 1
TRACK COMPONENT TORQUE VALUES
11.19
Track shoe bolts and nuts are designed
specifically for this purpose and should not be
substituted with standard off the shelf hardware. SINGLE GROUSER
Only bolts with grade '12.9' or '170' designation BERC-9
forged in the head are approved.
When checking the torque values at the first 100
hours and every 125 hours thereafter use the DOUBLE GROUSER
checking torque value.
BERC-10
Track shoe bolts ~ 3/4" UNC
TORQUE-TURN ............ 220LBF/FT. + 1/3 TURN.
CHECKING TORQUE ....................... 450 LBF/FT. TRIPLE GROUSER
ROLLER RETAINING BOLTS BERC-1
The rollers must be fastened to the lower frame GROUSER WEAR (HEIGHT)
applying the exact torque values shown below. WEAR LIMITS
When installing new rollers, apply "NEVER-SEEZ" TRACK SHOE GROUSER HEIGHT WEAR
to the bolt.
WEAR LIMITS
When checking the torque values at the first 100 New 75% wear 100% wear
hours and every 125 hours thereafter use the Single 2.82"(716.2mm) ... 1.37" (348mm) ........ 0.93" (236.2mm)
torque value(s) shown below. Double 1.37"(348mm) ...... 0.71" (180.3mm) ..... 0.43" (109.2mm)
Triple 1.06"(269.2mm) ... 0.51" (129.5mm) ..... 0.36" (91.4mm)
Roller bolts ~ 7/8" UNC
TORQUE .......................................... 450 LBF/FT. NOTE: Allowable wear for soft ground conditions
is 100%. Allowable wear for rocky ground
For a complete maintenance check Refer to the
conditions is 75%.
PREVENTIVE MAINTENANCE SCHEDULE in
SECTION 3 of this manual.
BERC-2 TRACK LINK WEAR (HEIGHT)
TRACK LINK WEAR

WEAR LIMITS
New link height ........................ 4.78" (121.5mm)
50% wear ................................ 4.60" (116.8mm)
75% wear ................................ 4.48" (113.8mm)
100% wear .............................. 4.34" (110.2mm)
11.20
PIN AND BUSHING WEAR BUSHING WEAR, OUTSIDE DIAMETER
To obtain the track internal wear, i.e., the wear Use a calliper to measure the wear of the bushing
between the pin and the internal diameter of the O.D. in three places.
bushing, measure the track pitch over four
sections of track (5 pins).
45° 45° REVERSE

FORWARD SIDE
SIDE VERTICAL WEAR
WEAR WEAR
BERC-3 MEASURING TRACK PITCH MEASURING BUSHING WEAR BERC-5
To take this measurement, NOTE: Bushing outside diameter is measured at

1. Remove slack by placing a steel pin between three places because of the forward and reverse
sprocket and chain, then slowly move travel of the machine and a vertical wear that
machine in reverse to tighten chain. takes place.
2. Measure pitch across two four link sections, WEAR LIMITS

except section on each side of the master pin, New bushing O.D. ........................ 2.62" (66.6mm)
to find average chain wear. 75% worn ..................................... 2.5" (63.5mm)
100% worn ................................... 2.43" (61.7mm)
INTERNAL PIN & NOTE: Allowable wear in rocky ground is 75%
BUSHING WEAR
180° ROLLER WEAR

EXTERNAL TURN
BUSHING PIN &
Measure the roller diameter on the tread contact
WEAR ROTATION BUSHING surface with a large calliper to obtain the worst
180°
wear condition.
BERC-4 PIN/BUSHING INTERNAL WEAR
NOTE: Wear to the pins and bushings only occurs
in a small localised area, to extend the life of
these components, the pins and bushings may be
turned 180° or replaced provided other
components are within specified wear limits:
1. Track link wear is 75% or less.
2. Change in track pitch is 32.50:" (825.5mm)
per link or less.
3. Bushing external wear less than 100% or BERC-6 MEASURING ROLLER WEAR
75% or less in rocky ground.
If accessibility to the rollers is impaired by guards,
4. There is at least 0.008" (0.2mm) press fit then concentrate on the front and rear rollers,
available between pin and bushing and link. these will be the most worn.
WEAR LIMITS WEAR LIMITS, LARGER ROLLERS
New length of four sections ............. 32" (813.0mm) New roller. ................................... 8.26" (210.0mm)
75% worn ......................................... 32.37"(822.2mm) 75% worn .................................... 7.64" (194.0mm)
100% worn ....................................... 32.50"(825.5mm) 100% worn .................................. 7.36" (187.0mm)
NOTE: Allowable wear in rocky ground is 75% WEAR LIMITS, SMALLER & UPPER ROLLERS
NOTE: These wear limits are to be used as a New roller. ................................... 6.61" (168.0mm)
guide for when to turn the pins and bushings. If 75% worn .................................... 6.10" (155.0mm)
pins and bushings are not to be turned, the chain 100% worn .................................. 5.91" (150.0mm)
can be run past the 100% wear limit, until chain
failure.
11.21
IDLER WEAR
Measure the idler wheel side diameters (tread
contact surface) at several points to obtain the
worst wear condition. Position a depth gauge or
measuring tape as close as possible toward the
centre of the idler with the gauge flat on the
centre flange and parallel to the idler shaft.
BERC-7 MEASURING IDLER WEAR

WEAR LIMITS
New idler dimension ...................... 0.85"(22.0mm)
100% wear .................................... 1.18"(30.0mm)
11.22
SECTION 12 - BOOM
AUGUST, 2006
CIRCUIT DESCRIPTION ............................................................................. 12.4
CIRCUIT DIAGRAM ..................................................................................... 12.5
CONTROL VALVES
HOIST CONTROL VALVE ........................................................................ 12.2
JOYSTICK CONTROL VALVE. SEE SERVICE MANUAL SECTION 5
STICK CONTROL VALVE ........................................................................ 12.2
FILTERS
HYDRAULIC RETURN ............................................................................. 12.3
HOIST VALVE RELIEF VALVE SETTINGS ................................................. 12.6
PRESSURE SETTINGS
SUMMARY ..................................................................................... 12.6, 12.7
STICK VALVE RELIEF VALVE SETTINGS .................................................. 12.7
Tigercat T240B Track Loader Boom functions
BOOM SYSTEM COMPONENTS The operation of a typical external gear pump (so
called because the gear teeth are on the external
BOOM PUMP
surface of the hub) is shown in Figure gear1.
The pump is bolted onto the bell housing and
A gear pump carries oil from the inlet to the outlet
driven directly off the engine. To ensure optimum
in the spaces between gear teeth. The pumping
performance of the hydraulic system when
chamber is formed by the gears, the pump
operating the machine, the engine must always
housing, and side plates. One of the two gears,
be set at FULL throttle.
called the drive gear, will be connected to the
BOOM PUMPS drive shaft. The other idler gear is driven by the
•• SWING PUMP drive gear.
BELL JOYSTICK CONTROL VALVE

HOUSING
The hoist boom and stick boom functions are
controlled by the left and right joysticks which
when operated send proportional pilot signals to
• • • the two boom control valves which supply oil to
the two boom cylinders.
For a detailed description of the joystick control
valve refer to SECTION 5 in THIS MANUAL.
BOOM CONTROL VALVES

