Tigercat 215 LOADER OPERATOR’S MANUAL SN 2150101 - 2151000 - PDF DOWNLOAD

215 LOADER

OPERATOR’S MANUAL SERIAL NUMBER 2150101 TO 2151000

ISSUE 2.0 AUGUST, 2013

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

Tigercat 215 Loader

Introduction

ii

Tigercat 215 Loader

Introduction

Tigercat 215 LOADER TABLE OF CONTENTS SECTION INTRODUCTION....................................................................................................................................... v NON-APPROVED FIELD PRODUCT CHANGES.................................................................................... vi SAFETY..................................................................................................................................................... 1 CONTROLS AND OPERATION................................................................................................................ 2 LUBRICATION AND MAINTENANCE....................................................................................................... 3

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

215 Loader Available Literature Operator's Manual, English (this manual)............................................ Part No. 37622AENG Service Manual English........................................................................ Part No. 37623AENG Parts Catalog........................................................................................ Part No. 37624A

iii

Tigercat 215 Loader

Introduction

iv

Tigercat 215 Loader Tigercat 215 Loader

Introduction

INTRODUCTION An Operator's manual, Service manual and a Parts catalog are made available by Tigercat to assist the dealer, customer and operator in becoming familiar with the features of the 215 Loaders Serial numbers:2150101 TO 2151000.

The 215 Loader is designed for log processing, sorting, log transfering and loading.

The operator's manual will assist the operator with the techniques of proper and safe operation of the 215 Loader. There is also important information regarding the safe operation of the attachment. The service manual contains safety and servicing procedures and a preventive maintenance schedule to ensure optimum machine performance. ,,,,

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

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

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

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

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

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

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

Tigercat Industries Inc.

v

Tigercat 215 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 it's ability to perform safely 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 to be undertaken 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 having created 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 dispute resulting from changes made to the product without proper authorization by Tigercat as stated above, Tigercat will take whatever action is appropriate to protect its interests.

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

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

Tigercat Industries Inc.

vi

Tigercat 215 LOADER SECTION 1 - SAFETY Read and understand this safety section prior to operating any equipment.

Read and understand all manuals for any attachment or accessories.

CONTENTS - SECTION 1 B

AUGUST, 2013

BATTERY DISCONNECT SWITCH........................................................................................................... 1.9 BATTERY SAFETY.................................................................................................................................... 1.6 C

CAB EXITS.................................................................................................................................................1.7 COOLING SYSTEM................................................................................................................................. 1.12 E

EMERGENCY CAB EXITS......................................................................................................................... 1.7 ENGINE DOORS...................................................................................................................................... 1.13 EXHAUST FUMES................................................................................................................................... 1.13 F

FALL PROTECTION................................................................................................................................. 1.15 SERVICE ACCESS POSITION 1......................................................................................................... 1.16 SERVICE ACCESS POSITION 2......................................................................................................... 1.17 SERVICE ACCESS POSITION 3......................................................................................................... 1.18 FIRE PREVENTION................................................................................................................................. 1.22 DRY CHEMICAL CLEANUP PROCEDURES....................................................................................... 1.26 FIRE PREVENTION GUIDELINES....................................................................................................... 1.22 WHAT TO DO AFTER A MACHINE FIRE HAS OCCURRED............................................................... 1.25 WHAT TO DO TO PREPARE FOR A MACHINE FIRE......................................................................... 1.23 WHAT TO DO WHEN A MACHINE FIRE OCCURS............................................................................. 1.24 FLUID INJECTION INJURY..................................................................................................................... 1.14 FLUID LEAKS.......................................................................................................................................... 1.11 G

GREASE INJECTION INJURY................................................................................................................. 1.15 H

HYDRAULIC PRESSURE HAZARD........................................................................................................ 1.11 L

LIGHTNING SAFETY AWARENESS LIGHTNING SAFETY................................................................................................................. 1.20, 1.21 WHAT IS A LIGHTNING STRIKE?........................................................................................................ 1.19 LOOSE CLOTHING HAZARD.................................................................................................................. 1.12 P

PARKING HAZARDS................................................................................................................................. 1.9 PROTECTIVE CLOTHING......................................................................................................................... 1.2 S

SAFETY INTERLOCK SWITCHES ON CAB DOORS............................................................................... 1.8 SAFETY LABELS................................................................................................................. 1.27, 1.28, 1.29 SAFETY PRECAUTIONS, GENERAL....................................................................................................... 1.2 SAFETY PRECAUTIONS, OPERATING.................................................................................................... 1.7 SAFETY PRECAUTIONS, SERVICING............................................................................... 1.10, 1.15, 1.19 SAFETY SYMBOLS................................................................................................................................... 1.2 SIGNAL WORDS........................................................................................................................................ 1.2 W

WELDING, PRIOR TO............................................................................................................................. 1.11 WORKING WITH OIL................................................................................................................................. 1.4

Tigercat 215 Loader

Safety

GENERAL SAFETY PRECAUTIONS

SAFETY SYMBOLS

Remember that safety is a prime responsibility of all.

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

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

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

The safety alert symbol identifies important safety messages on machines, safety signs, in manuals, or elsewhere. When you see this symbol, be alert to the possibility of personal injury or death.

Follow the instructions in the safety message.

Understanding Signal Words

DANGER

Follow all instructions from safety inspector and supervisors.

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

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

WARNING

Do not let untrained persons operate the machine.

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

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

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

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

1.2

Tigercat 215 Loader

Safety

KEEP CLEAR

All personnel should be made AWARE of and keep clear of the HAZARD ZONE. It should be considered off limits to all individuals while the machine is operating.

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

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

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

When approaching an operating machine, stay at least 150 m (500 ft) away from the machine and all related attachments including the grapple, delimber, topping saw and ground saws until the operator recognizes your presence. Make sure that all equipment is shut down with the attachment resting securely on stable ground before advancing to the machine.

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

Do not jump off the machine at any time.

Always avoid the discharge path of all saws.

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

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

Do not use the machine foot controls as steps.

When mounting or dismounting the machine always use the three point technique; use one hand with two feet or two hands with one foot.

WARNING

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

1.3

Tigercat 215 Loader

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

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

Check all fluid levels.

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

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

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

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

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

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

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

Some advice which should be observed: •

To reduce risk of fire, machines should be completely cleaned of debris at least daily, particularly around the engine exhaust components. Hydraulic oil leaks, excess grease, fuel and oil accumulation (including spillage) should be eliminated immediately, always shut off engine before cleaning machine.

• • •

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

• •

Machine should be washed completely at every major service.

•

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

•

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

• •

Check windows and door guards for damage.

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

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

1.4

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

Avoid contact with oil, particularly heated oil.

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

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

Don't put oily rags in your pockets.

Oil soiled clothing should be changed as soon as possible.

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

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

Avoid breathing in oil fumes.

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

Tigercat 215 Loader

Safety

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

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

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

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

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

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

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

•

If these are found, Do Not Touch!!!

•

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

•

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

•

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

If State/Provincial, local or job site regulations require even greater safety distances than stated above, adhere strictly to these regulations for your own protection.

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

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

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

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

Safety Hazards - Operating Maintain a charged fire extinguisher on the vehicle at all times and KNOW HOW TO USE IT. Do not carry passengers either in the cab or anywhere else on the machine. The vehicle is provided and approved with seating for the operator only.

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

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

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

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

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

1.5

Tigercat 215 Loader

Safety

Avoid Injury from Backover Accidents

WARNING

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

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

Wash hands after handling.

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

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

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

To avoid backover accidents:

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

•

Disconnect battery before working on electrical systems as follows: -

turn off master switch in cab

-

disconnect negative starter motor cable from both battery posts

-

disconnect positive master solenoid cable from both battery posts

•

• •

Connect ground terminal last when reconnecting.

Do not short out battery terminals for any reason.

Serious burns or an explosion can result.

• •

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

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

1.6

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

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

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

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

Keep windows, mirrors and lights in good condition.

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

Tigercat 215 Loader

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

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

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

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

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

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

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

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

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

For additional information, refer to EMERGENCY EXITS in SECTION 2 of the OPERATOR'S MANUAL.

OPERATING SAFETY PRECAUTIONS

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

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

Sound the machine horn before starting the machine.

The operator’s seat is equipped with lap and shoulder harness belts. Use both of these restraint systems at all times when operating the machine.

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

WARNING

Never use a liquid staring aid to start an engine.

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

1.7

Tigercat 215 Loader

Safety

SAFETY INTERLOCK SWITCH ON FRONT DOOR:

2. Maintain a safe operating distance between the machine and other personnel. Never operate the boom or attachment over the heads of bystanders.

The front door is equipped with a safety interlock switch to prevent the machine from being operated while the front door is open (pilot system is shut off).

SWITCH

ACTUATOR ON DOOR

WARNING

3. Never travel near co-workers or other pieces of equipment with attachment running.

INTERLOCK SWITCH (FRONT DOOR)

822-D02

4. Do not allow people or other pieces of equipment near the harvesting operation.

5. Do not turn on attachment until machine is at the harvesting site.

6. Use only prearranged and approved signalling practices.

Do not open an escape hatch or the cab doors to increase ventilation when operating the machine.

Push the red PILOT OFF switch and confirm the yellow PILOT OFF light is ON before removing seat belt. DO NOT use the front door interlock switch to turn pilot OFF. NOTE: The engine can be started but the machine functions cannot be operated with the door open.

CAUTION

WARNING

Do not open cab doors or window screens when cab is on a slope. The doors and screens are heavy and could swing out with considerable force. Anyone in the path of swing could be injured.

Anyone opening the door or screen and holding on to it could be pulled out of the cab and injured.

The door safety interlock switch and the pilot reset switch are a safety feature and their function must not be defeated in any way.

To operate: Close the front door and press the PILOT RESET switch.

Keep the cab doors closed when driving or steering the machine to prevent accidental entry of branches and debris into the cab.

Keep the cab doors closed and use seat belt when driving or steering the machine to prevent being thrown from the operator's cab.

Secure loose items in the cab.

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

Make sure that all safety screens and guards including the skylight are installed and properly secured.

Always rest the attachment on the ground when operation is stopped, regardless if the engine is running or shut off.

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

Watch for ground hazards such as metal debris, wire fencing or rocks.

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

WARNING

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

1.8

Tigercat 215 Loader

Safety

When travelling position attachment and boom so as not to impair vision.

If vision is limited by dust, smoke, fog, rain or snow, stop the machine until visibility is restored.

If saw guard has been installed, DO NOT REMOVE until at the cutting site. Remove guard before starting engine.

Park machine at least 15 m (50 ft) away from other equipment and in a cleared area. In the event of a fire, this distance will minimize the chance of the fire spreading to other equipment.

Before leaving operator's cab, lower the felling attachment onto the ground.

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

• Do not use the boom to service other equipment.

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

• Do not modify the boom system.

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

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

If out of the operator's cab for an extended period shut the machine off.

When parking the machine; •

Park on level ground only and engage the swing brake.

•

Do not park on a hillside or incline.

•

Lower attachment onto level ground.

•

Stop the engine.

24863A

•

OFF

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

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

ON 24863A R0

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

NOTE: Wait 30 seconds after engine shut down before turning off battery disconnect switch. If battery disconnect is turned off before this the engine ECM (Engine Control Module) will register a fault.

When transporting the machine watch that enough clearance is available on both sides and above the machine or any of its attachments to avoid contact with power or telephone lines, bridge structures, etc.

Before transporting the machine check to ensure that all doors, panels and access covers are installed properly and secured. Improperly secured doors or panels pose a serious danger to pedestrians and other vehicles.

1.9

Tigercat 215 Loader

Safety The radiator and the engine cooling system should be cleaned and serviced daily to maintain moderate engine temperatures.

SERVICING SAFETY PRECAUTIONS

WARNING

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

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

24863A

OFF

ON 24863A R0

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

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

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

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

1.10

•

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

•

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

•

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

Tigercat 215 Loader

Safety

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

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

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

Disconnect the negative (-) battery cable from all the batteries.

This machine is equipped with sensitive electronic control equipment, prior to welding:1

2

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.

215-011

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

Disconnect the computer connector and the control module connector.

Pressure can be maintained in a hydraulic system long after the power source and pump have been shut down. Lower the attachment to the ground, stop engine and relieve trapped pressure before performing work on components, or disconnecting any hoses. Accumulators will self drain within 2 minutes of stopping the engine.

1.11

Tigercat 215 Loader

Safety

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

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.

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

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

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

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

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

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

1.12

Tigercat 215 Loader

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

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

• Do not use the boom to service other equipment.

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

• Do not modify the boom system.

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

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

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

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.

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

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

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.

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

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

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

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

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

When performing required hydraulic checks and blade speed adjustments. Install the saw blade guard. Refer to attachment manufacturer's instructions.

CAUTION Do not open cab doors or window screens when cab is on a slope. The doors and screens are heavy and could swing out with considerable force. Anyone in the path of swing could be injured.

Anyone opening the door or screen and holding on to it could be pulled out of the cab and injured.

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

1.13

Tigercat 215 Loader

Safety

FLUID INJECTION INJURY

WARNING

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

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

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

• Seek professional medical attention immediately.

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

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

Always wear thick protective gloves.

• Be sure to wear safety goggles for eye protection.

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

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

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

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

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

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

•

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

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

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

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

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

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

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

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

1.14

Tigercat 215 Loader

Safety

GREASE INJECTION INJURY WHEN USING PNEUMATIC GREASE GUNS

FALL PROTECTION

Pneumatic grease guns can deliver grease at pressures from 17 - 400 Bar (246 - 5801 psi).

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

Falls are among the most common causes of serious work injuries and deaths.

Where there is a danger of falling, fall protection equipment must be worn.

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

All personal fall protection equipment must comply with applicable governmental regulations and must be inspected and used in accordance with the manufacturer's recommendations. Inspect fall protection equipment for defects before use.

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

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

Only attach personal fall protection equipment to approved tie-offs on the machine.

WARNING Tie-off handles are not for lifting.

Do not use these handles to lift, anchor, secure or support any other apparatus or material.

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

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

•

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

•

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

•

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

•

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

•

Remove dirt and grease from grease fittings prior to greasing.

•

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

•

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

When mounting or dismounting the machine always use the three point technique; use one hand with two feet or two hands with one foot.

WARNING

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

1.15

Tigercat 215 Loader

Safety

SERVICE ACCESS POSITION 1

From the service platform, attach your personal safety restraint to the tie-off handle located on the inside wall of the fuel tank.

Ensure the loader/flail unit is on level ground and secured from moving. Position the machine boom above the intake of the flail (as shown below).

Lower the grapple to the ground and stop the engine.

NOTE: Some machines may have a tie-off handle located at the top of the return filter bracket.

WARNING Tie-off handles are not for lifting.

Do not use these handles to lift, anchor, secure or support any other apparatus or material.

TIE-OFF HANDLE

SERVICE PLATFORM

FLAIL INTAKE

LOWER GRAPPLE TO THE GROUND 215-050

TIE-OFF HANDLE

215-051

OPTIONAL TIE-OFF HANDLE LOCATION NOT SHOWN

FIG. 1 - SERVICE ACCESS POSITION 1

1.16

Tigercat 215 Loader

Safety

SERVICE ACCESS POSITION 2

Lower the grapple to the ground and stop the engine.

Ensure the loader/flail unit is on level ground and secured from moving. Position the machine boom beside the grapple support cradle (as shown below).

Attach your personal safety restraint to the tie-off handle located on the top plate above the engine.

GRAPPLE SUPPORT CRADLE

LOWER GRAPPLE TO THE GROUND 215-052

WARNING Tie-off handles are not for lifting.

Do not use these handles to lift, anchor, secure or support any other apparatus or material.

TIE-OFF HANDLE

SERVICE PLATFORM

215-054

SIDE DOOR

215-053

FIG. 2 - SERVICE ACCESS POSITION 2

1.17

Tigercat 215 Loader

Safety

SERVICE ACCESS POSITION 3

From the service platform, open the front cooler access door. Secure the door with the prop rod located on top of the cooler door.

Ensure the loader/flail unit is on level ground and secured from moving. Position the machine boom beside the grapple support cradle (as shown below). Lower the grapple to the ground and stop the engine.

Attach your personal safety restraint to the tie-off handle located above the cooler.

Remove the engine access plate to access the engine and components.