The hoist boom and stick boom are each
278-3A GEAR PUMP controlled by two spool sections located in two
separate identical control valves. Each control
A gear pump consisting of three gear housing valve consists of three pilot operated, open center
sections, all connected together internally supply spool sections, an inlet section and an outlet
hydraulic oil to all of the functions on the machine section. The outlet section directs return oil back
except the pilot system. The first two gear to tank. The control valves are located in the
housings at the shaft end supply oil for the boom upper frame below the floor plates inside the
functions and the end gear housing supplies oil valve compartment.
for the swing circuit.
OUTLET
DRIVEN DRIVE
(IDLER) GEAR
GEAR
• •
INLET
GEAR1 TYPICAL GEAR PUMP
12.2
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 psi
against overload pressures. cracking pressure so that oil can bypass the filters
if they become restricted. The "in" side of the filter
HYDRAULIC RETURN FILTERS heads are connected to a return manifold. A filter
The majority of return oil entering the hydraulic restriction indicator and an oil sampling connector
tank passes through 4 spin-on hydraulic oil filters. are mounted onto the manifold. To check the
One of the filters is a water absorbing filter (color condition of the filter elements; With the hydraulic
blue) which is in place to assist with the removal oil at normal operating temperature, place
of unwanted moisture from the hydraulic oil (the engine throttle control to FULL and with no
filters are 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
PASSAGE BRIDGE
12.3
HOIST 'DOWN' STICK 'DOWN'
PORT RELIEF PORT RELIEF
(1500 PSI) (1500 PSI)
MAIN RELIEF
(3000 PSI)
OUTLET OUTLET
SECTION SECTION
• •
• •
•
LEFT FORWARD
FORWARD TRACK REVERSE
SLASHER
DOWN
DOWN
GRAPPLE
CLOSE
OPEN/
TRACK
RIGHT
HOIST
STICK
• •
REVERSE
SPARE
UP
UP
• •
• GAUGE •
TEST PORT GAUGE
TEST PORT
INLET
SECTION INLET
SECTION
HOIST 'UP'
PORT RELIEF STICK 'UP' PORT RELIEF
(3000 PSI) (3000 PSI)
AT047IL TRACK & BOOM CONTROL VALVES
BOOM CIRCUIT DESCRIPTION

The boom circuit is supplied with oil from two of
the three gear housing sections on the main
pump. Each of the two boom valves receive oil at
the inlet sections and directs the oil through the
three open center spool sections, to the outlet
section. From there it is directed back to tank via
a check valve to the return manifold and two dual
element filters, which are equipped with an
internal 25 psi element bypass valve.
Moving either of the joysticks in the cab will direct
pilot oil to the ends of the hoist or stick spool
sections in the boom valves to shift the spools and
direct hydraulic oil from the pump to the hoist or
stick hydraulic cylinders to raise or lower to
booms. Return oil from the cylinders is directed
back through the spool sections, to the outlet
section, through the return manifold, the two dual
head return oil filters and back to tank.
12.4
240T2-012 BOOM CIRCUIT
12.5
IMPORTANT
CAUTION Approach the gauge reading slowly and
Use caution when in the cab as a slight deliberately by turning the adjusting screw in
touch of the controls can cause a little at a time. The pressure setting must
sudden rotation of the upper frame and not exceed the above value.
booms or movement of the tracks the FULL position.
7. While holding the L.H. joystick in the HOIST
CAUTION UP position (fully extended), check gauge
Be aware of other personnel in the area. pressure reading. If less than set value, turn
Operator is responsible for the safe relief valve adjusting screw in until set value
operation of the machine. is obtained on gauge.
8. Tighten locknut on adjusting screw taking
care not to turn the adjusting screw.
WARNING
Ensure that no one is standing near the DOWN position (fully retracted), check gauge
grapple during this procedure. pressure reading. If less than set value, turn
relief valve adjusting screw in until set value
IMPORTANT is obtained on gauge.
Avoid blowing oil over relief for longer 10. Tighten locknut on adjusting screw taking
than five seconds, as this will cause care not to turn the adjusting screw.
excessive heating of the hydraulic fluid. 11. Repeat steps 7 and 9 to verify settings.
PRESSURE SETTINGS reset main relief valve:
HOIST VALVE RELIEF VALVE SETTINGS 12. Loosen locknut on "hoist" main relief and
unscrew adjusting screw 3 full turns.
Hoist main relief setting ...................... 3000 psi
Hoist up port relief setting .................. 3500 psi
UP position (fully extended), check gauge
Hoist down port relief setting ............. 1500 psi pressure reading. If less than set value, turn
relief valve adjusting screw in until set value
1. Position machine on flat level ground.
is obtained on gauge.
temperature.
3. Connect a 0 - 5000 p.s.i. pressure gauge to
15. Stop engine. Remove pressure gauge and
the "hoist" control valve test port on the inlet
wipe up any excess oil from test port area.
4. Loosen the locknut on the "hoist" main relief SUMMARY:
valve and turn the relief adjusting screw all
the way in, tighten locknut.
temperature.
5. Turn both port relief valve adjusting screws on
2. Connect gauge to "hoist" valve.
the "hoist" spool section of the valve out until
spring pressure is relieved then turn adjusting 3. Turn main relief fully "in".
screws one full turn in. 4. Turn both "hoist" port reliefs out.
6. Start the engine, and put the throttle control to 5. Start engine.
6. Set HOIST UP port relief.
7. Set HOIST DOWN port relief.
8. Reset main relief.
12.6
CAUTION IMPORTANT
Use caution when in the cab as a slight Approach the gauge reading slowly and
touch of the controls can cause deliberately by turning the adjusting screw in a
sudden rotation of the upper frame and little at a time. The pressure setting must not
booms or movement of the tracks exceed the above value.
7. While holding the R.H. joystick in the STICK
CAUTION OUT position (fully extended), check gauge
pressure reading. If less than set value, turn
Be aware of other personnel in the area. relief valve adjusting screw in until set value is
Operator is responsible for the safe obtained on gauge.
8. Tighten locknut on adjusting screw taking care
not to turn the adjusting screw.
WARNING
9. While holding the R.H. joystick in the STICK
Ensure that no one is standing near the IN position (fully retracted), check gauge
grapple during this procedure. pressure reading. If less than set value, turn
relief valve adjusting screw in until set value is
obtained on gauge.
IMPORTANT
Avoid blowing oil over relief for longer
than five seconds, as this will cause
excessive heating of the hydraulic fluid. 11. Repeat steps 7 and 9 to verify setting.
reset main relief valve:
STICK VALVE RELIEF VALVE SETTINGS 12. Loosen locknut on "stick" main relief and
Stick main relief setting ....................... 3000 psi unscrew adjusting screw 3 full turns.
Stick out port relief setting .................. 3500 psi 13. While holding the R.H. joystick in the stick
OUT position (fully extended), check gauge
Stick in port relief setting .................... 1500 psi
pressure reading. If less than set value, turn
1. Position machine on flat level ground. relief valve adjusting screw in until set value is
obtained on gauge.
temperature. 14. Tighten locknut on adjusting screw taking care
the "stick" control valve test port on the inlet 15. Stop engine. Remove pressure gauge and
section of the valve. wipe up any excess oil from test port area.
4. Loosen the locknut on the "stick" main relief
SUMMARY:
valve and turn the relief adjusting screw all
the way in, tighten locknut. 1. Ensure hydraulic oil is at operating temperature.
5. Turn both port relief valve adjusting screws 2. Connect gauge to "stick" valve.
on the "stick" spool section of the valve out 3. Turn main relief fully "in".
until spring pressure is relieved then turn
adjusting screws one full turn in. 4. Turn both "stick" port reliefs out.
6. Start the engine, and put the throttle control 5. Start engine.
to the FULL position. 6. Set STICK UP port relief.
7. Set STICK DOWN port relief.
12.7
12.8
SECTION 15 - SWING
AUGUST, 2006
CIRCUIT DIAGRAM ..................................................................................... 15.7
CONTROL VALVES
FOOT PEDAL CONTROL VALVE. SEE SERVICE MANUAL SECTION 5
SWING CONTROL VALVE ...................................................................... 15.2
GEARBOX, SWING DRIVE ......................................................................... 15.5
PRESSURE SETTINGS
SET SWING MOTOR CROSSLINE RELIEF VALVES ............................. 15.9
SET SWING RELIEF VALVES ................................................................. 15.8
SUMMARY ............................................................................................... 15.9
SWING MOTOR ........................................................................................... 15.4
MOTOR CROSSLINE RELIEF VALVE ..................................................... 15.6
MOTOR REMOVAL NOTE ....................................................................... 15.4
SWING PUMP .............................................................................................. 15.2
Tigercat T240B Track Loader Swing
SWING DRIVE COMPONENTS In the neutral position the foot pedal is held
SWING PUMP centered by return springs (4). When the lever
(1) is operated, the plunger (5) is pushed against
The swing pump is a fixed displacement external its return spring (4). At the same time the
triple gear pump. regulating spool (2) is moved down against the
BOOM PUMPS
regulating spring (3). When the regulating stroke
•• SWING PUMP
begins, there is a connection made between the
pressure port, via holes (8) in the spool and work
BELL ports in the base of the valve.
HOUSING
Pilot pressure is directly proportional to the
operator position of the foot pedal and the
regulating spring characteristics.
• • •
SWING CONTROL VALVE
The swing drive is controlled by one of three
spool sections in a three section control valve.
The control valve consists of three pilot operated,
open center spool sections, an inlet section and
an outlet section. The outlet section directs return
GEAR PUMP oil back to tank. The control valve is located in
278-3A
the upper frame below the floor plates inside the
The swing drive system utilizes the third gear valve compartment.
housing from the shaft end of the pump to supply CONTROL VALVE OPERATING DESCRIPTION
hydraulic oil to the swing valve. Oil enters the inlet section and is allowed to pass
For a more detailed description of the triple gear through the three spool sections and back to tank
pump, refer to SECTION 12 in THIS SERVICE via the outlet section. Each of these spool
MANUAL. 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
1 applied to either end of the spool. Shifting the
• spool directs oil to operate any one of the three
5 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
3 have a port relief valve with an anti-cavitation
•
• • function.
TANK
PORT A main relief valve is installed in the inlet section
4
of the valve to protect the hydraulic system
8 against overload pressures.
•
•
2
• •
WORK PRESSURE WORK
PORT PORT PORT
FOOT PEDAL PILOT VALVE (KAWASAKI)

AW017
FOOT PEDAL CONTROL VALVE

The swing function is controlled by the center foot
pedal valve which sends proportional pilot signals
to the swing valve which supplies oil to the swing
motor.
15.2
SWING 'CW'
PORT RELIEF
(3000 PSI)
MAIN RELIEF
(2500 PSI)
• •
GAUGE
TEST
PORT
RETRACT
SLASHER
CW
GRAPPLE
ROTATE
SWING
•
DELIMBER
CCW
OPEN
• •
INLET
SECTION
OUTLET
SECTION
SWING 'CCW'
PORT RELIEF
(3000 PSI)
AT041ZIL SWING CONTROL VALVE
RELIEF
PORT 'A' VALVE
PORT 'B'
A B
SPOOL
CENTERING
SPRINGS
• •
•
• • •
•
•
• •
• •
• • •
PILOT
END PILOT
CAP SPOOL END
CAP
PASSAGE BRIDGE
AT041YIL
CROSS SECTION OF SPOOL SECTIONS
15.3
SWING MOTOR coupling, and the other is an idler gear. Not shown
in the illustration are the side plates, which create
The swing motor is a gear motor with two, 2-stage
a sealing wear surface on the sides of the gear
crossline relief valves mounted on the port end
set.
cover. The crossline relief valves provide a
CROSS LINE RELIEF VALVES Gear motors operate because of a pressure
differential, between the motor inlet and outlet.
This pressure differential acts across the gear
•• •• teeth, creating a force that tries to rotate the gear.
As the diagram shows, there are two paths
around the periphery of the gears, and one path
• •• through the intersection of the two gears. In each
path, the pressure works against the area of one
CASE tooth so that there are two tooth forces working in
DRAIN
PRESSURE LINE one direction, and one tooth force working in the
PORTS •• opposite direction. The net result is the force of
•• SYSTEM
one tooth working around the periphery to rotate
the output shaft.
PRESSURE
LINES ••
SWING DRIVE
266-7 SWING MOTOR MOTOR
cushion to the high forces that occur during start

and stop of the boom swing. The 2-stage relief
involves increasing the relief setting by 1000 psi ••
during swing acceleration. When coasting to a
stop, the relief valve opens at a lower pressure
CONNECTING
resulting in a soft stop. HOSE FROM OIL
RESERVOIR
4. THESE TWO TEETH HAVE ONLY

TANK LINE PRESSURE
OPPOSING THEM.
3. PRESSURE BETWEEN
TEETH IN THIS 3. PRESSURE BETWEEN
••
SEGMENT PUSHES TEETH IN THIS
BOTH WAYS AND SEGMENT PUSHES
DOES NOT AFFECT BOTH WAYS AND
TORQUE AS OIL IS DOES NOT AFFECT
CARRIED AROUND TO TORQUE AS OIL IS
OUTLET. CARRIED AROUND TO
OUTLET.
• • ••
•
• ••
OIL FILL
• TUBE
• • SWING DRIVE
GEARBOX
206-15A SWING DRIVE GEARBOX

1. THESE TWO TEETH ARE 2. SEGMENTS OF TWO
SUBJECT TO HIGH PRESSURE MESHING TEETH TEND TO MOTOR REMOVAL NOTE:
AND TEND TO ROTATE GEARS OPPOSE ROTATION
IN DIRECTION OF ARROWS. MAKING NET TORQUE Before removing the drive motor, drain the oil
AVAILABLE A FUNCTION OF
ONE TOOTH. from the reservoir bottle by disconnecting the
GEAR3 TYPICAL GEAR MOTOR hose at the oil fill tube. Replace the oil fill tube.
A cross sectional view of an external gear
IMPORTANT: Do not allow dirt to enter the
hydraulic motor is shown in Figure Gear3 This
gearbox during and after the motor has been
design is referred to as “external gear” design
removed.
because the gear teeth are machined on the
outside of the gears. One of the gears is After the motor has been replaced, partly fill the
connected to an output shaft which in turn is reservoir with correct oil. Bleed swing gearbox by
connected to the swing drive gearbox input loosening air bleed plug. Add oil to reservoir until
half full.
15.4
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
SWING CIRCUIT DESCRIPTION
The swing circuit is supplied with hydraulic oil by a
fixed displacement gear pump. The swing valve
receives oil at the inlet section and directs it
through the three open center spool sections, to
the outlet section. From there it is directed back to
tank via the oil cooler, a check valve to the return
manifold and two dual element filters. A 50 psi.
relief valve is installed in the oil cooler line to
bypass the oil around the oil cooler, usually on
cold start ups when the oil is cold and thicker.
Pressing the foot pedal in the cab directs pilot oil
to either end of the swing spool section on the
swing valve to shift the spool and direct hydraulic
oil to the swing motor causing it to rotate either
clockwise or counterclockwise.
HIGH RELIEF VALVE LOCKNUT