GRAPPLE SUPPORT CRADLE

LOWER GRAPPLE TO THE GROUND

215-055

WARNING Tie-off handles are not for lifting.

Do not use these handles to lift, anchor, secure or support any other apparatus or material.

FRONT COOLER ACCESS DOOR PROP ROD

TIE-OFF HANDLE

TIE-OFF HANDLE

ENGINE ACCESS PLATE

TIE-OFF HANDLE

215-056

FIG. 3 - SERVICE ACCESS POSITION 3

1.18

Tigercat 215 Loader

Safety LIGHTNING SAFETY

LIGHTNING SAFETY AWARENESS

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

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

1. Designate a member of your crew to

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

•

Monitor daily weather forecasts

•

Observe local weather conditions

•

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

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

3. Anticipate a high-risk situation and take action early by moving to a low-risk location. Do not hesitate. If there is lightning, you are in danger.

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

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

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

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

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

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

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

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

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

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

1.19

Tigercat 215 Loader

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

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

2. If inside a building:

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

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

•

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

•

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

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

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

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

•

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

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

•

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

•

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

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

•

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

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

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

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

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

1.20

Tigercat 215 Loader

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

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

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

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

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

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

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

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

3. Get away from open water such as ponds or streams.

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

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

2. Call your local emergency response telephone number immediately.

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

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

Use a portable defibrillator if one is available.

6. Avoid entering any small enclosures or shelters.

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

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

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

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

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

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

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

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

11. Do not use the telephone except for emergencies.

1.21

Tigercat 215 Loader

Safety 4. Clean out all accumulated forest debris (twigs, pine needles, branches, bark, leaves, saw dust, small wood chips) and any other combustible materials from inside the machine belly pans or lower machine structures as well as from areas in proximity to the engine, fuel and hydraulic oil systems no less frequently than at the completion of each work shift.

FIRE PREVENTION

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

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

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

1. Maintain a CHARGED fire extinguisher on the machine at all times and KNOW HOW TO USE IT. 2. Remove debris and blow out dust regularly from the air intake doors, engine radiator and charge air cooler, hydraulic oil cooler, diesel fuel cooler and air conditioning condenser core to prevent overheating of the engine and hydraulics and to maintain efficient operation of the machine. Refer to CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR in SECTION 2 of the OPERATOR’S MANUAL. 3. Blow off all forest debris and fine organic material accumulated near hot engine exhaust components (turbocharger and exhaust manifold as well as exhaust pipes and muffler) at the completion of each work shift or more frequently when working in logging conditions where large amounts of combustible forest debris are present. Visual inspection after blow off to ensure thorough cleanliness is vital. Engine exhaust systems provide numerous small pockets where saw dust, small wood chips and other flammable forest debris can gather. Even small accumulations close to hot exhaust components can ignite and smolder. If dislodged this smoldering debris can fall into other areas of the machine and thereby spread a fire.

1.22

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

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

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

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

8. Use only nonflammable solutions for cleaning the machine and components.

9. Inspect the exhaust system daily for any signs of leakage. Check for worn, cracked, broken or damaged pipes or muffler.

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

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

11. Park the machine at least 15 m (50 ft) away from other equipment at the end of each shift.

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

Tigercat 215 Loader

Safety 17. AFTER transporting (trucking) a machine from one job site to the next, open all doors and access panels and blow off any debris that may have repositioned itself onto the engine and exhaust parts due to wind turbulence caused by the journey.

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

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

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

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

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

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

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

•

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

•

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

•

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

•

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

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

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

1.23

Tigercat 215 Loader •

•

•

• •

•

•

Safety WHAT TO DO WHEN A MACHINE FIRE OCCURS

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

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

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

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

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

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

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

•

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

2. Shut the engine off.

3. Activate the fire suppression system**.

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

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

6. At all times ensure your own personal safety and the safety of anyone that may be in the area. Approach any fire with extreme caution. All fires can be very dangerous and life threatening.

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

•

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

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

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

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

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

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

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

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

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

suppression system** on your machine.

There is not enough time available to read instructions during a fire emergency.

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

1.24

Tigercat 215 Loader •

Safety

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

•

•

•

•

WHAT TO DO AFTER A MACHINE FIRE HAS OCCURRED

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

Break the plastic seal as the pin is pulled.

•

Before returning the machine to work.

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

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

Release the hose before taking aim.

2. Ensure that the fire detection system*

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

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

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

•

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

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

*NOTE: Fire detection systems are offered by

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

**NOTE: Dry chemical fire suppression systems

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

20229A

• • •

• •

TYPICAL FIRE EXTINGUISHER ACCESS HOLE

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

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

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

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

Remain with the machine until help arrives.

1.25

Tigercat 215 Loader

Safety

DRY CHEMICAL CLEANUP PROCEDURES

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

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

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

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

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

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

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

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

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

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

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

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

Rinse thoroughly with water. Blow-dry to remove all residual water.

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

1.26

Tigercat 215 Loader

Safety READ OPERATOR'S MANUAL

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

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

DO NOT LIFT FROM THIS POINT 36810BUNI R0

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

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

EXPLOSION HAZARD

WARNING • EXPLOSION HAZARD. • DO NOT USE ETHER. • ENGINE EQUIPPED WITH HEATER STARTING AID.

This label is located at all personal safety harness tie-off handles. It warns people not to use the tie-off handles for lifting the machine.

• USE OF ETHER COULD RESULT IN DEATH OR SERIOUS INJURY. 36782BENG R0

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

USING ETHER COULD CAUSE AN EXPLOSION WHICH COULD RESULT IN DEATH OR SERIOUS INJURY. 1.27

Tigercat 215 Loader

Safety

NO RIDERS

ENTANGLEMENT HAZARD

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

Persons riding on the outside of the machine are subject to hazards such as falling off the machine, crush hazards, thrown object hazards and many other hazards WHICH COULD RESULT IN DEATH OR SERIOUS INJURY.

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

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

If any person attempts to climb onto the machine during operation, STOP THE MACHINE IMMEDIATELY. Do Not Operate the machine until other personnel are a safe distance away from the machine.

1.28

Tigercat 215 Loader

Safety ELECTROCUTION HAZARD!

CRUSH HAZARD

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

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

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

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

1.29

Tigercat 215 Loader

Safety

FIRE PREVENTION!

CHECK DAILY

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

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

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

FIRE EXTINGUISHER ACCESS HOLE

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

Maintain a CHARGED fire extinguisher on the machine at all times, know where it is and KNOW HOW TO USE IT! This label indicates the location of each FIRE EXTINGUISHER ACCESS HOLE. The label is installed on each fire extinguisher hole on the engine door, pump compartment door and L.H. service door.

1.30

Tigercat 215 Loader SECTION 2 - CONTROLS & OPERATION CONTENTS - SECTION 2

AUGUST, 2013

A/C ON/OFF SWITCH.............................................................................................................................. 2.16 AIR CLEANER.........................................................................................................................................2.62 AIR CLEANER UNLOADER VALVE........................................................................................................ 2.62 AIR CONDITIONER/HEATER.................................................................................................................. 2.16 AIR SOURCE...........................................................................................................................................2.17 AM/FM STEREO RADIO/CD.................................................................................................................... 2.18 AUXILIARY POWER OUTLET................................................................................................................. 2.16 BATTERY DISCONNECT - SWITCH....................................................................................................... 2.12 CAB CONTROLS..................................................................................................................................... 2.10 2 WAY RADIO - OPTIONAL.................................................................................................................. 2.18 A/C HEATER AIR DISCHARGE OUTLETS.......................................................................................... 2.17 AIR CONDITIONER/HEATER.............................................................................................................. 2.16 A/C ON/OFF SWITCH....................................................................................................................... 2.16 AIR CONDITIONING - VARIABLE.................................................................................................... 2.17 FAN SPEED - OFF/LOW/MED/HIGH................................................................................................ 2.16 HEAT - VARIABLE............................................................................................................................ 2.17 AM/FM STEREO RADIO/CD................................................................................................................ 2.18 AUXILIARY POWER OUTLET, 12 VOLTS........................................................................................... 2.16 BATTERY DISCONNECT - SWITCH.................................................................................................... 2.12 CONTROL PANEL................................................................................................................................ 2.12 EMERGENCY STOP SWITCH............................................................................................................. 2.14 FAN CONTROL - SWITCH................................................................................................................... 2.12 AUTOMATIC POSITION................................................................................................................... 2.12 FULL ON POSTION.......................................................................................................................... 2.13 FILTERS...............................................................................................................................................2.18 FIRE EXTINGUISHER.......................................................................................................................... 2.19 HORN - SWITCH.................................................................................................................................. 2.13 HOT WATER SHUT OFF VALVE (ENGINE)......................................................................................... 2.17 INTERIOR LIGHT................................................................................................................................. 2.18 KEY SWITCH........................................................................................................................................ 2.15 OFF POSTION................................................................................................................................. 2.15 RUN POSTION................................................................................................................................. 2.15 START POSITON.............................................................................................................................. 2.15 LEFT HAND JOYSTICK....................................................................................................................... 2.10 GRAPPLE ROTATE.......................................................................................................................... 2.10 STICK BOOM.................................................................................................................................... 2.10 SWING ROTATE............................................................................................................................... 2.10 LEFT HAND JOYSTICK LINEAR MOTION FUNCTION...................................................................... 2.10 LIGHTER - 24 VOLT OUTLET.............................................................................................................. 2.15 MD3 COMPUTER AND DISPLAY........................................................................................................ 2.19 USB PORT - MD3 COMPUTER....................................................................................................... 2.19 OPTIONAL ACCESSORY SWITCHES................................................................................................. 2.12 PILOT RESET - SWITCH..................................................................................................................... 2.13 PILOT SYSTEM SHUT OFF - LIMIT SWITCH..................................................................................... 2.14 REAR WORK LIGHTS.......................................................................................................................... 2.16 RIGHT HAND JOYSTICK..................................................................................................................... 2.11 GRAPPLE CLOSE............................................................................................................................ 2.11 GRAPPLE OPEN.............................................................................................................................. 2.11 GRAPPLE ROTATE.......................................................................................................................... 2.11 HOIST BOOM................................................................................................................................... 2.11

Tigercat 215 Loader Tigercat 215 Loader SECTION 2 - CONTROLS & OPERATIONControls and operation SERVICE LIGHTS................................................................................................................................ 2.16 THROTTLE CONTROL........................................................................................................................ 2.14 AUTO IDLE DOWN........................................................................................................................... 2.15 WINDOWS............................................................................................................................................2.19 WINDSHIELD WASHER FLUID........................................................................................................... 2.19 WINDSHIELD WIPER/WASHER.......................................................................................................... 2.18 WORK LIGHTS..................................................................................................................................... 2.16 CAB CONTROLS - ELECTRONIC CONTROLS DESCRIPTION.............................................................. 2.8 CARE OF THE MACHINE........................................................................................................................ 2.71 CASE DRAIN STRAINERS...................................................................................................................... 2.61 CHECK ENGINE OIL LEVEL................................................................................................................... 2.65 COLD WEATHER STARTING.................................................................................................................. 2.53 COMPUTER.............................................................................................................................................2.20 ADJUSTMENT MENU.......................................................................................................................... 2.23 CONTROL ADJUSTMENT MENU.................................................................................................... 2.25 LIMP MODE......................................................................................................................................2.26 MACHINE MODE.............................................................................................................................. 2.24 OIL GRADE....................................................................................................................................... 2.24 ADJUST MENU.................................................................................................................................... 2.29 LM BOOM SPEED ADJUSTMENTS................................................................................................. 2.33 MACHINE MODE.............................................................................................................................. 2.29 MACHINE PARAMETERS................................................................................................................ 2.30 GRAPPLE OPEN/CLOSE FINE CONTROL RANGE (%).............................................................. 2.31 IDLE DOWN WAIT TIME................................................................................................................ 2.30 OIL GRADE.................................................................................................................................... 2.31 STICK BOOM CUSHION ON/OFF................................................................................................. 2.32 STICK BOOM STOP CUSHION (%).............................................................................................. 2.31 REVERSING FAN CONTROLS........................................................................................................ 2.33 VALVE CURRENT SETTINGS................................................................................................ 2.32, 2.33 ALERT MESSAGES............................................................................................................................. 2.48 CRITICAL MESSAGES........................................................................................................................ 2.41 DATE/TIME ADJUSTMENT.................................................................................................................. 2.36 DISPLAY ADJUSTMENT...................................................................................................................... 2.35 ENGINE MENU..................................................................................................................................... 2.23 FAN CONTROL SWITCH, COOLING................................................................................................... 2.12 INFO MENU PAGE............................................................................................................................... 2.38 LOGS................................................................................................................................................2.39 MODULES......................................................................................................................................... 2.39 INFORMATION MODE......................................................................................................................... 2.28 MAIN DISPLAY..................................................................................................................................... 2.22 MAIN MENU SCREEN......................................................................................................................... 2.28 MD3 COMPUTER AND DISPLAY........................................................................................................ 2.19 USB PORT - MD3 COMPUTER....................................................................................................... 2.19 MEASURE MENU................................................................................................................................. 2.34 MESSAGES AND WARNINGS............................................................................................................. 2.40 ALERT MESSAGES (YELLOW)....................................................................................................... 2.48 CRITICAL MESSAGES AND WARNINGS (RED)............................................................................ 2.41 MESSAGES AND WARNINGS - ALERT ENGINE FAULT CODE MESSAGES - ALERT.................................................................................. 2.49 HARDWARE FAULT - JOYSTICK..................................................................................................... 2.50 HARDWARE FAULT- MD3................................................................................................................ 2.51 HARDWARE FAULT - XA2................................................................................................................ 2.51

2.2

Tigercat 215 Loader Tigercat 215 Loader SECTION 2 - CONTROLS & OPERATIONControls and operation MESSAGES AND WARNINGS - CRITICAL COMMUNICATION FAULT - LH - JOYSTICK................................................................................... 2.46 COMMUNICATION FAULT - RH - JOYSTICK.................................................................................. 2.46 ENGINE FAULT CODE MESSAGES - CRITICAL............................................................................. 2.47 ENGINE STOP.................................................................................................................................. 2.44 HARDWARE FAULT - ENGINE......................................................................................................... 2.45 HARDWARE FAULT - MD3............................................................................................................... 2.44 HARDWARE FAULT - XA2................................................................................................................ 2.45 HYDRAULIC OIL LEVEL LOW.......................................................................................................... 2.42 HYDRAULIC OIL TEMPERATURE HIGH......................................................................................... 2.43 PREFERENCES MENU....................................................................................................................... 2.35 DATE/TIME ADJUSTMENT.............................................................................................................. 2.36 DATE ADJUSTMENT...................................................................................................................... 2.37 TIME ADJUSTMENT...................................................................................................................... 2.38 DISPLAY ADJUSTMENT.................................................................................................................. 2.35 BACKLIGHT ADJUSTMENT........................................................................................................... 2.35 SCREEN SAVER ADJUSTMENT................................................................................................... 2.36 SCREEN SAVER ADJUSTMENT......................................................................................................... 2.36 WARNING BUZZER............................................................................................................................. 2.20 WARNING LIGHT................................................................................................................................. 2.20 CONTROL PANEL.................................................................................................................................... 2.12 ELECTRONIC CONTROLS DESCRIPTION.............................................................................................. 2.8 ENGINE OIL LEVEL................................................................................................................................. 2.65 ENGINE SPEED - SWITCH..................................................................................................................... 2.14 FAN CONTROL - SWITCH....................................................................................................................... 2.12 FAN SPEED - OFF/LOW/MED/HIGH....................................................................................................... 2.16 FILTER AIR CLEANER...................................................................................................................................... 2.62 CAB......................................................................................................................................................2.18 HYDRAULIC RETURN......................................................................................................................... 2.60 FIRE EXTINGUISHER............................................................................................................................. 2.19 FUEL - REFUELING PROCEDURE......................................................................................................... 2.64 FUEL TANK AND FILLER......................................................................................................................... 2.63 FUSES AND RELAYS.............................................................................................................................. 2.54 HAND FILL PUMP.................................................................................................................................... 2.59 HORN - SWITCH...................................................................................................................................... 2.13 HOT WATER SHUT OFF VALVE............................................................................................................. 2.17 HYDRAULIC OIL RESERVOIR.........................................................................................................................................2.59 HYDRAULIC OIL TANK HYDRAULIC OIL HEATER (OPTIONAL).............................................................................................. 2.64 HYDRAULIC RETURN FILTERS............................................................................................................. 2.60 ICONS, PICTOGRAM DESCRIPTIONS............................................................................................ 2.5, 2.6 JOYSTICK LEVERS................................................................................................................................. 2.10 JOYSTICKS, LEFT AND RIGHT HAND................................................................................................... 2.10 KEY SWITCH...........................................................................................................................................2.15 LIGHT - DOME......................................................................................................................................... 2.18 LIGHTER..................................................................................................................................................2.15 LIMIT SWITCH.........................................................................................................................................2.14

2.3

Tigercat 215 Loader Tigercat 215 Loader SECTION 2 - CONTROLS & OPERATIONControls and operation MACHINE OPERATION........................................................................................................................... 2.65 PRE-START CHECKS.......................................................................................................................... 2.65 MACHINE PREPARATION....................................................................................................................... 2.69 MAX RPM - SWITCH............................................................................................................................... 2.12 MD3 COMPUTER.................................................................................................................................... 2.20 MD3 COMPUTER MAIN DISPLAY.......................................................................................................... 2.22 OPTIONAL ACCESSORY SWITCHES.................................................................................................... 2.12 PICTOGRAM DESCRIPTIONS.......................................................................................................... 2.5, 2.6 PILOT RESET - SWITCH......................................................................................................................... 2.13 PILOT SYSTEM SHUT OFF.................................................................................................................... 2.14 PRE-START CHECKS............................................................................................................................. 2.65 RADIO - 2 WAY........................................................................................................................................2.18 REFUELING PROCEDURE..................................................................................................................... 2.64 SCREEN SAVER ADJUSTMENT............................................................................................................. 2.36 SEAT........................................................................................................................................................2.56 SERVICE LIGHTS.................................................................................................................................... 2.16 SETTING THE MACHINE........................................................................................................................ 2.69 STARTING THE ENGINE......................................................................................................................... 2.68 STEREO AM/FM RADIO CD PLAYER..................................................................................................... 2.18 STOPPING THE ENGINE........................................................................................................................ 2.70 THROTTLE CONTROL............................................................................................................................ 2.14 UNLOADER VALVE................................................................................................................................. 2.62 WAIT TO START...................................................................................................................................... 2.52 WARNING LIGHTS ENGINE OIL PRESSURE..................................................................................................................... 2.52 WINDOWS..................................................................................................................................... 2.19, 2.71 CARE OF POLYCARBONATE WINDOWS.......................................................................................... 2.71 CAUTIONS........................................................................................................................................2.73 CLEANING INSTRUCTIONS............................................................................................................ 2.73 CONCEALING HAIRLINE SCRATCHES.......................................................................................... 2.73 FIRE PRECAUTIONS....................................................................................................................... 2.74 GRAFFITI REMOVAL........................................................................................................................ 2.74 INSPECTION AND MAINTENANCE................................................................................................. 2.72 RESISTANCE TO CHEMICALS........................................................................................................ 2.72 RESISTANCE TO WATER................................................................................................................ 2.72 WINDSHIELD WASHER FLUID............................................................................................................... 2.19 WINDSHIELD WIPER/WASHER............................................................................................................. 2.18 WORK LIGHTS........................................................................................................................................ 2.16

2.4

Tigercat 215 Loader

Controls and operation

PICTOGRAM DESCRIPTIONS Diagrams in pictorial form are used to represent machine function operation. Some of the symbols are signs, characters, figures, or any components related to the operation of the machine. They are a simple universal language of symbols or pictograms that illustrate a function or component without the use of words. Pictograms are installed on or in close proximity to the switch or device used to activate or deactivate the machine function or they may be a sign used on a warning or indicator light of a function that is operating or advising of an alarm condition.

Examples of these pictograms are the turtle speed such as SLOW =

or FAST =

and the rabbit

that are often used to describe

.

= Adjustment Menu Icon

= Critical Message Symbol

= Air Conditioner ON

= Engine ANTI-STALL = Engine STOP

= Air Conditioner OFF

= Engine WAIT TO START = Air Source, Fresh Air = Engine WARNING = Air Source, Recirculate

= Engine Menu Icon

= Alert Message Symbol

= Engine Run

= Auxiliary Power Outlet 12 V

= Engine Start

= Battery Disconnect = Error Message Symbol

P

= Control Lever Multiple Direction

P

= Flow Adjustment

= Control Lever One Direction

= Fuel - Diesel

= Control Lever Two Direction

2.5

Tigercat 215 Loader

Controls and operation

PICTOGRAM DESCRIPTIONS CONTINUED = Fuel Level Low

= Information Menu Icon

= Information Message Symbol

= Grapple CLOSE

= Instrument Bulb Test

= Grapple OPEN

= Joystick and Switches = Grapple ROTATE CLOCKWISE = Lights, Work = Grapple ROTATE COUNTERCLOCKWISE = Lights, Engine Service = Horn = Hoist Boom DOWN

= Hydraulic Oil Temperature

= Hoist Boom UP

= Hydraulic Oil Temperature High

= Stick Boom IN

= Hydraulic Oil Level Low

= Stick Boom OUT = Hydraulic Oil Level = Oil Cooler Bypass = Hydraulic Oil Level High

= Park Brake = No Park Brake

= Hydraulic Oil Level Low = Pilot Reset ON = Imperial/Metric Toggle Symbol

2.6

Tigercat 215 Loader

Controls and operation = Fan Auto Reversing/Cleaning

= Pilot Reset OFF

= Fan Full ON

= Remote Hydraulic Cylinder Extend = Remote Hydraulic Cylinder Retract

= Fan Reverse/Clean

= Speed FAST or Hi

= Speed SLOW or LOW

= Switch ON

= Switch OFF

= SWING CLOCKWISE

= SWING COUNTERCLOCKWISE

= Variable Speed = Ventilation Blower Fan = Windshield Washer = Boom OUT - LM Function = Boom IN - LM Function

2.7

Tigercat 215 Loader

Controls and operation

ELECTRONIC CONTROLS DESCRIPTION ENGINE ELECTRONIC CONTROL MODULE

MD3 COMPUTER CONTROL MODULE

ELECTRONIC JOYSTICKS

ELECTRO HYDRAULIC CONTROL VALVES

XA2 EXPANSION MODULE

215-008

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

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

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

Moving either of the joysticks will send an electronic signal to the MD3 computer module.

The signal is then directed to the XA2 expansion module and from the module the signal is directed to the solenoid control for the function that is selected.

SOLENOID CONTROLS

234-051

CONTROL VALVE SECTION

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

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

2.8

Tigercat 215 Loader

Controls and operation

ELECTRONIC JOYSTICK FUNCTION Components and Operation: When not actuated the lever (1) is held in neutral position by the return springs (8). When operating the lever (1), the plunger (5) pushes against return spring (8). The magnet (7) mechanically linked to the plunger (5) moves upward or downward while following the levers actuation direction. The electrical signal generated by the sensor (4) is proportional to the deflection of the lever. A rubber boot (6) protects the mechanical components of the housing from external contamination.

1

6

MAIN VALVE SPOOL SECTIONS All of the main valve spool sections are equipped with proportional electro-hydraulic solenoid controls. The spools are spring centered to the neutral position. Sending an electrical signal to the desired electro-hydraulic solenoid control causes the solenoid to shift and direct internal pilot oil to the chosen spool actuator shifting the spool and directing pump oil flow to the selected cylinder or motor.

FEED REDUCER

PORT RELIEF ‘A’ SIDE

5

2

8 4 3

215-002

PORT RELIEF ‘B’ SIDE

7

ELECTRONIC JOYSTICK

24V PROPORTIONAL ELECTRO-HYDRAULIC SOLENOID CONTROLS

SPOOL PRESSURE COMPENSATOR 234-068

CROSS SECTION OF ELECTRO-HYDRAULIC OPERATED SPOOL SECTION

2.9

Tigercat 215 Loader

Controls and operation

IMPORTANT!

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

CAB CONTROLS NOTE: All joystick and Foot Pedal controls require that the pilot system be activated for the controls to function. Refer to PILOT RESET in THIS SECTION.

1

1A

50632BUNI R0

855C-016A

1. LEFT HAND JOYSTICK Stick Boom Push the joystick forward to move the Stick Out. Pull the joystick back to move the Stick In.

855C-016A

1A. LEFT HAND JOYSTICK LINEAR MOTION FUNCTION Thumb switch, center right Press and hold to activate the Linear Motion function of the stick and hoist booms.

To move the stick and hoist booms Out, press and hold the thumb switch while pushing the joystick forward.

Swing Rotate Move the joystick to the right to Swing Right.

To move the stick and hoist booms In, press and hold the thumb switch while pulling the joystick back.

Move the joystick to the left to Swing Left.

Grapple Rotate Pull on the front button to Rotate the grapple counterclockwise (left).

2.10

Tigercat 215 Loader

Controls and operation

2

50632BUNI R0

855C-016

2. RIGHT HAND JOYSTICK Hoist Boom Push the joystick forward to lower the Hoist Boom.

Pull the joystick back to raise the Hoist Boom.

Grapple Open Move the joystick to the right to open the Grapple Arms.

Grapple Close Move the joystick to the left to close the Grapple Arms.

Grapple Rotate Pull on the front button to Rotate the grapple clockwise (right).

2.11

Tigercat 215 Loader

Controls and operation

3. CONTROL PANEL The control panel is located on the R.H. side of the cab. The following machine functions are controlled by switches located on this control panel:

• • • • • • • • • • • • •

3 4

Battery Disconnect Switch (4) Optional Accessory Switch (5) Fan Control Switch (6) Horn Switch (7) Pilot Reset Switch (8) Emergency Stop Switch (9) Throttle Control Switch (10) Ignition Key Switch (11) Lighter/Auxillary Power (24V) Outlet (12)

6

Auxillary Power (12V) Outlet (13) Rear Work Lights Switch (14)

5

7

Service lights Switch (15) Front Work Lights Switch (16)

4. BATTERY DISCONNECT - SWITCH This switch completely disconnects all electrical circuits on the machine from the battery. Turn this switch to OFF whenever the machine is left unattended for an extended period of time (overnight etc.).

8 9 AUTO

5. OPTIONAL ACCESSORY SWITCH This switch position is used for various optional functions

10

6. FAN CONTROL - SWITCH (IF EQUIPPED - VARIABLE PITCH FAN)

12

This is a three position switch, labelled / / (FULL ON/ AUTOMATIC/ CLEAN).

This switch controls the operation of the optional Flexxaire® cooling fan.

11 15

The Flexxaire® cooling fan blade pitch is hydraulically varied to control the flow and direction of air through the cooling assembly AUTOMATIC Position - AUTOMATIC is the normal operating position for the fan control switch. When the switch is in the AUTOMATIC position, the fan will operate completely in an automatic mode. The computer control system will automatically control the fan pitch to minimize system energy losses and improve performance

13

14

215-001

2.12

16

Tigercat 215 Loader

Controls and operation

based on the temperature of the charge air, engine coolant and hydraulic oil. The computer system automatically adjusts fan air flow to the minimum required level to maintain optimal operating conditions.

Automatic control of fan air flow to match your operating conditions can lower fuel consumption and reduce operating costs. In high temperature operating conditions the fan air flow is increased to improve cooling ability and efficient operation of the cooling assembly and air conditioning systems. In low temperature operating conditions fan air flow is reduced, as less cooling is required for efficient operation of the cooling assembly.

In addition, when this switch is in the AUTOMATIC position, the system will automatically cycle through an auto clean cycle.

by overheating. Ensure that there are no personnel standing directly to the sides of the machine when performing this operation, as dust and debris will fly out.

When the CLEAN cycle is complete the fan automatically returns to normal air flow direction.

The auto clean cycle is adjustable through the computer control system menu (ADJUST MENU - REVERSING FAN CONTROLS).

It is also important to manually clean debris from the machine on a regular basis to maintain low machine operating temperatures.

7. HORN - SWITCH Press Horn switch (14) to sound horn..

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

The auto clean cycle is adjustable through the computer control system menu (ADJUST MENU - REVERSING FAN CONTROLS).

Note that when the switch is in the AUTOMATIC position and the fan has stopped due to low charge air, engine coolant and hydraulic oil temperatures, turning ON the A/C will cause the computer system to immediately place the fan blades at a pitch to provide 30% air flow. This is to ensure that sufficient air flow is available for the cab A/C even while the machine is still warming up.

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

215-003

FULL ON Position - When the switch is in the FULL ON position, the computer control system is overridden and the fan will run at FULL air flow (blades pitched to 100%), for cooling regardless of charge air, engine coolant or hydraulic oil temperatures.

Normally the fan control switch is placed in the AUTOMATIC position for optimal cooling.

The FULL ON position is intended for use in the event of a temporary failure of the control system.

PILOT SYSTEM SHUT OFF LIMIT SWITCH - CAB DOOR

PILOT SYSTEM SHUT OFF - LIMIT SWITCH

CLEAN Position - Momentarily pressing the switch to the CLEAN position will manually start the automatic clean cycle, reversing the flow of air (there is no need to hold the switch down). The pitch of the fan blades is changed and the direction of airflow through the engine enclosure is reversed. This change in airflow blows debris from the machines engine enclosure to eliminate potential overheating and poor machine performance caused 2.13

Tigercat 215 Loader

Controls and operation

8A PILOT SYSTEM SHUT OFF - LIMIT SWITCH The cab door is equipped with an interlock switch to prevent the machine from being operated while the door is open (pilot system shut off).

3 4

To operate: Close the door and press the pilot reset switch.

NOTE: All functions on the machine can now be operated, either as intended or by accidentally touching them.

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

This door interlock switch and the pilot reset switch are safety features and their function must not be defeated in any way.

6

9. EMERGENCY STOP SWITCH

5

7

When the emergency stop switch (21) is pressed DOWN, it immediately turns OFF electrical power to the engine ECM and the pilot system which, in turn shuts down the engine and hydraulic systems. To return the power to the cab, turn the knob clockwise to allow it to pop back up.

8 9

10. THROTTLE CONTROL SWITCH AUTO

This is a three position "momentary" switch connected to the MD3 computer and is used to adjust the engine RPM. between the (IDLE) and

(FULL) throttle set points.

10

NOTE: Engage the pilot reset to increase engine speed. When pilot system is deactivated the engine speed will reset to minimum rpm.

PRESS and HOLD this switch in the FULL

12

position to increase engine speed (rpm), release switch at desired rpm. or continue to HOLD to place engine at the correct FULL throttle setting.

PRESS and HOLD this switch in the IDLE position to decrease engine speed (rpm), release switch at desired rpm. or continue to HOLD to place engine at the correct MINIMUM throttle setting.

NOTE: All operations should be performed at FULL throttle.

11

13

15 14

215-001

2.14

16

Tigercat 215 Loader Maintaining Correct Engine RPM. It is most important that the IDLE and FULL RPMs. of the engine be correct at all times: IDLE 1000 RPM (No Load) FULL 2200 RPM max (No Load) RATED WORKING 2200 RPM NOTE: At start-up the engine will always default to IDLE. IMPORTANT! At no time should the high idle speed exceed the recommended value as serious damage to the pumps will result.

The above values are with the hydraulic and engine oil at normal operating temperatures and no functions activated. These values are pre-set into the engine CPU (computer) and cannot be adjusted without the proper electronic equipment programming software.

AUTO IDLE DOWN - If the engine is set to run a full throttle and no functions are activated for *five seconds (*time is adjustable), the engine will idle down. The engine will return to the set idle speed as soon as a function is activated.

NOTE: During cold weather the computer limits maximum idle speed until the hydraulic oil has reached a specific temperature based on the oil grade selected. See COLD WEATHER STARTING in this section.

11. IGNITION KEY SWITCH

Controls and operation 12. LIGHTER - 24 VOLT OUTLET Depress lighter fully into socket and wait until it pops back up. Pull lighter out of socket and use coil to light cigar(ette). CAUTION: Lighter coil reaches high temperature which can cause burns to skin and can start fire.

Handle with care. DO NOT use in presence of explosive or flammable liquids or vapor.