PRESSURE ADJUSTER ADJUSTING SHIMS FOR
HOSE SECOND STAGE ADDITIONAL
CONNECTION 1000 PSI RELIEF SETTING
(FACTORY SET)
• •
•
AQ014-2MOTOR CROSSLINE RELIEF VALVE

Crossline relief valves on the motor provide a
cushion to the high forces that occur during start
and stop of the boom swing. The crossline relief
valves used on this motor are 2-stage which
means that when the foot pedal is pressed and
the control valve spool shifts to swing the upper
frame, inertia caused by the mass of the upper
frame creates a pressure increase at the inlet
section of the control valve. This pressure
increase is transmitted through a hose line
connected to the ends of the crossline relief
valves. A piston in the end of each relief valve
moves to activate the high pressure relief setting
to provide a faster swing acceleration time. During
deceleration the relief valve opens at the low
pressure setting resulting in a softer stop. Internal
leakage in the swing motor is returned to tank via
the case drain port on the motor, through the dual
element return filter.
15.6
240B-018
SWING DRIVE CIRCUIT - LATER MACHINES
15.7
PRESSURE SETTINGS 8. Lower boom assembly to the ground and
restrict boom swing movement in both
CAUTION directions.
Use caution when in the cab as a slight 9. With the aid of an assistant, Press and hold
touch of the controls can cause the swing foot pedal in the SWING LEFT
sudden rotation of the upper frame and position, check gauge pressure reading. If
booms or movement of the stabilizers less than set value, turn swing left relief valve
adjusting screw in until set value is obtained
CAUTION on gauge.
Be aware of other personnel in the area.

Operator is responsible for the safe IMPORTANT
operation of the machine. Approach the gauge reading slowly and
deliberately by turning the adjusting screw in
a little at a time. The pressure setting must
WARNING not exceed the above value.
11. Press and hold the swing foot pedal in the
IMPORTANT SWING RIGHT position, check gauge
Avoid blowing oil over relief for longer pressure reading. If less than set value, turn
than five seconds, as this will cause swing right relief valve adjusting screw in until
excessive heating of the hydraulic fluid. set value is obtained on gauge.
SET SWING RELIEF VALVES care not to turn the adjusting screw.
Swing main relief valve setting ........... 2500 psi 13. Repeat steps 9 and 11 to verify settings.
Swing left port relief setting ................ 3000 psi reset main relief valve:
Swing right down port relief setting ... 3000 psi 14. Loosen locknut on swing main relief and
Motor crossline relief valves (low setting) unscrew adjusting screw 3 full turns.
Left ................................................... 2000 psi 15. While holding the foot pedal in the SWING
Right ................................................ 2000 psi LEFT position, check gauge pressure
1. Position machine on flat level ground. reading. If less than set value, turn swing
main relief valve adjusting screw in until set
value is obtained on gauge.
temperature.
3. Loosen locknut on the swing main relief valve
and turn main relief adjusting screw all the
way in, tighten locknut.
4. Turn both port relief valve adjusting screws on
the swing spool section of the valve out until
spring pressure is relieved then turn adjusting
screws one full turn in.
5. Loosen locknut on motor crossline relief
valves and turn relief valve adjusters all the
6. Install a 0-5000 psi pressure gauge on the
test port at the inlet section of the swing
valve.
7. Start engine and place throttle control in
FULL.
15.8
SET SWING MOTOR CROSSLINE RELIEF VALVES
17. Set engine throttle control to IDLE.
18. Disconnect each hose from the ends of the
crossline relief valves and install steel plugs in
hose ends. Install caps on crossline relief
valves.
19. While holding the foot pedal in the SWING
LEFT position, check gauge pressure
reading. If less than set value, turn swing left
crossline relief valve adjuster in until set
20. Tighten locknut on adjuster taking care not to
turn the adjuster.
21. While holding the foot pedal in the SWING
RIGHT position, check gauge pressure
reading. If less than set value, turn swing right
crossline relief valve adjuster in until set
22. Tighten locknut on adjuster taking care not to
turn the adjuster.
23. Repeat steps 18 and 21 to verify settings.
24. Stop engine. Remove pressure gauge and
25. Reconnect two hoses to ends of crossline
relief valves.
SUMMARY:
temperature.
2. Turn main relief on "swing" valve fully in.
3. Turn both "swing" port reliefs out.
4. Turn motor crossline relief full in.
5. Connect gauge to "swing" valve.
6. Start engine.
7. Set SWING LEFT port relief.
8. Set SWING RIGHT port relief.
Set swing motor crossline reliefs:-
10. Disconnect hoses from both crossline reliefs
and plug hoses .
11. Set SWING LEFT crossline relief.
12. Set SWING RIGHT crossline relief.
13. Reconnect hoses to crossline reliefs.
15.9
15.10
SECTION 17 - GRAPPLE
AUGUST, 2006
CIRCUIT DIAGRAM ..................................................................................... 17.5
GRAPPLE CONNECTIONS TO BOOM ....................................................... 17.2
GRAPPLE CONTROL VALVES ................................................................... 17.2
GRAPPLE PUMP ......................................................................................... 17.2
JOYSTICK CONTROL VALVE ..................................................................... 17.2
PRESSURE SETTINGS
GRAPPLE OPEN/CLOSE ......................................................................... 17.6
GRAPPLE ROTATE ................................................................................. 17.7
SUMMARY ............................................................................................... 17.8
Tigercat T240B Track Loader Grapple
GRAPPLE SYSTEM COMPONENTS GRAPPLE CONTROL VALVES
PUMP The grapple open/close function is controlled by
one of three spool sections in the "hoist" valve
This is a fixed displacement external triple gear
and the grapple rotate motor is controlled by one
pump.
of three spool section in the "swing" valve. The
control valves are located in the upper frame
below the floor plates inside the valve
GRAPPLE ROTATE PUMP compartment.
GRAPPLE PUMP STICK PUMP For a detailed description of the "hoist" and
"swing" control valves, refer to SECTIONS 12 and
15 in THIS MANUAL.
•• GRAPPLE CONNECTIONS TO BOOM

• • When a factory installed grapple is not specified,
hydraulic lines are provided up to the end of the
boom and sealed off with steel plugs.
•
BELL
HOUSING
278-3A GEAR PUMP
The grapple circuit utilizes two of the three gear

housings of this pump to supply hydraulic oil to
the grapple open/close control valve spool section
and the grapple rotate control valve spool section
in the "hoist" valve and the "swing" valve.
For a more detailed description of the triple gear
pump, refer to SECTION 12 in THIS SERVICE 277-8 GRAPPLE CONNECTIONS
MANUAL.
JOYSTICK CONTROL VALVE

The grapple open/close and grapple rotate
functions are controlled by the left and right
joysticks which when operated send proportional
pilot signals to the "hoist" and "swing" control
valves to shift a spool(s) and supply system oil to
the grapple open/close cylinders and the grapple
rotate motor.
For a detailed description of the joystick control
valve refer to SECTION 5 in THIS MANUAL.
17.2
GRAPPLE
ROTATE GRAPPLE 'CLOSE'
'CLOCKWISE' PORT RELIEF
PORT RELIEF (3500 PSI)
MAIN RELIEF (3000 PSI)
(2500 PSI)
OUTLET OUTLET
SECTION SECTION
• •
• •
•
FORWARD TRACK REVERSE

•
RETRACT
SLASHER
DOWN
CW
GRAPPLE
GRAPPLE
SWING
ROTATE
CLOSE
OPEN/
RIGHT
HOIST
• •
DELIMBER
OPEN
UP
CCW
• •
• • GAUGE
GAUGE TEST
TEST PORT PORT
INLET
INLET SECTION
SECTION
GRAPPLE ROTATE GRAPPLE 'OPEN'

'COUNTERCLOCKWISE' PORT RELIEF
PORT RELIEF (3500 PSI)
(1750 PSI)
AT047IL GRAPPLE OPEN/CLOSE & GRAPPLE ROTATE CONTROL VALVES
RELIEF
PORT 'A' VALVE
A B PORT 'B'
SPOOL
CENTERING
• • SPRINGS
•
• •
• •
•
• •
• •
• •
•
PILOT
END PILOT
CAP SPOOL END
CAP
PASSAGE BRIDGE
17.3
GRAPPLE CIRCUIT DESCRIPTION
The grapple circuit is supplied with oil from two of
the three gear housing sections on the main
pump. The "hoist" and "swing" valves receive oil
at their inlet sections and direct the oil through the
three open center spool sections, to the outlet
section. From there it is directed back to tank via
a check valve to the return manifold and two dual
element filters, which are equipped with an
internal 25 psi element bypass valve.
Moving L.H. joystick in the cab will direct pilot oil
to the ends of the open/close spool section in the
"hoist" valve to shift the spool and direct hydraulic
oil from the pump to the grapple open/close
hydraulic cylinders to OPEN or CLOSE the
grapple arms.
Return oil from the cylinders is directed back
through the spool sections, to the outlet section,
through the dual head return oil filter and back to
tank.
Moving R.H. joystick in the cab will direct pilot oil
to the ends of the grapple rotate spool section in
the "swing" valve to shift the spool and direct
hydraulic oil from the pump to the swing motor to
rotate the grapple in either a CLOCKWISE or
COUNTERCLOCKWISE direction.
17.4
230B-17 GRAPPLE CIRCUIT
17.5
7. While holding the L.H. joystick in the
CAUTION GRAPPLE OPEN position (cylinders fully
Use caution when in the cab as a slight retracted), check gauge pressure reading. If
touch of the controls can cause less than set value, turn relief valve adjusting
sudden rotation of the upper frame and screw in until set value is obtained on gauge.
booms or movement of the tracks
IMPORTANT
CAUTION Approach the gauge reading slowly and
Be aware of other personnel in the area. deliberately by turning the adjusting screw in
Operator is responsible for the safe a little at a time. The pressure setting must
operation of the machine. not exceed the above value.
WARNING care not to turn the adjusting screw.
GRAPPLE CLOSE position (cylinders fully
extended), check gauge pressure reading. If
less than set value, turn relief valve adjusting
IMPORTANT screw in until set value is obtained on gauge.
Avoid blowing oil over relief for longer 10. Tighten locknut on adjusting screw taking
than five seconds, as this will cause care not to turn the adjusting screw.
excessive heating of the hydraulic fluid.
reset main relief valve:
PRESSURE SETTINGS 11. Loosen locknut on "hoist" main relief and
unscrew adjusting screw 3 full turns.
GRAPPLE OPEN/CLOSE RELIEF VALVE SETTINGS
Grapple open/close "Hoist" main relief setting:-
GRAPPLE CLOSE position (cylinders fully
......................................................... 3000 psi extended), check gauge pressure reading. If
Grapple open port relief setting .......... 3500 psi less than set value, turn relief valve adjusting
screw in until set value is obtained on gauge.
Grapple close port relief setting ......... 3500 psi
1. Position machine on flat level ground . care not to turn the adjusting screw.
2. Ensure that the hydraulic oil is at operating 14. Stop engine. Remove pressure gauge and
temperature. wipe up any excess oil from test port area.
3. Loosen the locknut on the "hoist" main relief
valve and turn the relief adjusting screw all the
4. Loosen the locknuts on both port relief valve
adjusting screws for the GRAPPLE OPEN AND
GRAPPLE CLOSE spool section of the "hoist"
valve and turn the adjusting screws out until
spring pressure is relieved then turn adjusting
screws one full turn in.
5. Connect a 0 - 5000 p.s.i. pressure gauge to the
"hoist" control valve test port on the inlet
6. Start the engine, and put the throttle control to
the FULL position.
17.6
CAUTION IMPORTANT
Use caution when in the cab as a slight Approach the gauge reading slowly and
touch of the controls can cause deliberately by turning the adjusting screw in
sudden rotation of the upper frame and a little at a time. The pressure setting must
booms or movement of the tracks not exceed the above value.
7. While holding the R.H. joystick in the
CAUTION ROTATE CLOCKWISE position, check gauge
Be aware of other personnel in the area. pressure reading. If less than set value, turn
Operator is responsible for the safe relief valve adjusting screw in until set value
operation of the machine. is obtained on gauge.
IMPORTANT
9. 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
until set value is obtained on gauge.
GRAPPLE ROTATE RELIEF VALVE SETTINGS
Grapple rotate/"Swing" main relief setting:- care not to turn the adjusting screw.
......................................................... 2500 psi 11. Release grapple from it's secured position.
Rotate clockwise port relief setting .... 1750 psi 12. Remove pressure gauge and wipe up any
Rotate counterclockwise excess oil from test port area.
port relief setting .................................. 1750 psi
1. Position machine on flat level ground.
temperature.
3. Position and secure grapple to prevent from
rotating in either direction.
WARNING
4. Loosen the locknuts on both port relief valve
adjusting screws for the GRAPPLE ROTATE
spool section of the "swing" valve and turn the
adjusting screws out until spring pressure is
relieved then turn adjusting screws one full
turn in.
the "swing" control valve test port on the inlet
the FULL position.
17.7
SUMMARY:
1. Ensure that hydraulic oil is at operating
temperature.
2. Turn main relief on "hoist" valve fully in.
3. Turn GRAPPLE OPEN and CLOSE port
reliefs on "hoist" valve out.
4. Connect gauge to "hoist" valve.
5. Start engine.
6. Set GRAPPLE OPEN port relief on "hoist"
valve.
7. Set GRAPPLE CLOSE port relief on "hoist"
valve.
Grapple rotate/"stick" valve:-