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

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

14. REAR WORK LIGHTS This switch controls the work lights located on the rear of the cab. The circuit draws current directly from the battery and is protected by a fuse located in the fuse panel 15. SERVICE LIGHTS This switch controls the service light located in the engine enclosure. The circuit draws current directly from the battery and is protected by a fuse located in the fuse box.

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

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

This is a three position switch.

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

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

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

2.15

Tigercat 215 Loader

Controls and operation AIR DISCHARGE OUTLETS

C 244-003

B

A

D

E

A/C HEATER CONTROL PANEL

215-005

17. AIR CONDITIONER/HEATER

17A. A/C HEATER AIR DISCHARGE OUTLETS

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

There are five remote air outlets for the A/C Heater unit. Two are located in the rear of the roof, two are located in the roof to the right of the operator.

A. A/C ON/OFF SWITCH

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

B. FAN SPEED - OFF/LOW/MED/HIGH

AIR DISCHARGE OUTLET

This is a rotary, four position switch for the fan speed.

C. AIR SOURCE

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

234E-153

One outlet is located at floor level under the front of the seat.

D. HEAT - VARIABLE

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

E. AIR CONDITIONING - VARIABLE

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

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

2.16

Tigercat 215 Loader

Controls and operation

R.H. SIDE OF MACHINE HOSE TO A/C HEATER UNIT

215-004

SHUT-OFF VALVE

18

HOT WATER SHUT OFF VALVE

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

RECIRCULATION AIR FILTER

A/C HEATER UNIT

234E-009

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

EXTERNAL AIR FILTER ACCESS PANEL

FILTER

LOWER RIGHT SIDE OF OPERATOR'S CAB 215-041

EXTERNAL AIR FILTER

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

2.17

Tigercat 215 Loader

Controls and operation

20

1075-076

22. AM/FM STEREO RADIO/CD

234E-010

Consult the manufacturer's manual for operation instructions.

20. 2 WAY RADIO - OPTIONAL Refer to radio manufacturer's manual.

21

23

234E-006 234E-011

23. WINDSHIELD WIPER/WASHER

21. INTERIOR LIGHT

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

Push the lens cover of the light forward/ rearward to turn the light ON and OFF.

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

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

2.18

Tigercat 215 Loader

Controls and operation 24

ASHTRAY

CUP HOLDER 215-007

WINDSHIELD WASHER FLUID

26. WINDSHIELD WASHER FLUID

234E-012

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

PORTABLE FIRE EXTINGUISHER

24. FIRE EXTINGUISHER A portable fire extinguisher is located in operator's cab. The extinguisher should be checked daily to ensure that it is charged. The pointer on the charge gauge should point to the green region. If the indicator falls out of this green area, the extinguisher should be serviced immediately.

244-019

IQAN USB PORT

27 234E-006

27. MD3 COMPUTER AND DISPLAY The MD3 computer, electronic control and display is the operator interface with the electronic control system. The MD3 is the central unit in the control system which works as both a master controller and a display unit.

Refer to the MD3 COMPUTER system later in this section for complete description and detailed operation information.

SLIDING WINDOWS HANDLE

25. WINDOWS

USB PORT - MD3 COMPUTER

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

This USB port is used to access the MD3 computer. A laptop with appropriate IQAN software can be plugged into this port for software updates, diagnostics and some adjustments.

NOTE: This USB connection should only be used by a trained service technician.

Refer to COMPUTER in SECTION 6 of the SERVICE MANUAL for more information and safeguards related to the use of this port.

2.19

Tigercat 215 Loader

Controls and operation

WARNING BUZZER

MD3 COMPUTER USB PORT

WARNING LIGHT MD3 COMPUTER

COLOUR DISPLAY

234E-006 234E-074

MD3 COMPUTER, ELECTRONIC CONTROL AND DISPLAY

MD3 COMPUTER ELECTRONIC CONTROL & DISPLAY

• Up and down arrow buttons

The MD3 computer, electronic control and display is the operator interface with the electronic control system. The MD3 is the central unit in the control system which works as both a master controller and a display unit. It has a 3.5" backlit colour graphic transflective display for reading system information.

The front of the MD3 consists of a control panel with a display and nine buttons. The buttons are arranged on the bottom and right hand side of the display.

• F1 through F4 function buttons,

,

,

, .

Programmed buttons that are configured by program software to bring up a display page, bring up an adjustment group or act as an input.

.

Navigation buttons that are used to scroll thru selections on a menu page. The buttons are configured by program software to bring up a display page, bring up an adjustment group or act as a virtual input.

• OK button .

Pushing this button equals ’enter’. Saves the value or confirms the selection you have made.

• Main Menu button .

Always brings up the Menu page. It is not programmable.

• ’Esc’ or BACK button

.

Returns you to the previous display page. May be configured by program software to bring up a display page, bring up an adjustment group or act as a virtual input.

2.20

Tigercat 215 Loader

Controls and operation ENGINE ELECTRONIC CONTROL MODULE

MD3 COMPUTER CONTROL MODULE

ELECTRONIC JOYSTICKS

ELECTRO HYDRAULIC CONTROL VALVES

XA2 EXPANSION MODULE

215-008

MD3 COMPUTER ELECTRONIC CONTROL & DISPLAY The MD3 computer control system is part of a network of components (shown above). The system is made up of the following components: •

MD3 Computer and Display Module

•

Electronic Joysticks

•

XA2 Expansion Module

•

Engine Electronic Control Module

•

Hydraulic Control Valve Electronic Solenoids

•

Various controls, switches, sensors and valves not shown.

The MD3 computer is the main controller in the system. The MD3 computer program is the operating system for the computer display as well as the control system for the machine operating parameters.

As an example, the joystick movement/position is transmitted to the MD3 controller electronically.

This message is then transmitted to the XA2 expansion module from the MD3 control and on to the hydraulic control valve solenoid controls.

The applicable hydraulic control valves will be activated allowing hydraulic oil to flow to the boom or grapple functions activated by the joystick movement.

The engine electronic control module provides electronic information to the MD3 computer via the J1939 CAN BUS link. This information is displayed on the computer display.

2.21

Tigercat 215 Loader

Controls and operation

MD3 COMPUTER/ELECTRONIC CONTROL/DISPLAY CONT’D 2

1

3

4

12

11

5

6

7

8

215-015

9

10

MAIN DISPLAY

MD3 COMPUTER MAIN DISPLAY

215-012

ELECTRONIC JOYSTICKS

1. MD3 COMPUTER MODULE

MD3 COMPUTER MODULE

2. PILOT RESET ON/OFF 3. MACHINE MODE ENGINE ELECTRONIC CONTROL MODULE

4. FUEL LEVEL LOW 5. ENGINE TACHOMETER RPM 6. ENGINE MENU - Press F1 to select

HYDRAULIC CONTROL VALVES

7. ADJUSTMENT MENU - Press F2 to select 8. ENGINE COOLANT TEMPERATURE GAUGE

XA2 EXPANSION MODULE

9. INFORMATION MENU - Press F3 to select 10. ALARM INDICATORS - Press F4 to select 11. OIL GRADE INDICATOR 12. HYDRAULIC OIL TEMPERATURE GAUGE

MD3 COMPUTER SYSTEM COMPONENTS 2.22

Tigercat 215 Loader

Controls and operation

ENGINE MENU

ADJUSTMENT MENU

From the main display press the F1 button to select the engine display.

When selected the engine menu icon is on display and the engine functions will also be displayed.

The engine functions on display are as follows: • Charge Air Temperature - °C or °F • Turbocharger Boost Pressure - (bar or psi) • Engine Load % • Engine Speed rpm • Engine Temperature - °C or °F • Battery Voltage - Volts • Engine Oil Pressure - (bar or psi)

From the main display press F2 button to select the ADJUSTMENT MENU.

The adjustment menu screen will be displayed.

The adjustment icon is on display and all the adjustment selections are displayed. The adjustment selections are as follows: •

Control Adjustments - select F1

•

Oil Grade Adjustments - select F2

•

Fuel Rate - L/h or gph (instantaneous) Note: To set metric or imperial measure press F1 to change mode.

2.23

Tigercat 215 Loader

Controls and operation MACHINE MODE ADJUSTMENT SELECTION

OIL GRADE SELECTION

Press F2 button to select OIL GRADE Menu from the ADJUSTMENT MENU. The oil grade menu will appear. Five choices are given ISO22, ISO32, ISO36, ISO46 and ISO68.

Press the arrow up or arrow down to scroll to the desired oil grade and press OK when complete.

Press the Back button to return to the adjustment menu. Press the Back button again to return to the main display.

From the main menu display press F2 to select the adjust menu.

In the adjust menu press F1 to select the control adjust menu.

2.24

Tigercat 215 Loader

The control adjustment (F1) provides access to the machine mode adjustments.

Press F1 button to select the machine mode from the CONTROL ADJUSTMENT MENU.

Controls and operation

When F1 has been selected a dialogue box will appear in the lower right side of the display. There are four choices to choose from: •

M0 = Training Mode

•

M1 = Machine Mode 1

•

M2 = Machine Mode 2

•

M3 = Machine Mode 3

The machine is factory set at M2. Select M1 for smoother operation and M3 for more aggressive operation. Use the arrow up button or arrow down button to scroll to the desired selection and the OK button to set the selection.

Press the back button menu display.

2.25

to return to the main

Tigercat 215 Loader

Controls and operation

LIMP MODE OPERATION

The Machine adjust menu appears, press the F1 button to access the Machine Mode Adjustments.

When a critical joystick communication fault occurs the fault warning message appears on the display.

The message reads "No contact or invalid data.

Limp mode is now available." The limp mode provides the operator with the ability to operate the fault joystick functions using the buttons on the MD3 display.

This will allow the boom to be placed in a safe position before the machine is shut down. Seek service assistance if a joystick fault is active.

The machine mode adjustment menu appears on the display with the Limp Mode Icon above the F2 button.

located

Press the F2 button to select the limp mode feature.

To access the limp mode, press the F2 button to hide the warning message.

Press the F2 button to access the machine adjust menu.

2.26

Tigercat 215 Loader

Controls and operation

An information message appears on the display.

The message requires confirmation before the limp mode will be activated. The message is: Entering Limp Mode Screen commands are now active! Extra care must be taken when manually activating controls.

Pilot system is ACTIVE! Press the F2 button to hide the message to proceed to the limp mode.

Stick Boom In/Out - select and hold F2 button then press arrow up to extend the clinder (boom Out) or arrow down cylinder (boom In).

to retract the

Swing Rotate - select and hold F4 button then press arrow up arrow down

to rotate clockwise or

to rotate counterclockwise.

Grapple Open/Close - select and hold F3 button then press arrow up grapple or arrow down

to close the to open the grapple.

NOTE: Holding the arrow up or down will increase the function speed to a maximum of 50%. To stop the function, simply release the F1, F2, F3 or the F4 button and the speed will reset to 0%.

The limp mode menu appears on the display and the following functions can be operated: Hoist Boom Up/Down - select and hold F1 button then press arrow up to extend the cylinder (raise the boom) or arrow down retract the cylinder (lower the boom).

to

2.27

Tigercat 215 Loader

Controls and operation

INFORMATION MODE SELECTION

Press the F3 button to access the information menu.

The information displays the following information:

MAIN MENU SCREEN

Press the menu button menu screen.

to go to the main

•

Engine Hours

The main menu page displays the following selections:

•

Machine Hours

•

Adjust - Select F1

•

Hydraulic Oil Temperature

•

Measure - Select F2

•

Fuel Used in US gal or Liter

•

Preferences - Select F3

•

Metric/Imperial Measure Reset - Select F1

•

Info - Select F4

Select F1 to set imperial or metric measure.

Press the back button display.

to return to the main

To return to the Main display press the back button.

2.28

Tigercat 215 Loader

Controls and operation

ADJUST MENU

MACHINE MODE

From the main menu screen press the F1 button (Adjust) to access the adjust menu.

Press the OK button to select Mode Select.

This menu is an alternate method of accessing the adjustment menu to make machine adjustments. See ADJUSTMENT MENU earlier in this section for details.

The Main menu appears and the following menu items can be selected.

•

Machine Mode

•

Machine Parameters

•

Valve current settings

•

Reversing Current Settings

•

LM Boom Speed Adjustments Use the Arrow Up or Arrow Down to select the menu item. Press OK to confirm the selection.

There are four choices to choose from: •

M0 = Training Mode

•

M1 = Machine Mode 1

•

M2 = Machine Mode 2

•

M3 = Machine Mode 3

The machine is factory set at M2. Select M1 for smoother operation and M3 for more aggressive operation. Use the arrow up button or arrow down button to scroll to the desired selection and the OK button to set the selection.

Press the back button menu.

to return to the adjust

Use the Arrow Up or Arrow Down to select the Machine Parameters menu item. Press OK to confirm the selection.

2.29

Tigercat 215 Loader

Controls and operation

MACHINE PARAMETERS

IDLE DOWN WAIT TIME

In the machine parameters menu the following items can be selected:

In the Idle Down Wait Time menu the value can be adjusted from 2 seconds to 60 seconds using the arrow up/down buttons to change the value, then press the OK button to set the new value.

The factory default value is 5 seconds. This function is an automatic idle down feature.

If the engine is set to run at full throttle and no functions are activated for a 5 seconds, the engine will idle down automatically. The engine will return to the set idle speed as soon as a function is activated.

NOTE: During cold weather the computer limits maximum idle speed until the hydraulic oil has reached a specific temperature based on the oil grade selected. See COLD WEATHER STARTING in this section.

•

Idle Down Wait Time

•

Grapple Open/Close Fine Control Range (%)

•

Oil Grade

•

Stick Boom Stop Cushion (%)

•

Stick Boom Cushion On/Off

Press the back button to return to the Machine Parameters menu.

Use the arrow up button or arrow down button to scroll to the next selection and the OK button to set the selection.

Use the arrow up button or arrow down button to scroll to the Idle Down Wait Time selection and the OK button to set the selection.

2.30

Tigercat 215 Loader GRAPPLE OPEN/CLOSE FINE CONTROL RANGE (%)

Controls and operation In the Oil Grade menu five choices are available, ISO 22, ISO32, ISO36, ISO46 and ISO 68.

Use the arrow up/down buttons to scroll to the desired selection then press the OK button to set selection.

Press the back button to return to the machine parameters menu.

Use the arrow up button or arrow down button to scroll to the next selection and the OK button to set the selection.

STICK BOOM STOP CUSHION (%)

The grapple open/close fine control range (1% to 100%) is an adjustment for the span of fine control in the grapple open/close function. Increasing the % value increases the amount of fine control for the function. Decreasing the % value brings the function to full speed sooner in the joystick travel.

For example, if the grapple open/close fine control is set at 40% (factory default setting), the function speed will proportionally increase from minimum to maximum speed within the first 40% of the joystick travel. For any joystick position from 40% to 100% the function will operate at full speed.

Press the back button to return to the machine parameters menu.

Use the arrow up button or arrow down button to scroll to the next selection and the OK button to set the selection.

OIL GRADE

The stick boom stop cushion is a feature that slows the stick boom down just before the stick boom reaches the limits of it's travel. It protects the boom components from damage caused by running the boom to the end of it's stoke at full speed. This machine parameter allows the operator to adjust the stop cushion (0% to 100%).

A high value (100%) is the maximum amount of cushion and a low value (0%) is minimum cushion. The factory default is 80% cushion.

Press the back button to return to the machine parameters menu.

Use the arrow up button or arrow down button to scroll to the next selection and the OK button to set the selection.

2.31

Tigercat 215 Loader

Controls and operation

STICK BOOM CUSHION ON/OFF

VALVE CURRENT SETTINGS

The stick boom cushion on/off feature allows the operator to turn the stick boom cushion on or off.

The following menu items can be selected.

Use the Arrow Up or Arrow Down to select the menu item. Press OK to confirm the selection.

Press the back button menu.

to return to the adjust

• Stick • Hoist • Grapple Arms • Grapple Rotate • Grapple Open/Close Fine Control Range (%) • Hoist BWL FP • Stick BWL FP • Swing COUT • Maximum Stick Reduction % FP Use the Arrow Up or Arrow Down to select the menu item. Press OK to confirm the selection.

This menu is used by Tigercat service technicians.

Refer to SECTION 6 of the SERVICE MANUAL for more information. Press the back button to return to the Valve Current Settings menu.

Continue to press the back button to go to the adjust menu.

Use the Arrow Up or Arrow Down to select the Valve Current Settings menu item. Press OK to confirm the selection.

2.32

Tigercat 215 Loader REVERSING FAN CONTROLS

Use the Arrow Up or Arrow Down to select the Reversing Fan Controls menu item. Press OK to confirm the selection.

In the reversing fan controls menu the following items can be selected: •

Time fan is reversed.

•

Time between automatic fan reversals.

Press the back button to return to the Reversing Fan Controls menu. Continue to press the back button to go to the adjust menu.

Controls and operation LM (LINEAR MOTION) BOOM SPEED ADJUSTMENTS

Use the Arrow Up or Arrow Down to select the LM Boom Speed Adjustment menu item. Press OK to confirm the selection.

The following menu items can be selected.

• LM Hoist up % of Max. Flow.

• LM Hoist Down % of Max. Flow.

Use the Arrow Up or Arrow Down to select the menu item. Press OK to confirm the selection.

Press the back button to return to the LM Boom Speed Adjustments menu. Continue to press the back button to go to the main menu screen.

2.33

Tigercat 215 Loader

Controls and operation

MEASURE MENU

From the main menu screen press the F2 button (Measure) to access the measure menu.

Use the Arrow Up or Arrow Down to select the menu item. Press OK to confirm the selection.

This menu is used by Tigercat service technicians.

Refer to SECTION 6 of the SERVICE MANUAL for more information. Press the back button (or F1) to return to the main menu screen.

The following menu items can be selected.

• • • • • • • • • • • • • • •

Engine Parameters IQAN Status L.H. Joystick R.H. Joystick Boom Controls Grapple Controls Swing Controls Input/Output Fault Information Stick Boom Cushion Channels Engine Speed Idle Down Command Fan Control Inputs/Outputs LM Boom Channels Stick boom test 2.34

Tigercat 215 Loader PREFERENCES MENU

From the main menu screen press the F3 button (Preferences) and the preferences menu page appears.

Controls and operation DISPLAY ADJUSTMENT

After selecting F1 the display adjustment screen opens and the following adjustments can be selected: RETURN TO MAIN MENU - Select F1 BACKLIGHT ADJUSTMENT - Select F2 SCREEN SAVER - Select F3 BACKLIGHT ADJUSTMENT

The following menu items can be selected.

•

Display

•

Date/Time

•

Language After selecting F2 the backlight adjustment screen opens. Use the Arrow Up or Arrow Down buttons to adjust the display backlight. The range is 10 to 100. The default setting is 100.

When the desired setting is selected press the OK button. A good rule to follow is the lower the number the longer the life of the display unit.

2.35

Tigercat 215 Loader

Controls and operation

SCREEN SAVER ADJUSTMENT

DATE/TIME ADJUSTMENT

Select F3 to open the screen saver adjustment screen. Use the Arrow Up and Arrow Down buttons to scroll through the choices. Three choices are available:

Press F2 to select the DATE/TIME adjustments in the PREFERENCES menu.

•

SCREEN SAVER OFF

•

DIMMED - Timeout 5 seconds

•

BLACK - Timeout 5 seconds

The DATE/TIME menu screen turns on. Two choices are available for adjustment: DATE - select F1 TIME - select F2

After making a selection press the OK button to confirm selection and press the back button to return to the preferences screen.

2.36

Tigercat 215 Loader

Controls and operation

DATE ADJUSTMENT

Press F1 to select DATE. Use the Arrow Up or Arrow Down to scroll through the YEAR list to select the year. Press OK to confirm year selected.

When the year has been confirmed the display will highlight the MONTH. Use the Arrow Up or Arrow Down to select the month. Press OK to confirm month selected.

When the month has been confirmed the display will highlight the DAY. Use the Arrow Up or Arrow Down to select the day. Press OK to confirm day selected.

The display will return to the DATE TIME menu.

2.37

Tigercat 215 Loader

Controls and operation

TIME ADJUSTMENT

INFO MENU PAGE

Select F2 Time adjustment from the DATE/TIME display screen.

From the main menu screen press the F4 button (Info) and the Info menu page appears.

The Time display screen will turn on. Use the Arrow Up or Arrow Down to select the HOUR. Press the OK button to confirm selection. The display will show the MINUTES highlighted.

The following menu items can be selected.

Use the Arrow Up or Arrow Down to select the minute. Press OK button to confirm the selection.

The display will return to the DATE/TIME menu screen. Press the back button main menu screen.

•

Modules - Select F1

•

Modem - Select F2

•

Logs - Select F3

The machine ID information will be displayed on the screen.

to return to the

2.38

Tigercat 215 Loader

Controls and operation

MODULES

LOGS

Press F1 to select the modules menu. This menu provides information on the following machine modules:

Press F3 from the info menu page to select logs.

This menu lists System Logs and Alarm Logs and the number of records within each log. The records are a list of all the fault occurrences in each log.

•

MD3 Computer Module

•

XA2 Expansion Module

•

LH Joystick

•

RH Joystick

•

Engine ECM (CAT C4.4)

Use the Arrow Up or Arrow Down to select the menu item. Press OK to confirm the selection.

This menu is used by Tigercat service technicians.

Refer to SECTION 6 of the SERVICE MANUAL for more information.

Press the back button main menu page.

Shown above the MD3 module has been selected. Specific information for the MD3 is displayed on the screen.

This menu is used by Tigercat service technicians.

Refer to SECTION 6 of the SERVICE MANUAL for more information.

Press the back button main menu screen.

(or F1) to return to the

2.39

(or F1) to return to the

Tigercat 215 Loader

Controls and operation

MESSAGES AND WARNINGS MD3 COMPUTER

215-034

WARNING LIGHT

WARNING BUZZER

The MD3 computer displays messages and warnings, activates the master alarm and alarm light whenever a system fault occurs. Note that the computer control system will automatically perform a bulb test at engine start up to ensure that master alarm and alarm light are functioning.

Refer to STARTING ENGINE in THIS SECTION. There are different types of Messages and Alarms, they appear on the screen as a block message.

The types of messages are: • CRITICAL MESSAGE - Colour RED • ALERT MESSAGE - Colour YELLOW • INFORMATION MESSAGE - Colour BLUE Messages can be hidden or acknowledged by pressing the F2 button (Hide or OK).

All messages that have been hidden or acknowledged are stored in the computer.

In some instances it will be necessary to immediately stop the machine, shut the engine OFF and repair the problem causing the message.

Active fault messages that have been hidden can be reviewed by pressing the F4 button. Recalled messages and warnings will be displayed in order starting with the highest priority first.

2.40

Tigercat 215 Loader

Controls and operation

CRITICAL MESSAGES AND WARNINGS (RED) Critical messages advise the operator that a critical machine fault is about to occur or a system fault has occurred.

Critical messages have the highest level of priority and are used to alert operator that immediate action must be taken to prevent damage to machine or to ensure operator safety.

When a critical message is displayed, the master alarm and alarm light will sound and flash continuously. The message remains on the screen until the operator hides it.

Critical messages and warnings flash the critical symbol above the F4 button when active messages are hidden. The symbol will continue to flash until the problem is resolved and the fault becomes inactive.

Active messages that have been hidden can be reviewed by pressing the F4 button.

The message will give brief details of the fault and advise what action is necessary.

In some instances the machine requires immediate action to correct the problem which requires the operator to STOP machine operation, SHUT THE ENGINE OFF and service the machine to correct the problem.

However, if the machine cannot be stopped immediately for safety reasons, the operator can hide the message. In this instance the machine should only be operated long enough to make the machine safe, then STOP machine operation and SHUT THE ENGINE OFF before serious machine damage can occur!

Messages can be hidden by pressing the F2 button (Hide).

A list of CRITICAL MESSAGES is as follows: Hydraulic Oil Level Low. Hydraulic Oil Temperature High Engine Stop Hardware Fault - MD3 Hardware Fault - Engine Hardware Fault - XA2 Engine Coolant Temperature High Engine Coolant Level low Engine CAC Temperature High Engine Oil Pressure Low Engine Fault Code Messages - Critical

2.41

Tigercat 215 Loader

Controls and operation

CRITICAL MESSAGES AND WARNINGS HYDRAULIC OIL LEVEL LOW

Hydraulic Oil Level Low.

This warning will be displayed, alarm warning light will flash and alarm will sound when the main hydraulic tank oil level is low.

Stop the engine immediately when this alarm is activated. Operating machine with a low hydraulic oil level can cause hydraulic pumps to fail.

When this alarm is activated stop the engine and look for signs of broken hoses or other leaks.

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

2.42

Tigercat 215 Loader

Controls and operation

HYDRAULIC OIL TEMPERATURE HIGH

Hydraulic Oil Temperature High.

This warning will be displayed, alarm warning light will flash and alarm will sound when the oil temperature exceeds the recommended operating range for the type of hydraulic oil in use.

If the temperature rises above the recommended operating range for the type of hydraulic oil in use check the following: • • • • • •

Plugged oil cooler Malfunction in a hydraulic system High loads on the hydraulic system Malfunction of the cooling fan Low hydraulic oil level Correct Hydraulic Oil Grade Selection

If hydraulic oil temperature rises above the recommended operating range DO NOT continue to operate the machine.

This alarm must not be used to monitor the hydraulic oil. The operator must use the hydraulic oil temperature gauge on the main menu, together with the operating range chart in SECTION 3 to prevent damage to the hydraulic system.

Hydraulic oil grade information is shown on the main menu below the hydraulic oil temperature gauge.

Operating outside the recommended operating range will shorten hydraulic component life.

Refer to COMPUTER ~ ADJUSTMENT MENU SERVICE SETTINGS ~ HYDRAULIC OIL GRADE in THIS SECTION for hydraulic oil grade selection settings information.

Refer also to APPROVED HYDRAULIC OILS in SECTION 3 of THIS MANUAL for hydraulic oil operating range information.

Refer to COMPUTER ~ INFORMATION MODE MENU ~ HYDRAULIC OIL TEMPERATURE in THIS SECTION for hydraulic oil temperature information display.

2.43

Tigercat 215 Loader ENGINE STOP

Controls and operation HARDWARE FAULT - MD3

Hardware Fault - MD3

Engine Stop

Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

Critical engine fault active - contact service.

Hardware Fault - MD3 Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

This warning will be displayed, alarm warning light will flash and alarm will sound when the engine stops while the ignition switch is in the RUN position and/or when critical engine alarms are triggered.

Refer to engine manufacturer's manual for specific information regarding the engine.

This warning will be displayed, alarm warning light will flash and alarm will sound when a critical active hardware fault related to the MD3 Display module has been hidden.

To recall the original active fault(s) the operator must turn the key off and on.

A VREF error is an example of the type of hardware fault which will be the original active fault which triggers this message.

2.44

Tigercat 215 Loader HARDWARE FAULT - XA2

Controls and operation HARDWARE FAULT - ENGINE

Hardware Fault - XA2

Hardware Fault - Engine

Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

Hardware Fault - XA2

Hardware Fault - Engine

Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

This warning will be displayed, alarm warning light will flash and alarm will sound when a critical active hardware fault related to the XA2 module has been hidden.

This warning will be displayed, alarm warning light will flash and alarm will sound when a critical active hardware fault related to the Engine has been hidden.

To recall the original active fault(s) the operator must turn the key off and on.

To recall the original active fault(s) the operator must turn the key off and on.

A VREF and no contact errors are examples of the type of hardware fault which may be the original active fault which triggers this message.

No contact error is an example of the type of hardware fault which may be the original active fault which triggers this message.

2.45

Tigercat 215 Loader COMMUNICATION FAULT - L.H. JOYSTICK

Controls and operation COMMUNICATION FAULT - R.H. JOYSTICK

LH Joystick Communication

RH Joystick Communication

No contact or invalid data. Limp mode is now available.

No contact or invalid data. Limp mode is now available.

This warning will be displayed, alarm warning light will flash and alarm will sound when a critical communication fault related to the L.H. joystick is activated.

This warning will be displayed, alarm warning light will flash and alarm will sound when a critical communication fault related to the R.H. joystick is activated.

Limp mode is now activated. The limp mode provides alternate operation of the fault joystick using the buttons on the MD3 module. The limp mode should only be used long enough to place the machine in a safe condition then stop machine operation, shut the engine off and repair the joystick malfunction. Refer to LIMP MODE OPERATION in this section for complete details.

Limp mode is now activated. The limp mode provides alternate operation of the fault joystick using the buttons on the MD3 module. The limp mode should only be used long enough to place the machine in a safe condition then stop machine operation, shut the engine off and repair the joystick malfunction. Refer to LIMP MODE OPERATION in this section for complete details.

No contact error (the joystick has lost the electrical connection with the MD3 computer) is an example of the type of fault that triggers this message.

No contact error (the joystick has lost the electrical connection with the MD3 computer) is an example of the type of fault that triggers this message.

2.46

Tigercat 215 Loader

Controls and operation

ENGINE FAULT CODE MESSAGES - CRITICAL

SPN: 0 FMI: 0 1 of 1 Engine fault parameter - Fault Identifier

SPN: 0 FMI: 0 1 of 1 Engine fault parameter - Fault Identifier

Critical engine fault message(s) will be displayed, alarm warning light will flash and alarm will sound when a critical engine fault message is received from the engine electronic control module.

They provide the SPN code (suspect parameter number) and the FMI code (fault mode identifier) as well as a message describing the fault (when available).

Critical engine fault codes are higher priority messages than alert level engine fault code messages. Critical messages can be hidden but immediate action must be taken, STOP machine operation and service engine immediately to resolve the cause of the fault.

An example of a critical engine fault message is shown above.

Note that some less common engine fault codes will appear without a message describing the fault. Make a note of the SPN and FMI codes and contact service for more information.

Refer to engine manufacturer's manual for specific information regarding the engine.

2.47

Tigercat 215 Loader

Controls and operation

ALERT MESSAGES (YELLOW)

There are two types of alert messages:

Alert messages advise the operator that machine operation will be compromised.

Alert programmed messages generally triggered by machine function related conditions.

Alert messages have the second level of priority and are used to indicate to the operator that action is required to prevent future damage to the machine.

When an alert message is displayed, the external alarm and light will sound and flash three times to alert the operator of the message. The message remains on the screen until the operator hides it.

All alert message will give brief details of the fault and advise what action is necessary.

Action should be taken to service the machine to correct the problem at the earliest opportunity to prevent future damage to the machine.

Messages can be hidden by pressing the F2 button (Hide).

Alert computer system generated messages are generally triggered by computer system error and fault related conditions.

When a system generated alert message is displayed the external alarm and light will sound and flash three times to alert the operator of the message.

Alert messages flash the alert symbol above the F4 button when active messages are hidden.

Active messages that have been hidden can be reviewed by pressing the F4 button. The symbol will continue to flash until the problem is resolved and the fault becomes inactive.

Note that if both a critical level fault and an alert level fault are present the critical symbol will take priority until the critical fault becomes inactive.

The message remains on the screen until the operator hides it.

Note that active hardware fault alert messages are acknowledged by pressing the F2 button (OK). To recall these messages turn key off and on. On screen messages will indicate to the operator that an active hardware fault has been hidden.

INTERACTIVE ALERT MESSAGES •

Eng Warning MSG - Alert

•

Engine Fault Code Messages - Alert

•

LH Joystick DM1 Alert

•

Module MD3 Alert MSG

•

Module XA2 Alert MSG

•

RH Joystick DM1 Alert

•

COUT hardware fault MSG

•

DOUT hardware fault MSG

•

DIN hardware fault MSG

•

VIN hardware fault MSG

2.48

Tigercat 215 Loader

Controls and operation

ENGINE FAULT CODE MESSAGES - ALERT

SPN: 110 FMI: 16 1 of 1 Engine coolant temperature high Above normal, severe

Alert engine fault message(s) will be displayed, alarm warning light will flash and alarm will sound when an alert engine fault message is received from the engine electronic control module.

They provide the SPN code (suspect parameter number) and the FMI code (fault mode identifier) as well as a message describing the fault (when available).

Alert engine fault codes are lower priority messages than critical level engine fault code messages. Alert messages can be hidden but action (service engine) is required to resolve the cause of the fault.

An example of an alert engine fault message is shown above.

Note that some less common engine fault codes will appear without a message describing the fault. Make a note of the SPN and FMI codes and contact service for more information.

Refer to engine manufacturer's manual for specific information regarding the engine.