1. Secure grapple to prevent from rotating.
2. Ensure that hydraulic oil is at operating
temperature.
3. Turn GRAPPLE ROTATE C/W and CC/W port
reliefs on "swing" valve out.
5. Set GRAPPLE ROTATE C/W port relief on
"swing" valve.
6. Set GRAPPLE ROTATE CC/W port relief on
"swing" valve.
17.8
SECTION 18 - DELIMBER/SLASHER
AUGUST, 2006
CIRCUIT DESCRIPTION ......................................................................... 18.6
CIRCUIT DIAGRAM ........................................................................ 18.7, 18.8
CONTROL VALVE DELIMBER ................................................................ 18.2
CONTROL VALVE SAWS RETRACT SLASHER CUT ............................ 18.2
DELIMBER/SLASHER CIRCUIT DESCRIPTION ..................................... 18.5
DELIMBER/SLASHER PUMP .................................................................. 18.2
ELECTRICAL CIRCUIT .......................................................................... 18.13
FUSE AND RELAY PANEL .................................................................... 18.16
PILOT MANIFOLD ................................................................................... 18.2
PRESSURE SETTINGS ........................................................................... 18.9
TROUBLE SHOOTING DELIMBER RELAY CIRCUIT .................. 18.6, 18.12
Tigercat T240B Track Loader Delimber/Slasher
DELIMBER/SLASHER DELIMBER CONTROL VALVE (SWING VALVE)
CIRCUIT COMPONENTS The delimber arms OPEN/CLOSE functions are
PUMP controlled by one of three spool sections in the
three section "swing" control valve.
This is a fixed displacement external triple gear
pump. SAW CUT CONTROL VALVE (STICK VALVE)
The saw cutting function is controlled by one of
three spool sections in the "stick" control valve.
DELIMBER
PUMP SAWS RETRACT CONTROL VALVE (SWING
SAWS CUT VALVE)
PUMP
The slasher saw cutting function and the
retraction of both the slasher saw and the top saw
are controlled by one of three spool sections in
• the "swing" control valve.
•• •• For a detailed description of the "swing", "hoist"

and "stick" control valves, refer to SECTION 12
and 15 in THIS MANUAL.
••
BELL
HOUSING
278-3A GEAR PUMP

The delimber and slasher circuits utilize two of the
three gear housings of this pump to supply
hydraulic oil to the two main control valve spool
sections of the swing valve and stick valve.
For a more detailed description of the triple gear
pump, refer to SECTION 12 in THIS SERVICE
MANUAL.
PILOT MANIFOLD
Four solenoid operated pilot valves (positions 1, 2,
and 4) on the pilot manifold control the flow of pilot
oil to operate the delimber, and saw functions.
'PB' TO SPARE SLASHER CUT
STABILIZER TOP/SLASHER
PILOT DELIMBER SAWS RETRACT
MANIFOLD OPEN
• PILOT SHUT
• •
OFF VALVE
PILOT
• • RELIEF
VALVE
•
• •
•
RETURN OIL FROM GAUGE
STABILIZER PILOT TEST PORT
MANIFOLD
For a detailed description of the pilot manifold
refer to SECTION 5 in THIS MANUAL.
18.2
MAIN RELIEF MAIN RELIEF SLASHER 'CUT' MAIN RELIEF

'SLASHER' (2500 PSI) (3000PSI) PORT RELIEF (3000PSI)
RETRACT (3000 PSI)
PORT
RELIEF
(1500 PSI)
•
• •
• •
SLASHER
RETRACT
CUT
SAWS
GRAPPLE
TRACK
STICK
ROTATE
GRAPPLE
L.H.
SWING
HOIST
TRACK
CLOSE
OPEN/
R.H.
•
SPARE
•
DELIMBER
•
OPEN
• • • •
• • • •
AT047IL
AT041ZIL AT047IL
OUTLET
SECTION
OUTLET OUTLET
SECTION SECTION GAUGE GAUGE
INLET TEST PORT TEST PORT
INLET
SECTION GAUGE SECTION
TEST INLET
PORT SECTION
DELIMBER SPARE
PORT RELIEF
(3000 PSI)
"SWING", "HOIST" AND "STICK"

CONTROL VALVES
RELIEF
PORT 'A' VALVE
PORT 'B'
A B
SPOOL
CENTERING
SPRINGS
• •
•
• • •
•
•
• •
• •
• • •
PILOT
END PILOT
CAP SPOOL END
CAP
PASSAGE BRIDGE
AT041YIL
CROSS SECTION OF SPOOL SECTIONS
18.3
DELIMBER OPEN/DUMP VALVE
The delimber open/dump valve is a solenoid
operated three way directional valve consisting of
an aluminium valve body, a screw-in, solenoid
operated valve cartridge and a screw-in check
valve cartridge. The valve is located in the upper
frame.
SOLENOID VALVE
CARTRIDGE
"D" TO DELIMBER
ARMS CYLINDER
• •
BASE END, VIA
ROTARY MANIFOLD
CHECK
VALVE
••
"V" SUPPLY FROM
DELIMBER VALVE
(SWING VALVE)
"T" TANK LINE TO
STICK VALVE
OUTLET SECTION ••
•
240B-D25 DELIMBER OPEN/DUMP VALVE
SLASHER CONNECTIONS - STANDARD

BULKHEAD
DELIMBER OPEN/DUMP VALVE

240B-027 SCHEMATIC SLASHER CONNECTIONS -
240T-028 STANDARD BULKHEAD
In the neutral position with the solenoid coil de-
activated, port 'D' is open to tank port 'T', allowing Hydraulic connections for the slasher (Standard
oil to flow from the base end of the delimber arms Bulkhead) are located on the undercarriage. The
cylinder and "dump" to tank. An orifice in the connections consist of one No.12 JIC connector
connecting port controls the flow of this return oil fittings and two No. 16 JIC connector fittings. All
so that the delimber arms do not CLOSE too fast. fittings are capped when not in use with special
steel caps to prevent leakage. Always ensure caps
When the LH. joystick switch is pressed to OPEN
are tightly in place when not operating a slasher.
the delimber arms, the solenoid coil on the dump
When making the hydraulic connection to the
valve is energized and shifts the valve cartridge to
slasher, it is very important to clean around the
block the connection between ports 'D' and 'T' and
fittings before disconnecting them to prevent dirt
instead allow system oil to flow from port 'V',
from entering the system
"through" the check valve to port 'D' to the base
end of the cylinder to open the delimber arms.
IMPORTANT
Always check hydraulic oil level after
connecting and running the delimber
and/or slasher.
18.4
CHECK SHUT-OFF CHECK SAWS CUT

VALVE BALL VALVE VALVE THREE WAY PILOT
OPERATED VALVE
•
• •• •• •
240T-025 DELIMBER SLASHER CONNECTIONS

DELIMBER/SLASHER CONNECTIONS DELIMBER BOX
Hydraulic connections for the delimber and slasher
are located on the undercarriage in the delimber
box. The connections consist of two No.12 JIC ••
connector fittings and three No. 16 JIC connector
fittings. All fittings are capped when not in use with
special steel caps to prevent leakage. Always
ensure caps are tightly in place when not operating
a delimber or slasher. When making the hydraulic
connection to either the delimber or the slasher, it
is very important to clean around the fittings before
240T-027 DELIMBER BOX
disconnecting them to prevent dirt from entering
the system. SHUT-OFF (BALL) VALVES
Two ball valves, one in the saws retract circuit and
one in the delimber open circuit provide a means
IMPORTANT
of shutting off these circuits when connecting or
Always check hydraulic oil level after disconnecting hoses.
connecting and running the delimber
and/or slasher. CHECK VALVES
Two check valves prevent the flow of hydraulic
For information on the DELIMBER or SLASHER, fluid from the tank return circuit and saws cut
please refer to the MANUFACTURERS MANUAL. circuit when connecting and disconnecting hoses.
PILOT OPERATED THREE-WAY VALVE
A pilot operated three-way directional valve
consisting of an aluminium valve body and a
screw-in, pilot operated valve cartridge is used to
divert hydraulic oil flow from the stick valve saws
cut circuit and direct the flow to the top saw cut
circuit when the pilot is deactivated and slasher cut
circuit when the pilot is activated by the delimber
open circuit.
18.5
DELIMBER/SLASHER CIRCUIT In this condition oil from the base end of the
DESCRIPTION DELIMBER ARMS CYLINDER is returned to tank
REFER TO CIRCUIT DIAGRAMS via the DELIMBER OPEN/DUMP VALVE, due to
oil entering the rod end of the cylinders from the
The delimber/slasher circuit is supplied with DELIMBER ACCUMULATOR to close the arms.
hydraulic oil by a fixed displacement gear pump.
One spool section in the stick and swing control Cut with delimber top saw; Push RIGHT side of
valves hydraulically control all of the delimber or L.H. Joystick switch, Push LEFT side of R.H.
slasher functions. The stick and swing control joystick switch, Current flows through wire 97 to
valves each receive oil at their inlet sections, from wire 39 and energizes SAW SOLENOID valve on
there it is directed through the three open center pilot manifold.
spool sections, to the outlet sections. From there Pilot oil flows through the SAW CUT solenoid pilot
it is directed back to tank via a check valve to the valve to shift the spool in the SAW CUT (stick
return manifold and two dual element filters, valve) to allow system oil to flow through the
which are equipped with an internal 25 psi ROTARY MANIFOLD to the pilot operated three-
element bypass valve. way valve. Because the delimber knives are
Two 3-position joystick switches and two relays closed there is no pressure to shift the three-way
(numbers 6 and 7) electrically control the delimber valve and the system oil flows to the TOP SAW
and slasher functions:- MOTOR and the rod end of the TOP SAW
CYLINDER to run the saw motor and cut with the
Open delimber arms; Push LEFT side of L.H. saw bar.
Joystick switch, Current flows through wires 18 to
energize a DELIMBER OPEN SOLENOID valve Cut with slasher saw; Push LEFT side of L.H.
on the pilot manifold and allow pilot oil to shift the Joystick switch, Push LEFT side of R.H. joystick
spool in the delimber spool section of the swing switch, Current flows from L.H. joystick switch
valve and direct system oil to the delimber arms through wire 18 and 19, to open delimber knives.
cylinders. Current also flows through wire 18 to Current also flows from R.H. joystick switch
energize the DELIMBER OPEN RELAY (7) and through wire 97 to wire 39, to energize SLASHER
allow current to energize the DELIMBER OPEN/ CUT solenoid valve on pilot manifold.
DUMP VALVE SOLENOID. This will allow system Pilot oil flows through the SLASHER CUT
oil from the delimber spool section of the swing solenoid pilot valve on the pilot manifold to shift
valve to flow through the ROTARY MANIFOLD to the spool in the SLASHER CUT (stick valve) to
the base end of the DELIMBER ARM allow system oil to flow through the ROTARY
CYLINDERS to open the arms. MANIFOLD to the pilot operated three-way valve.
Current also flows via the contacts of DELIMBER Because the delimber knives are open there is
CLOSE RELAY (6) through wire 88 and jumper pressure to shift the three-way valve and the
wire 19 to "latch" RELAY (7) in the energized system oil flows to SLASHER SAW MOTOR and
position so that the joystick switch may be the rod end of the BAR CYLINDER to run the saw
released to the spring return center position while motor and cut with the saw bar.
the delimber arms remain in the OPEN position. A Retract delimber top saw and/or slasher saw;
diode in diode module #1 in wire 18 prevents the Push RIGHT side of R.H. joystick switch, Current
current from traveling back to the joystick switch flows through wire 40 and energizes TOP SAW/
and also the DELIMBER OPEN SOLENOID valve SLASHER SAW RETRACT solenoid valve on
on the pilot manifold, which was de-energized pilot manifold.
when the joystick switch was released.
Pilot oil flows through the TOP SAW/SLASHER
Close delimber arms; Push RIGHT side of L.H. SAW RETRACT solenoid pilot valve to shift the
Joystick switch, Current flows through wire 86 (96 spool in the SAW RETRACT VALVE (swing valve)
on later machines) and energizes DELIMBER to allow system oil to flow through the ROTARY
CLOSE RELAY (6). MANIFOLD to the base end of the TOP SAW
BAR CYLINDER and the SLASHER SAW
CYLINDER base end to retract the saw bar(s).
18.6
240T2-019 DELIMBER/SLASHER CIRCUIT