2.49

Tigercat 215 Loader

Controls and operation

HARDWARE FAULT - JOYSTICK

This warning will be displayed when an alert level active fault related to the Joystick module has been triggered.

Short circuit alert message is an example of the type of fault that triggers this message. Restart power on joystick (turn key off then back on). If problem persists contact the service department.

2.50

Tigercat 215 Loader HARDWARE FAULT - MD3

Controls and operation HARDWARE FAULT - XA2

Hardware Fault - MD3

Hardware Fault - XA2-A0

Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

Hardware Fault - XA2-A0

Hardware Fault - MD3 Active fault has been hidden. Turn key off and on

Active fault has been hidden. Turn key off and on

to recall active hidden hardware faults.

to recall active hidden hardware faults.

This warning will be displayed when an alert level active hardware fault related to the MD3 Display module has been hidden.

This warning will be displayed when an alert level active hardware fault related to the XA2-A0 module has been hidden.

To recall the original active fault(s) the operator must turn the key off and on.

To recall the original active fault(s) the operator must turn the key off and on.

High temperature, low supply voltage and high supply voltage module alert messages are examples of the type of hardware fault which will be the original active faults which trigger this message.

High temperature, low supply voltage and high supply voltage module alert messages are examples of the type of hardware fault which will be the original active faults which trigger this message.

2.51

Tigercat 215 Loader LOW FUEL LEVEL - FLASHING ICON

Controls and operation WAIT TO START

1

This icon

(1) is a Low Fuel Level warning.

The icon will flash ON and OFF when the FUEL level drops below 76 L ( 20 US gal ).

This icon will appear on the display during the "key ON" engine pre-heat time. Heating elements (grid heater elements) located in the engine air intake manifold are turned ON to heat the intake air when starting the engine. The engine must not be started until this icon turns OFF automatically.

2.52

Tigercat 215 Loader

Controls and operation

COLD WEATHER STARTING During cold weather, the engine idle speed is controlled by the computer to limit maximum engine speed until the hydraulic system temperature has warmed to a specific temperature based on the oil grade selected.

TEMPERATURE

21°C (70°F)

4.5°C (40°F) 1400 RPM

2200 RPM

ENGINE SPEED As the machine hydraulic system temperature rises the engine idle speed can be increased. The length of time it takes is dependent on ambient temperature and oil grade selected.

Example: ISO 46 oil grade at 21°C (70°F) or above, engine speed can be increased to max idle speed 2200 rpm.

NOTE: The idle down function will not work until the engine idle speed can be increased to full rpm.

2.53

Tigercat 215 Loader

Controls and operation

CAB FUSE AND RELAY PANEL

215-040

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

Each circuit of the machine is protected by a fuse.

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

2.54

Tigercat 215 Loader

215-038

Controls and operation

FUSE AND RELAYS - ELECTRICAL BOX

LABEL ~ FUSE AND RELAYS - ELECTRICAL BOX FUSES AND RELAYS (ELECTRICAL BOX) This Main Fuse and Relay electrical box is located in the engine compartment.

2.55

Tigercat 215 Loader

Controls and operation

BACK ANGLE ADJUSTMENT

To soften the air ride For a softer ride, pull on the air ride adjustment knob to decrease the air pressure in the suspension air bag.

ADJUSTABLE LUMBAR To increase lumbar support pressure, turn lumbar adjustment lever forward. To decrease lumbar support pressure, turn lumbar adjustment lever backwards .

LUMBAR HORIZONTAL ADJUSTMENT (NOT SHOWN)

LUMBAR HORIZONTAL ADJUSTMENT

ARMREST ADJUSTMENT

HEIGHT ADJUSTMENT LEVER

RIDE ADJUSTMENT KNOB S855C-020

FORE/AFT SLIDE LEVER

SEAT ADJUSTMENTS

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

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

To raise the seat Firmly lift up on the height adjustment lever and partially lift your body weight from the seat. When the seat rises to the desired height, FIRMLY PUSH DOWN on the lever into the locking position (a click should be heard).

H855-084

VIEW FROM RIGHT REAR OF SEAT

BACK ANGLE ADJUSTMENT Push down backrest angle adjustment lever to place backrest at the desired angle then release lever.

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

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

To lower the seat Firmly lift up on the height adjustment lever and add body weight to the seat until the seat is at the desired height. FIRMLY PUSH DOWN on the lever into the locking position (a click should be heard).

AIR RIDE ADJUSTMENT PROCEDURES After adjusting the seat height, the ride adjustment can be made by pulling or pushing the air ride control valve knob.

To stiffen the air ride For a stiffer ride push on the air ride adjustment knob to increase the air pressure in the suspension air bag.

2.56

Tigercat 215 Loader

Controls and operation

LUMBAR HORIZONTAL ADJUSTMENT

BACK ANGLE ADJUSTMENT

RIDE ADJUSTMENT KNOB S855C-020B

HEIGHT ADJUSTMENT LEVER

FORE/AFT SLIDE LEVER

SEAT ADJUSTMENTS

PROBLEMS AND CORRECTIVE ACTION RIDES TOO STIFF/SEAT TENDS TO PUSH OR THROW OPERATOR FORWARD The air ride control valve has over pressurized the seat air suspension. This typically happens because the operator is trying to use the air suspension to adjust the ride height rather than using height adjustment lever to raise the seat.

Refer to height adjustment.

RIDES TOO SOFT OR BOTTOMS OUT AND PINCHES OPERATOR The air ride control valve has under pressurized the seat air suspension ride adjustment Insufficient pressure exaggerates the knee-action movement of the seat. This usually happens because the operator is trying to lower the seat by decreasing the amount of air pressure instead of using the Height Adjustment lever. Refer to height adjustment.

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

OPERATOR’S LEGS FALLING ASLEEP The seat is adjusted too high, and the air ride control valve has under pressurized the seat air suspension ride adjustment, resulting in the operator sitting in a “bucket”. Refer to height adjustment and RIDE ADJUSTMENT.

2.57

Tigercat 215 Loader

Controls and operation

ENGINE COMPARTMENT

BATTERY DISCONNECT RELAY

12 VOLT BATTERIES

215-004

ENGINE COMPARTMENT ACCESS RIGHT SIDE - DOOR SHOWN REMOVED

ENGINE COMPARTMENT ACCESS

215-019

HINGED SCREEN PANEL

Located on the right side of the machine a large hinged door provides access to the engine compartment. Pull out the 'T' handle and rotate it 90°, swing the door open to enter the engine compartment.

1

Access to the front of the engine (cooler package) is through a hinged screen panel. The screen is held in place with a threaded handle, turn the handle (1) counterclockwise to remove it and swing the screen open to access the front of the cooler package.

ENGINE COOLER PACKAGE ACCESS 2.58

Tigercat 215 Loader

Controls and operation

BATTERY DISCONNECT RELAY

RESERVOIR MAIN PUMP

12 VOLT BATTERIES

215-004 ENGINE COMPARTMENT R.H. SIDE BATTERIES AND REMOTE DISCONNECT RELAY SWITCH

Located in the engine compartment on the right side of the machine. The relay switch is activated/ deactivated by the battery disconnect switch located in the cab on the control panel. Two batteries with 950 cold cranking amps each are connected in series provide a 24 volt electrical system.

215-008

CASE DRAIN STRAINER

HYDRAULIC OIL FILTERS

SIGHT GAUGE RESERVOIR

HYDRAULIC OIL RESERVOIR AND FILTERS HYDRAULIC OIL RESERVOIR A sight gauge on the side of the reservoir is visible from the rear access door at the rear of the machine. The hydraulic oil level must be kept between the HIGH and LOW limits at all times.

A low level switch is incorporated into the level indicator, when the hydraulic oil reaches this level the switch turns the warning alarm on the computer.

HAND FILL PUMP 215-021

HYDRAULIC HAND FILL PUMP

HYDRAULIC HAND FILL PUMP The hydraulic hand fill pump is used to add oil to the hydraulic reservoir. It is located inside the hydraulic pump compartment in the rear of the machine and is made accessible by removing the rear access panel.

ADDING OIL - Prior to adding oil to the reservoir, determine and repair the source of the oil loss.

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

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

If the oil level drops, inspect the machine including all fittings and hydraulic components for leaks.

Once the source of the oil loss is located and repaired, oil can be added to the reservoir.

2.59

Tigercat 215 Loader

Controls and operation CASE DRAIN STRAINER

HYDRAULIC OIL FILTERS

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

SIGHT GAUGE RESERVOIR 215-008

HYDRAULIC RETURN FILTERS

HYDRAULIC RETURN FILTERS The majority of return oil entering the hydraulic tank passes through 2 spin-on hydraulic oil filters (the filters are rated 10 micron abs).

Each filter head has a bypass valve with a 2 bar (25 psi) cracking pressure so that oil can bypass the filters if they become restricted.

The "in" side of the filter heads are connected to a return manifold. A filter restriction indicator and an oil sampling connector are connected to the manifold. To check the condition of the filter elements; With the hydraulic oil at normal operating temperature, place engine throttle control to FULL. Raise the boom so it is well above all obstacles. Swing machine and operate grapple open/close repeatedly. The filter restriction indicator should be in the GREEN zone.

If the pointer is in the RED zone replace both filter elements.

2.60

Tigercat 215 Loader

Controls and operation CASE DRAIN STRAINER

HYDRAULIC OIL FILTERS

SIGHT GAUGE RESERVOIR 215-008

CASE DRAIN STRAINER A case drain strainer element is located in the compartment between the hydraulic reservoir and the fuel tank. It services the main pump case drain, swing motor case drain, pilot return, and charge pressure filter bypass.

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

IMPORTANT! The strainer element is NOT a filter element.

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

2.61

Tigercat 215 Loader

Controls and operation AIR CLEANER

SAFETY ELEMENT

AIR FILTER RESTRICTION INDICATOR

PRIMARY ELEMENT

215-035

AIR CLEANER ASSEMBLY

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

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

215-036

AIR FILTER RESTRICTION INDICATOR

215-003

AIR CLEANER

UNLOADER VALVE

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

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

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

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

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

AIR FILTER RESTRICTION INDICATOR

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

FILTER RESTRICTION INDICATOR A filter restriction indicator is located on a bracket beside the air cleaner. The indicator is connected to the outlet side of the air filter with a 1/4" diameter hose. Replace the primary air filter when the indicator shows RED. This indicator provides a continuous reading whether the engine is running or is shut down. After replacing the filter, reset the indicator by pressing the reset button.

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

2.62

Tigercat 215 Loader

Controls and operation FILLER CAP

AIR CLEANER

FUEL TANK

215-070

FUEL TANK AND FILLER

FUEL CAP AND FILLER TUBE

215-018

AIR CLEANER ASSEMBLY

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

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

215-042

FUEL TANK AND FILLER The tank is located behind the cab and has a capacity of 100 US gallons. The fuel filler is located on the top of the fuel tank.

AIR VENT PASSAGE INNER FILL TUBE

248-20

TYPICAL FUEL FILL TUBE

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

2.63

Tigercat 215 Loader

Controls and operation

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

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

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

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

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

Inspect fill cap gasket.

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

Attach a grounding strap to an unpainted metal surface on the machine if the refueling tank or nozzle is so equipped.

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

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

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

2.64

Tigercat 215 Loader

Controls and operation

MACHINE OPERATION

HYDRAULIC TANK BREATHER

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

HYDRAULIC OIL FILTERS

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

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

Read and understand this entire manual prior to operating machine.

PRE-START CHECKS

CASE DRAIN STRAINER

SIGHT GAUGE

215-071

HYDRAULIC RESERVOIR

HYDRAULIC OIL RESERVOIR

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

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

1

215-010

CONNECTING HOSE TO GEARBOX

SWING DRIVE GEARBOX OIL RESERVOIR 5. Check swing drive gearbox oil level.

234-031

KEY SWITCH - OFF

1. Ensure Key (1) switch is in the STOP position.

CHECK FIRE EXTINGUISHER

ENGINE OIL LEVEL DIPSTICK

234E-029

PORTABLE FIRE EXTINGUISHER

2. Check fire extinguisher is sufficiently charged.

215-004

CHECK ENGINE OIL LEVEL

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

234E-020

3. Check gauge on side of fuel tank for fuel level.

2.65

Tigercat 215 Loader

Controls and operation

7. Check air filter restriction indicator.

RESERVOIR

CHECK ENGINE BELTS

WINDSHIELD WASHER FLUID

215-007

12. Check windshield washer fluid level.

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

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

215-004

8. Check tension and condition of all engine belts.

COOLANT LEVEL SIGHT GAUGE

215-004

RADIATOR SURGE TANK

9. Check engine coolant level.

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

215-019

HINGED SCREEN PANEL

CHARGE AIR COOLER

RADIATOR

1

A/C CONDENSER

ENGINE COOLER PACKAGE ACCESS

OIL COOLER

10. Clean cooler package and all screens and doors.

11. Ensure all doors and access panels are closed and/or securely fastened.

215-012

2.66

CLEAN A/C CONDENSER AND COOLER PACKAGE

Tigercat 215 Loader The A/C condenser core and cooler package should be manually checked every 8 hours (every shift) or more often where conditions cause accumulation of twigs, leaves, pine needles and dust. All of the engine enclosure doors should also be checked.

PROCEDURE: 1. Remove the threaded handle and swing open the screen door on the front of the engine compartment.

CAUTION • If using compressed air for cleaning, use at 2 bar (30 psi). or less.

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

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

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

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

USING THE FAN CONTROL SWITCH IN THE EVENT OF AN ENGINE COOLANT TEMPERATURE AND/OR HYDRAULIC OIL TEMPERATURE ALARM.

Controls and operation When the fan control switch is in the AUTOMATIC position, the system will automatically cycle through an auto clean cycle. The frequency and duration of the auto clean cycle is adjustable through the computer control system menu.

Refer to FAN CONTROL SWITCH in THIS SECTION for more information.

USING THE FAN CONTROL SWITCH IN THE EVENT OF AN ENGINE COOLANT temperature AND/OR HYDRAULIC OIL TEMPERATURE ALARM. In the event of an engine temperature and/or hydraulic oil temperature alarm: 1. Stop the machine.

2. Place the fan control switch in the FULL ON position until cooling is achieved.

3. If necessary use the CLEAN function to reverse fan flow and clean debris from the machine's engine enclosure 4. In severe operating conditions manual cleaning of debris may be required.

5. If the problem persists check engine coolant and/or hydraulic oil levels. Refer to MACHINE OPERATION - PRE-START CHECKS in THIS SECTION. 6. Return the fan control switch to the AUTOMATIC position and check for proper operation of the fan. In the event of a problem with the automatic control system the fan control switch should be placed in the FULL ON position while the machine is operating until the fan control can be properly repaired.

The Flexxaire® cooling fan has a CLEAN function for use in cleaning debris from the machines engine enclosure. The pitch of the fan blades is changed and the direction of airflow through the engine enclosure is reversed. This change in airflow blows debris from the machine's engine enclosure to eliminate potential overheating and poor machine performance caused by overheating. Ensure that there are no personnel standing directly to the sides of the machine when performing this operation, as dust and debris will fly out.

2.67

Tigercat 215 Loader

Controls and operation

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

2. Turn Battery Disconnect Switch ON.

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

Serious injury or property damage may result.

3. Turn ignition key to RUN position and observe display.

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

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

CAUTION 234E-022

COMPUTER DISPLAY

4. Wait for WAIT TO START warning on display to turn off 5. Sound horn to warn personnel of machine start-up.

6. Turn ignition key switch to the START position to crank the engine. When engine is started place key switch in RUN position and observe display and proceed to MACHINE PREPARATION procedure.

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

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

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

2. Ensure key is turned to OFF. 3. Refill fuel tank completely.

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

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

WARNING DO NOT USE ETHER! Engine is equipped with an electric heater starting aid. Use of ether may cause an explosion and severe injury.

215-015

COMPUTER DISPLAY

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

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

2.68

Tigercat 215 Loader MACHINE PREPARATION Prior to commencing any log loading operations follow steps (a) through (p) to accomplish the following: •

Warm up the hydraulic system.

•

Test all systems for proper operation.

•

Inspect for hydraulic oil leaks.