18.7
240T2-021 SLASHER CIRCUIT - STANDARD

18.8
PRESSURE SETTINGS FOR 4. Connect a 0 - 5000 psi.. pressure gauges to
TOP SAW CUT, SLASHER CUT the "stick" control valve test port on the inlet
AND DELIMBER section of the valve.
CAUTION the FULL position.
Use caution when in the cab as a slight 6. While holding the R.H. joystick switch in the
touch of the controls can cause SAW EXTEND position, check gauge pressure
sudden rotation of the upper frame and reading at "stick" valve test connection. If less
booms or movement of the tracks than set value, turn SAW CUT port relief valve
adjusting screw in until set value is obtained on
CAUTION gauge.
Be aware of other personnel in the area. not to turn the adjusting screw. SAW CUT port
Operator is responsible for the safe relief on "stick" valve is now set.
8. Stop engine, remove pressure gauges and
WARNING
IMPORTANT
Avoid blowing oil over relief for longer than
five seconds, as this will cause excessive
heating of the hydraulic fluid.
NOTE:
The Delimber and/or Slasher hydraulic hoses
must be disconnected at the loader bulkhead
connections before carrying out the following
procedure. Cap the hoses to keep clean and
use the appropriate steel caps on the bulkhead
fittings to prevent leakage during the pressure
setting procedure.
RELIEF VALVE SETTING
TOP SAW CUT (STICK VALVE)
Stick main relief setting ....................... 3000 psi
Saw cut port relief setting ................... 2500 psi
1. Position machine on level ground.
temperature.
3. Loosen the locknut on port relief valve
adjusting screw for the SAW CUT spool
section of the "stick" valve and turn the
adjusting screw out until spring pressure is
relieved then turn adjusting screw one full
turn in.
18.9
RELIEF VALVE SETTING RELIEF VALVE SETTINGS
SLASHER CUT, SAW RETRACT (SWING VALVE) DELIMBER ARMS (SWING VALVE)
"Swing" main relief setting ................... 3000 psi Delimber/"Swing" main relief setting:- .. 2500 psi
Saw retract port relief setting ............. 1500 psi Delimber open port relief setting:- ...... 3000 psi
1. Position machine on level ground. 1. Position machine on level ground.
2. Ensure that the hydraulic oil is at operating 2. Ensure that the hydraulic oil is at operating
temperature. temperature.
3. Loosen the locknuts on port relief valve 3. Loosen the locknut on the "swing" main relief
adjusting screw for the SAW RETRACT spool valve and turn the relief adjusting screw all the
section of the "swing" valve and turn the way in, tighten locknut.
adjusting screw out until spring pressure is
4. Loosen the locknut on the delimber port relief
relieved then turn adjusting screw one full turn
valve adjusting screw and turn the adjusting
in.
screw out until spring pressure is relieved then
4. Connect a 0 - 5000 psi.. pressure gauges to the turn adjusting screw one full turn in.
"swing" control valve test port on the inlet
5. Connect a 0 - 5000 psi.. pressure gauge to the
"swing" control valve test ports on the inlet
5. Start the engine, and put the throttle control to section of the valve.
the FULL position.
the FULL position.
IMPORTANT
7. While holding the L.H. joystick switch in the
Approach the gauge reading slowly and DELIMBER OPEN position, check gauge
deliberately by turning the adjusting screw in pressure reading at "swing" valve test
a little at a time. The pressure setting must connection. If less than set value, turn
not exceed the above value. DELIMBER port relief valve adjusting screw in
6. While holding the R.H. joystick switch in the
SAW RETRACT position, check gauge 8. Tighten locknut on adjusting screw taking care
pressure reading at "swing" valve test not to turn the adjusting screw. DELIMBER port
connection. If less than set value, turn SAW relief on "swing" valve is now set.
RETRACT port relief valve adjusting screw in reset main relief valves:
9. Loosen locknut on "swing" main relief and
7. Tighten locknut on adjusting screw taking care unscrew adjusting screw 3 full turns.
not to turn the adjusting screw. SAW RETRACT
port relief on "swing" valve is now set. 10. While holding the L.H. joystick switch in the
DELIMBER OPEN position, check gauge
8. Stop engine, remove pressure gauges and wipe pressure reading. If less than set value, turn
up any excess oil from test port area. "swing" main relief valve adjusting screw in until
set value is obtained on gauge.
12. Stop engine, remove pressure gauges and wipe
up any excess oil from test port area.
13. Re-connect delimber and slasher hoses to
bulkhead fittings on loader.
18.10
SUMMARY: Slasher cut, saw retract/"swing" valve:-
1. Disconnect Delimber and Slasher hoses from 1. Turn SAW RETRACT port reliefs on "swing"
Loader. valve out.
2. Ensure hydraulic oil is at operating 2. Connect gauge to "swing" valve.
temperature.
3. Start engine.
Top saw cut/"stick" valve:-
4. Set SAW RETRACT port relief on "swing" valve.
3. Turn SAW CUT port reliefs on "stick" valve out.
Delimber/"swing" valve:-
5. Connect gauge to "stick" valve.
6. Start engine.
2. Turn main relief fully in.
7. Set SAW CUT port relief on "stick" valve.
3. Turn DELIMBER port relief out.
8. Remove gauge.
4. Set DELIMBER port relief.
5. Re-set "swing" main relief.
6. Stop engine.
7. Remove all gauges.
8. Re-connect Delimber and Slasher units to
Loader.
18.11
TROUBLESHOOTING
DELIMBER RELAY CIRCUIT
If an electrical problem is suspected, the operation
of the joystick switches and the delimber relays
can be verified with the following procedure.
1. With the delimber arms switch in OPEN
position, voltage should be present at wires 18
and 19; if so, go to step 2. If voltage is not
present in wire 18, operate the joystick switch
in the other direction (ARMS CLOSE) and
check wire 86/96. If voltage is present at wire
86/96, there may be problem in the joystick
switch or in wire 18 from the joystick switch to
the instrument panel. If voltage is not present
in wire 86/96, check for voltage at wire 15 in
the instrument panel. If voltage is not present
at wire 15, check 15 amp fuse; if voltage is
present at wire 15, check joystick switch and
wiring to switch.
2. With the delimber arms switch RELEASED to
center position, voltage should still be present
at wire 19 but not at wire 18. If this is the case
go to step 3. If voltage is present at wire 18,
check diode module no. 1. If voltage is not
present at wire 19, check relays 6 & 7.
3. With the delimber arms switch in CLOSED
position, voltage should be present at wire 86/
96 and voltage at wire 19 will drop to zero. If
voltage on wire 19 does not drop to zero,
check relay 6 for operation.
4. With the delimber arms switch RELEASED to
center position, voltage will drop to zero on
wire 86/96 and will remain at zero on wire 19. If
this does not happen suspect the joystick
switch.
5. When the saw switch in the CUT (SAW
EXTEND) position, voltage should be present
at wire 97 and 39 regardless of the delimber
arms position. If this does not happen check
jumper wire between wire 97 and 39 at
terminal strip.
6. When the saw switch is in the RETRACT
position, voltage should be present in wire 40
regardless of the delimber arms position.
18.12
DELIMBER/SLASHER
CIRCUIT AT REST
240T2-022
OPEN DELIMBER ARMS
240T2-023
18.13
CLOSE DELIMBER ARMS
240T2-024
18.14
CUT WITH SLASHER SAW

OR TOP SAW
240T2-026
RETRACT DELIMBER TOP SAW

AND SLASHER SAW
240T2-027
18.15
240B-034 FUSE AND RELAY PANEL
FUSE AND RELAY PANEL
18.16

Service Manual: Tigercat T240B Track Loader

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SERVICE MANUAL

Tigercat T240B Track Loader

NON-APPROVED FIELD PRODUCT CHANGES ............................................................ iv

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

TRACK DRIVE ................................................................................................................ 11

BOOM FUNCTIONS ....................................................................................................... 12

Tigercat Industries Inc.

BATTERY DISCONNECT SWITCH ........................................................... 1.6, 1.8

This safety alert symbol means ATTENTION!

DANGER identifies the most serious hazards where

WARNING denotes a hazard exists which can result

CAUTION is used in areas where failure to follow

IMPORTANT is used to focus attention on items

Operators of this equipment must be fully trained by

Use the handrails and steps provided when mounting

Keep a first aid kit in an easily accessible location on WARNING

Keep the cab door closed when operating the machine

For engine starting and stopping procedures refer

Before leaving operator's cab, lower the grapple onto

Conduct maintenance inspections at least as

WARNING, HOT FLUIDS AND HOT MACHINE

• Before servicing the machine, allow the

SERVICING SAFETY PRECAUTIONS

• •• Never use your bare hand to check for fluid leaks.

Explosive release of fluids from the pressurized

SERVICING SAFETY PRECAUTIONS

Dispose of all fluids properly according to all applicable

If the engine is running inside a building, ensure that

*NOTE: Dry chemical fire suppression

TYPICAL FIRE EXTINGUISHER

PREVENTIVE MAINTENANCE SCHEDULE FOR

NEW MACHINE MAINTENANCE

*INITIAL PRE-DELIVERY INSPECTION:-

*FIRST 50-100 HOUR INSPECTION AND SERVICE REPORT:-

*IMPORTANT: TO QUALIFY FOR CONTINUED WARRANTY,

Tightening points:~ NOTE: Use of filters other than genuine Tigercat

Clean:~ • Cab fresh air filter

† NOTE: Use of filters other than genuine Tigercat

SQUARE SECTION GASKET INSTALLATION

 Square Section Gasket

205-23A HYDRAULIC PILOT FILTER

PILOT RETURN PRESSURE FILTER

PAG OIL A/C CONDENSER CORE

Any service work must be performed by

206-6A CHECK A/C CONDENSER CORE

If using water or compressed air for

Piston nut, grapple cylinder 1 3/4"-12 UNF (GC) 1750 2355

Gland, grapple cylinder 4 1/2" I/D CYLINDER 450 607

Cab securing bolts 7/8"-9 UNC (G8) 450-500 610-680

Swing bearing bolts 7/8"-9 UNC (G8) 400-450 540-610

GRADE 8 BOLTS GRADE 5 BOLTS

Square Section Gasket