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

Controls and operation (l) Continue testing and operating various functions until engine and hydraulic oil has warmed up to near normal operating temperatures. Never load the machine until it has sufficiently warmed up. Doing so may cause damage to the engine and hydraulic components. (m) Lower the grapple onto the trailer or stable ground ensuring grapple and booms are fully supported. (n) Set engine speed to LOW IDLE. (o) Exit cab and visually inspect machine for leaks or other machine damage. Ensure that machine is in proper working order and is in safe condition before continuing operation.

WARNING

(a) Perform PRE-START CHECKS, STARTING THE ENGINE and SETTING THE MACHINE procedures as outlined in THIS SECTION. (b) Sound horn to warn personnel of machine operation. (c) Ensure gauges and warning lights are indicating normal operating conditions.

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.

(d) Check that all personnel are safe and clear of the machine. (e) Ensure both armrests are in the lowered position and press the PILOT RESET button. (f) Set engine speed to warm-up position (1400 rpm). (g) Ensure all stabilizers are firmly set on level, stable ground. (h) Ensure grapple and booms are not attached, chained or clamped around trailer or any other stationary object. (i) Slowly raise and lower the hoist boom and stick boom and check for proper operation. (j) With the grapple raised slightly off the ground, test the grapple rotate in both directions and test the open and close functions. (k) Operate the swing in both direction to ensure proper operation.

2.69

Tigercat 215 Loader

Controls and operation

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

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

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

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

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

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

2.70

Tigercat 215 Loader

CARE OF THE MACHINE 1. Ensure that all fluid levels are always at the proper level. Refer to the LUBRICATION AND MAINTENANCE SCHEDULE provided in SECTION 3 of THIS MANUAL. 2. Follow proper procedure for cleaning windows described in this section.

3. Lubricate all necessary points as per the maintenance schedule in section 3.

4. Never apply a load to a cold engine.

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

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

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

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

Controls and operation CARE OF POLYCARBONATE WINDOWS IN CAB Most windows used in the cab are made from a polycarbonate resin thermoplastic. This material is a replacement for glass when improved strength, durability and safety is required.

Polycarbonate material is expected to resist heavy impact from large branches and falling tree tops and to absorb high levels of energy when contacted by high velocity thrown objects such as wood chips, disc saw blade teeth or broken harvester head saw chain.

The extreme operating environment seen in logging applications heightens the need to regularly inspect and properly maintain polycarbonate cab windows.

Polycarbonate windows are an essential piece of operator protective equipment and should be maintained as such. It is important to note that cracks, chips, notches or scarring anywhere on the viewing surface or edges of the window will decrease ability to resist heavy impacts and therefore compromise effectiveness as operator safety protective equipment. Windows with these defects must be replaced immediately.

Refer to the next section for detailed information regarding inspection and maintenance of polycarbonate windows.

2.71

Tigercat 215 Loader INSPECTION AND MAINTENANCE Daily inspection and maintenance is essential to confirm that the window’s ability to protect the operator has not been compromised.

• Inspect all windows daily and immediately after any impacts.

• Check for any damage to the window material or steel structure in the area of the window mounting.

• The edges of the polycarbonate window must be evenly and fully supported on a flat surface around the entire window opening at all times.

Bent or dented skylight structures must be replaced immediately. Bent or dented cab structures must be evaluated immediately for possible repair or replacement.

• The edges of the polycarbonate window must be free from cracks, chips, notches or scarring and must not be pinched or stressed.

These defects will decrease ability to resist heavy impacts. Windows with these defects must be replaced immediately.

• Cracks, chips, notches or scarring anywhere on the viewing surface of the window will decrease ability to resist heavy impacts.

Windows with these defects must be replaced immediately.

• Bent, dented or missing window retaining parts must be replaced immediately.

• Rubber materials used in mounting the window must be maintained in good condition.

• Identification of the polycarbonate originally used by Tigercat is hot stamped in a corner of the window to identify its composition. Do not use any replacement window without proof of its material composition. Do not substitute with any other materials.

• Skylights, cab structures, windows and window retaining parts must not be modified or replaced with components that are not approved by Tigercat.

Controls and operation RESISTANCE TO CHEMICALS The resistance of polycarbonate material to chemical exposure varies widely. Fortunately, polycarbonate materials have good resistance to diesel fuel, grease, hydraulic oil, kerosene and engine oil.

Other chemicals however can seriously weaken the polycarbonate.

DO NOT permit any of the following chemicals to come into contact with polycarbonate windows: • acetone • air conditioning refrigerant • ammonia • anti-freeze • benzene • brake fluid • carbon tetrachloride • cutting oils • gasoline • lacquer thinner • toluene • turpentine • xylene RESISTANCE TO WATER Polycarbonate material has good resistance to water up to approximately 65°C (150°F). Above this temperature the effect of water is timetemperature related. This means that the higher the water temperature, the shorter the time before the polycarbonate is adversely affected.

Exposing polycarbonate to repeated steam cleanings or high temperature pressure washing may result in crazing, a phenomenon that causes clouding of the surface. Crazing can ultimately result in a loss of physical strength and may precede a fracture.

2.72

Tigercat 215 Loader

Controls and operation

CLEANING INSTRUCTIONS

CAUTIONS

The viewing surfaces of polycarbonate cab windows are specially treated with a hard coating to provide enhanced resistance to abrasion and ultra-violet (UV) radiation.

•

DO NOT use abusive cleaning procedures either by hand or pressure washing on polycarbonate windows.

•

DO NOT use brushes, razor blades, scrapers, squeegees or other sharp tools on polycarbonate windows.

•

DO NOT clean polycarbonate windows when the daytime temperature is high or in direct sunlight.

•

DO NOT use abrasive or highly alkaline cleaners on polycarbonate windows.

•

DO NOT use glass cleaners in either aerosol or non-aerosol containers to clean polycarbonate windows.

•

Failure to follow these cleaning instructions will shorten the service life of polycarbonate and may cause visual hazing, loss of light transmission and delamination of the polycarbonate hard surface coating.

The following instructions are provided to prolong the life of this protective hard coating.

1. Rinse the window thoroughly with lukewarm water 2. Using a soft cloth, cellulose sponge or chamois, gently wash the window with a mild solution of soap or detergent in lukewarm water. Do not scrub or use brushes or squeegees.

Brand name soaps and detergents recommended for cleaning polycarbonate are: • Fantastik • Formula 409 • Hexcel F.O. 554 • Joy • Lysol • Mr. Clean • Neleco-Placer • Pine-Sol • Top Job 3. Rinse the window thoroughly with lukewarm water.

4. Dry the window with a moist soft cloth, cellulose sponge or chamois to prevent water spotting.

5. To remove grease or oil, first rub lightly with a good grade of VM&P Naphtha or isopropyl alcohol followed by the same rinse, wash, rinse and dry procedure described in steps 1 to 4.

CONCEALING HAIRLINE SCRATCHES The appearance of scratches and minor abrasions on the surfaces of polycarbonate windows can be minimized by using a mild automotive polish such as: • • •

Johnson’s Paste Wax Novus Plastic Polish #1 and #2 Mirror Glaze Plastic Polish

Be certain to clean the polycarbonate window as outlined prior to application of an automotive polish. Refer to CLEANING INSTRUCTIONS.

Refer also to RESISTANCE TO CHEMICALS for a list of chemicals which should not be permitted to come into contact with polycarbonate windows.

2.73

Tigercat 215 Loader

Controls and operation

GRAFFITI REMOVAL •

•

For removal of paints, marking pen inks, etc., the use of Butyl Cellosolve is generally effective. The use of masking tape, adhesive tape or lint removal tools works well for lifting off old weathered paints.

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

Refer also to RESISTANCE TO CHEMICALS for a list of chemicals which should not be permitted to come into contact with polycarbonate windows.

FIRE PRECAUTIONS Polycarbonate window material will ignite when exposed to an ignition source in excess of 427°C (800°F). When working around polycarbonate windows, observe similar fire precautions to those in place for wood.

WINDOW SCREEN HANDKNOB

173-25

SIDE WINDOW SCREEN

SIDE WINDOW SCREENS The side window screens (if equipped) can be removed to clean the windows. Screens are provided for the personal protection of the operator and must be reinstalled immediately after cleaning the windows.

A handknob is provided on both the inside and the outside. By unscrewing either (not both) of these knobs, the screen will be free to swing out on the hinges. Be aware that the screen will swing outwards with considerable force, if the door is open.

All handles should be hand tight only at all times.

20231A R1

2.74

Tigercat 215 Loader SECTION 3 - LUBRICATION & MAINTENANCE CONTENTS - SECTION 3 A

AUGUST 2013

AIR CLEANER FILTER RESTRICTION INDICATOR.................................................................................................... 3.20 IMPORTANT STEPS TO FOLLOW...................................................................................................... 3.19 IMPROPER SERVICING...................................................................................................................... 3.19 INTAKE TUBING AND JOINTS............................................................................................................ 3.20 MAINTENANCE.................................................................................................................................... 3.19 UNLOADER VALVE.............................................................................................................................. 3.20 AIR CONDITIONING, CHECKING THE SYSTEM................................................................................... 3.21 APPROVED HYDRAULIC OILS.............................................................................................................. 3.11 C

CASE DRAIN STRAINER........................................................................................................................ 3.15 COMMERCIAL WOOD, WEIGHTS OF.................................................................................................... 3.31 CONVERSION CHART, UNITS................................................................................................................ 3.30 E

EMERGENCY EXITS, CHECK MONTHLY................................................................................................ 3.6 F

FILTER RESTRICTION INDICATOR........................................................................................................ 3.20 FILTERS ENGINE FILTERS................................................................................................................................. 3.16 ENGINE FILTERS - REMOVE AND REPLACE.................................................................................... 3.16 HYDRAULIC OIL RETURN FILTERS................................................................................................... 3.14 HYDRAULIC OIL RETURN STRAINERS............................................................................................. 3.15 FIRE PREVENTION................................................................................................................................... 3.6 FIRST 125 HOUR INSPECTION AND SERVICE...................................................................................... 3.3 FUEL FILTER AND FUEL FILTER/WATER SEPERATOR....................................................................... 3.18 H

HYDRAULIC OIL RETURN FILTERS....................................................................................................... 3.14 L

LUBRICATION POINTS DIAGRAM......................................................................................................... 3.13 LUBRICATION SCHEDULE..................................................................................................................... 3.12 M

MAIN VALVE ORIENTATION.................................................................................................................. 3.28 N

NEW MACHINE MAINTENANCE.............................................................................................................. 3.3 FIRST 125 HOUR INSPECTION REPORT............................................................................................ 3.3 INITIAL PRE-DELIVERY INSPECTION.................................................................................................. 3.3 TIGHTENING POINTS........................................................................................................................... 3.3 O

OIL FILTERS............................................................................................................................................3.16 OIL SAMPLE COLLECTION PROCEDURES............................................................................................ 3.5 OIL SAMPLING PROGRAM............................................................................................................... 3.4, 3.5 FIRST SAMPLE...................................................................................................................................... 3.4 FOLLOW-UP SAMPLES......................................................................................................................... 3.4 OIL SAMPLE COLLECTION PROCEDURES........................................................................................ 3.5 GEARBOX SAMPLES........................................................................................................................ 3.5 HYDRAULIC OIL SAMPLES............................................................................................................... 3.5 TIGERCAT OIL ANALYSIS KITS............................................................................................................ 3.4 P

PRE-DELIVERY INSPECTION.................................................................................................................. 3.3 PRESSURE SETTINGS........................................................................................................................... 3.27 PREVENTIVE MAINTENANCE SCHEDULE............................................................................................. 3.3

Tigercat 215 Loader

Lubrication and Maintenance

S

SCHEDULED MAINTENANCE EVERY 8 HOURS:.................................................................................................................................. 3.7 EVERY 24 HOURS................................................................................................................................. 3.8 EVERY 125 HOURS:.............................................................................................................................. 3.8 EVERY 250 HOURS:.............................................................................................................................. 3.8 EVERY 500 HOURS:.............................................................................................................................. 3.8 EVERY 1000 HOURS............................................................................................................................. 3.9 EVERY 2000 HOURS............................................................................................................................. 3.9 T

TORQUE CHART..................................................................................................................................... 3.26 TORQUE CHART, GENERAL.................................................................................................................. 3.29 TORQUE, FLUID CONNECTIONS...................................................................................... 3.23, 3.24, 3.25 U

UNIT CONVERSION CHART................................................................................................................... 3.30 W

WEIGHTS OF COMMERCIAL WOOD..................................................................................................... 3.31 WIRE COLOUR CODE CHART............................................................................................................... 3.30 WOOD, WEIGHTS OF COMMERCIAL WOOD....................................................................................... 3.31

3.2

Tigercat 215 Loader

Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE NEW MACHINE MAINTENANCE

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

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

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

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

All hydraulic connections Hose clamps Pin retainers

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

Check torque on swing bearing retaining bolts Engine mounting bolts Pump mounting bolts Pilot pump mounting bolts Swing gearbox mounting bolts Swing motor mounting bolts Cab securing bolts Boom pin nuts Any other loose nut, bolt or fitting

*OIL LOST FROM LEAKAGE

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

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

3.3

Tigercat 215 Loader

Lubrication and Maintenance

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

200 Series

Location

First Sample

Follow-up Samples

Hydraulic Oil

125 hrs

Every 1000 Hours 6 Months

Swing Drive Gearbox

125 hrs

Every Oil Change (500 Hours or 3 Months)

Track Drive Gearboxes (If applicable)

125 hrs

Every 1000 Hours or 6 Months

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

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

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

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

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

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

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

Contact your Tigercat Dealer Parts Department to order Kits.

3.4

Tigercat 215 Loader

Lubrication and Maintenance

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

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

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

•

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

•

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

•

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

•

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

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

•

Purge the sample valve before taking a representative oil sample. Drain a minimum of 90 to 120 ml (3 to 4 ounces) of oil into a separate container and discard this oil using approved recycling methods.

•

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

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

•

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

•

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

•

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

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

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

3.5

Tigercat 215 Loader

Lubrication and Maintenance

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

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

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

Clean around filler caps before checking or adding fluids.

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

Clean up spills as soon as possible.

Always use clean oil and containers.

Drain dirty oil while still warm.

Do not exceed recommended fluid levels.

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

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

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

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

Clean up oil spills in engine enclosure immediately.

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

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

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

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

Clean away all branches, bark and chips.

Clean up all traces of oil to avoid fires.

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

Should any exhaust leaks or defective parts be found, repairs must be made immediately.

Engine exhaust leaks can cause fires, DO NOT OPERATE the machine until the exhaust leak is repaired.

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

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

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

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

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

Always have a fire extinguisher at hand.

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

3.6

Tigercat 215 Loader

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 8 HOURS:

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

• • • •

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

• Check air cleaner unloader valve.

• Check air intake filter restriction indicator.

Replace primary filter if indicator is in red zone.

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

• Check hydraulic oil level

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

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

• Exhaust system for leaks.

• Conduct an overall visual inspection.

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

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

2. Fully extend stick boom cylinder.

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

WARNING

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

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

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

• Yoke pins; 2-fittings - purge • Grapple rotate pinion; 1-fitting - 4 shots, rotate 90° after each shot • Grapple arm pins; 6-fittings - purge • Grapple cylinder pins; 4-fittings - purge 3.7

•

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

•

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

•

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

Tigercat 215 Loader

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 24 HOURS:

EVERY 250 HOURS:

• Perform 8 hour maintenance And in addition: • Lubricate grapple rotate bearing; 1-fitting - 4 shots, rotate 90° after each shot

• Perform 8 hour maintenance • Perform 24 hour maintenance • Perform 125 hour maintenance And in addition: • Replace engine fuel filter • Replace fuel/water separator filter

EVERY 125 HOURS:

• Check fire extinguisher and turn it to mix contents

• Perform 8 hour maintenance • Perform 24 hour maintenance

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

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

EVERY 500 HOURS:

• Engine rpm

• Perform 8 hour maintenance

• All hydraulic pressures

• Perform 24 hour maintenance

• Hydraulic pumps and motor securing bolts

• Perform 125 hour maintenance

• Torque tightening points as per new machine maintenance

• Perform 250 hour maintenance And in addition: • Replace oil in swing gearbox. Fill reservoir to half way mark

Visually check for damage to: • Main and stick booms and cylinders • Swing bearing area

• Replace hydraulic oil return filters †

• Attachment

• Replace swing pump charge pressure filter †

Make repairs immediately

• Replace hydraulic oil pilot pressure filter †

Visually inspect for: • Frayed electrical wiring and hydraulic hoses

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

• Wear in any other components

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

Clean/replace: • Air conditioner re-circulation filter

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

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

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

3.8

Tigercat 215 Loader

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 1000 HOURS:

EVERY 2000 HOURS:

• Perform 8 hour maintenance

• Perform 8 hour maintenance

• Perform 24 hour maintenance

• Perform 24 hour maintenance

• Perform 125 hour maintenance

• Perform 125 hour maintenance

• Perform 250 hour maintenance

• Perform 250 hour maintenance

• Perform 500 hour maintenance

• Perform 500 hour maintenance

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

• Replace air cleaner unloader valve.

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

See AIR INTAKE MAINTENANCE in THIS SECTION. • Refer to diesel engine service manual and attachment manual for additional required maintenance at this scheduled time period.

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

3.9

Tigercat 215 Loader

Lubrication and Maintenance

LUBRICATION POINTS DIAGRAM

3.10

Tigercat 215 Loader

Lubrication and Maintenance Tigercat 215 Loader SERVICE AND LUBRICATION POINTS

REFER TO Tigercat OPERATOR’S MANUAL FOR ADDITIONAL INFORMATION ®

2

ENGINE OIL AND FILTER

3

FUEL FILTER (ENGINE)

4

FUEL/WATER SEPARATOR

5

INTANK FUEL STRAINER

CHK CHK

•

DRN

24

7

60/40 ANTIFREEZE/DISTILLED WATER **

•

•

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

DESCRIPTION QTY

2000

1000

500

CHANGE COOLANT EVERY 2 YEARS

US GAL

COOLING SYSTEM

CAPACITY LITER

1

250

8

ITEM

125

SERVICE POINT NO.

SERVICE EVERY

REP

1

REP

1 CHK

1

AIR CLEANER PRIMARY ELEMENT

CHK

1

AIR CLEANER SAFETY ELEMENT

CHK

1

7

AIR CLEANER UNLOADER VALVE

CHK

8

AIR INTAKE CONNECTIONS

CHK

REP

9

HYDRAULIC TANK

CHK

D/R 197

10

RETURN FILTERS † . 2 STANDARD FILTERS

11

SWING GEARBOX

6

12

REP

CHK

REP

CHK

14

DOOR HINGES

REFER TO OPERATOR'S MANUAL SECTION 2 FOR DETAILS

1

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

52

2

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

SEE LUBRICATION POINTS DIAGRAM SEE MANUFACTURER'S MAINTENANCE SCHEDULE

GRAPPLE, OTHER MANUFACTURERS FIRE EXTINGUISHER

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

1

D/R

GRAPPLE, Tigercat

13

DRAIN TANK, CLEAN OR REPLACE AS NECESSARY

CHK LUB

LUBRICATION SCHEDULE

3.11

1

TURN TO MIX CONTENTS

6

LITHIUM BASE EP2 GREASE

Tigercat 215 Loader

Lubrication and Maintenance

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

HYDRAULIC OIL TEMPERATURE OPERATING RANGE

3.12

Tigercat 215 Loader HYDRAULIC TANK BREATHER

Lubrication and Maintenance CASE DRAIN STRAINER

OPTIONAL TIE-OFF HANDLE (LOCATION NOT SHOWN)

HYDRAULIC OIL FILTERS

SIGHT GAUGE

215-071

TIE-OFF HANDLE

HYDRAULIC RESERVOIR

HYDRAULIC OIL RESERVOIR

HYDRAULIC OIL RETURN FILTERS The majority of return oil entering the hydraulic tank passes through two spin-on hydraulic oil filters (the filters are rated 10 micron abs).

Each filter head has a bypass valve with a 1.72 bar (25 psi) cracking pressure so that oil can bypass the filters if they become restricted. The "in" side of the filter heads are connected to a return manifold. A filter restriction indicator and an oil sampling connector are connected to the manifold.

To check the condition of the filter elements with the hydraulic oil at normal operating temperature, place engine throttle control to FULL. Raise the boom so it is well above all obstacles.

Swing machine and operate grapple open/close repeatedly. The filter restriction indicator should be in the GREEN zone. If the pointer is in the RED zone replace both filter elements.

Changing the filters: 1. Position the machine into Service Access Position 1. Refer to FALL PROTECTION - SERVICE ACCESS POSITION 1 in SECTION 1 of THIS MANUAL.

215-060

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

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

4. Wearing face protection, unscrew the old filter.

Dispose of old filter and any oil properly.

5. The Tigercat spin-on filter element is supplied with two gaskets. The round ('O' ring style) section gasket is used for all return filters.

Discard the square section gasket.

Remove used gasket and clean gasket seat in head.

FILTER HEAD

Attach your personal safety restraint to the tie-off handle located on the inside wall of the fuel tank.

GASKET

NOTE: Some machines may have a tie-off handle located at the top of the return filter bracket.

The filter can be accessed from the rear of the loader.

FILTER ELEMENT FILTR_SEALS

'O' RING GASKET INSTALLATION

Apply clean oil to new gasket surfaces.

Install new gasket on inside lip of filter.

DO NOT pre-fill filter. Screw on new filter until gasket makes contact with filter head.

Tighten filter until top edge makes metal to metal contact with filter head. (Approximately 1 1/2 additional turns after gasket contact) 3.13

Tigercat 215 Loader

Lubrication and Maintenance

CASE DRAIN STRAINER

Changing the strainer:

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

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

1. Position the machine into Service Access Position 1. Refer to FALL PROTECTION - SERVICE ACCESS POSITION 1 in SECTION 1 of THIS MANUAL.

OPTIONAL TIE-OFF HANDLE (LOCATION NOT SHOWN)

IMPORTANT! The strainer element is NOT a filter element.

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

TIE-OFF HANDLE

CASE DRAIN STRAINER

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.

HYDRAULIC RESEVOIR

FUEL TANK

215-060

Attach your personal safety restraint to the tie-off handle located on the inside wall of the fuel tank.

NOTE: Some machines may have a tie-off handle located at the top of the return filter bracket.

The strainer can be accessed from the rear of the loader.

3.14

Tigercat 215 Loader 2. Wipe clean the area around the filter and head.

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

4. Wearing face protection, unscrew the old filter. Discard the filter and oil using approved recycling methods.

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

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

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

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

Lubrication and Maintenance ENGINE FILTERS - REMOVE AND REPLACE IMPORTANT! Failure to service and replace filters at the proper intervals specified in the manufacturer's manuals, could cause damage to the machine and result in the product warranty becoming NULL and VOID. Check Tigercat parts catalogue for replacement filters.

Refer to the appropriate engine manufacturer's operation and maintenance manual for correct procedures and time intervals when servicing the engine oil and fuel filters. Read and understand the SAFETY section in each of these manuals.

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

9. Start the engine and check for leaks.

HYDRAULIC FILTER SERVICING GUIDELINES IMPORTANT! NEVER PRE-FILL HYDRAULIC FILTERS

Tigercat does not recommend the pre-filling of spin-on filters due to the risk of damage to the hydraulic system caused by unfiltered oil. Unfiltered oil used to pre-fill filters enters directly into the hydraulic circuit. Contaminants in unfiltered oil can cause significant and costly damage to hydraulic valves, pumps and motors. The cleanliness of hydraulic oil cannot be guaranteed unless it is always pre-filtered before use.

ENGINE OIL FILTER

215-065

ENGINE OIL FILTER

To replace the engine oil filter, position the machine in Service Access Position 3. Refer to FALL PROTECTION - SERVICE ACCESS POSITION 3 in SECTION 1 of THIS MANUAL.

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.

TIE-OFF HANDLE

215-068

Attach your personal safety restraint to the tie-off handle located above the cooler.

3.15

Tigercat 215 Loader

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

FUEL FILTER

ENGINE OIL DRAIN PLUG 215-067

To access the engine oil drain plug and replace the engine oil, position the machine in Service Access Position 2. Refer to FALL PROTECTION SERVICE ACCESS POSITION 2 in SECTION 1 of THIS MANUAL.

TIE-OFF HANDLE

215-062

ENGINE FUEL FILTER

To service or replace the fuel filter, position the machine in Service Access Position 3. Refer to FALL PROTECTION - SERVICE ACCESS POSITION 3 in SECTION 1 of THIS MANUAL.

TIE-OFF HANDLE 215-059

Attach your personal safety restraint to the tie-off handle on the top plate above the engine.

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

If the fuel supply is dirty, the fuel filter must be replaced more frequently than recommended in the owner’s manual. Operating the machine with a clogged fuel filter will result in low engine power. It is also recommended that the fuel/water separator bowl be drained daily.

When installing a new fuel filter, DO NOT pre-fill with diesel fuel, or engine fuel pump damage will result. This type of failure is not warrantable by the engine manufacturer.

215-068

Attach your personal safety restraint to the tie-off handle located above the cooler.

3.16

Tigercat 215 Loader

Lubrication and Maintenance

FUEL FILTER/WATER SEPARATOR The fuel filter/water separator is a combination unit, with a replaceable fuel filter and a removable water sediment bowl on the bottom of the unit.

The water sediment bowl is only replaced if it becomes damaged or non-functional. For service and replacement intervals see SERVICE AND LUBRICATION CHART in THIS SECTION.

WATER SEPERATOR BOWL BOWL DRAIN

215-063

OPTIONAL TIE-OFF HANDLE (LOCATION NOT SHOWN) TIE-OFF HANDLE

215-060

Attach your personal safety restraint to the tie-off handle located on the inside wall of the fuel tank.

NOTE: Some machines may have a tie-off handle located at the top of the return filter bracket.

FUEL/WATER SEPARATOR

To replace the fuel/water seperator position the machine in Service Access Position 1. Refer to FALL PROTECTION - SERVICE ACCESS POSITION 1 in SECTION 1 of THIS MANUAL.

3.17

Tigercat 215 Loader

Lubrication and Maintenance

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

2. Release the seal gently to reduce the amount of dust dislodged.

AIR CLEANER MAINTENANCE

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

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

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

OVER SERVICING

5. Always clean the inside of the outlet tube.

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

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

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

7. Inspect the new filter for damage.

8. Insert the new filter properly. Apply pressure to the outer rim of the filter, not the flexible centre.

9. Check connection and ducts for air tight fit.

Ensure that all clamps, bolts and connections are tight. Leaks here send dust directly to the engine.

SAFETY ELEMENT

IMPORTANT STEPS TO FOLLOW 1. Position machine into Service Access Position 3. Refer to FALL PROTECTION SERVICE ACCESS POSITION 3 in SECTION 1 of THIS MANUAL.

AIR CLEANER

TIE-OFF HANDLE

PRIMARY ELEMENT

215-003

AIR CLEANER

UNLOADER VALVE

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

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

215-068

Attach your personal safety restraint to the tie-off handle located above the cooler.

The air cleaner can be accessed from the service platform.

3.18

Tigercat 215 Loader

Lubrication and Maintenance TUBING AND JOINTS

AIR CLEANER AIR FILTER RESTRICTION INDICATOR

UNLOADER VALVE 215-069

AIR CLEANER

AIR CLEANER UNLOADER VALVE 215-035

AIR CLEANER

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

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

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

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

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

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

The valve should suck closed at engine warm-up speed When operating in high dust conditions this valve should be checked and squeezed every two hours to release dust accumulation.

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

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

3.19

Tigercat 215 Loader

Lubrication and Maintenance

CHECKING THE AIR CONDITIONING SYSTEM

RECEIVER DRYER

Any service work must be performed by authorized A/C technicians. The system should be charged with R134a refrigerant (see table below for capacity). At least 74 ml (2.5 oz) of PAG (polyalkylene glycol) oil should be present in the system and must be used on O-rings and fittings during assembly.

A/C SYSTEM TOTAL CAPACITIES R134a REFRIGERANT

PAG OIL (polyalkylene glycol)

1.47 kg (3.25 lb)

74 ml (2.5 oz)

The compressor is located on the right side of the engine. The charge valves are on the compressor hoses.

215-044

HYDRAULIC PUMP COMPARTMENT

The receiver dryer is located in the hydraulic pump compartment behind the engine compartment.

Access to the receiver dryer is through the door on the rear of the machine below the hydraulic tank.

A/C COMPRESSOR OPTIONAL TIE-OFF HANDLE (NOT SHOWN) TIE-OFF HANDLE

215-043

A/C COMPRESSOR

To service the compressor and valves, position the machine in Service Access Position 2. Refer to FALL PROTECTION - SERVICE ACCESS POSITION 2 in SECTION 1 of THIS MANUAL.

TIE OFF HANDLE 215-060

To service the receiver dryer, position the machine in Service Access Position 1. Refer to FALL PROTECTION - SERVICE ACCESS POSITION 1 in SECTION 1 of THIS MANUAL. Attach your personal safety restraint to the tie-off handle located on the inside wall of the fuel tank.

NOTE: Some machines may have a tie-off handle located at the top of the return filter bracket.

215-059

Attach your personal safety restraint to the tie-off handle on the top plate above the engine.

3.20

Tigercat 215 Loader

Lubrication and Maintenance

To service the condenser core, position the machine in Service Access Position 3. Refer to FALL PROTECTION - SERVICE ACCESS POSITION 3 in SECTION 1 of THIS MANUAL.

CHARGE AIR COOLER

RADIATOR

A/C CONDENSER

TIE-OFF HANDLE OIL COOLER

215-068

Attach your personal safety restraint to the tie-off handle located above the cooler.

CAUTION If using pressurized water or compressed air for cleaning, use at 2 bar (30 psi) or less.

Always use personal protective equipment (safety glasses) to guard against flying debris.

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

215-012

CLEAN A/C CONDENSER AND COOLER PACKAGE

The condenser core is accessed from inside the front cooler access door.

Perform the following inspection along with 125 HOURS inspection outlined in SCHEDULED MAINTENANCE in THIS SECTION. a. Check and adjust compressor drive belt tension. Do not over tighten. b. Check fresh air filter and re-circulating air filter.

Clean or replace as required. c. Check to see that compressor clutch will engage. d. Check blower operation and air vents. e. Check the condenser core for dirt and debris.

3.21

Tigercat 215 Loader

Lubrication and Maintenance

Parker

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

Flange Port Assembly

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

• Four bolts and washer

WASHERS BOLTS FLANGE CLAMP

FLANGE HEAD

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

2. Lubricate the O-ring.

3. Position flange and clamp halves.

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

5. Hand tighten bolts.

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

O-RING TAPPED HOLES

FLANGE.JPG

Fig. T8 - 4 Bolt Split Flange Components

FLANGE2.JPG

Fig. T9 - Flange Bolt Tightening Sequence

Dash Size

Flange Size

Inch Bolt (J518)

Torque lbf-ft

Metric Bolt (ISO 6162)

Torque N-m

Dash Size

Flange Size

Inch Bolt (J518)

Torque lbf-ft

Metric Bolt (ISO 6162)

Torque N-m

8 12 16 20 24 32 40 48 56 64 80

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

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

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

M8 M10 M10 M12 M12 M12 M12 M16 M16 M16 M16

25 49 49 85 85 135 95 220 220 220 220

8 12 16 20 24 32

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

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

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

M8 M10 M12 M14 M16 M20

25 49 85 135 210 425

* Does not meet ISO 6162 specification.

Table T7 - Code 62 Flange Recommended Bolt Torque

3.22

Tigercat 215 Loader

Lubrication and Maintenance

Parker

Assembly Torque

JIC 37 Degree Flare SAE Dash Size

Thread Size

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

NPTF

Tube Connection Swivel or Hose Connection FFWR FFWR

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

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

SAE Dash Size

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

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

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

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

Thread Size

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

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

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

BSPT

Tube Connection Swivel or Hose Connection FFWR FFWR

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

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

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

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

Tube Connection Swivel or Hose Connection TFFT TFFT

Thread Size

SAE Dash Size

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

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

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

Thread Size

Tube Connection Swivel or Hose Connection TFFT TFFT

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

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

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

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

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

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

THREAD SIZE

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

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

N •m 20 20 20 40 46 80 135 185 235 270 340 415 510

TRIPLE-LOK FERULOK PIPE FITTINGS lbf•ft N •m (lbf•in) (85) 10 (155) 18 (260) 29 (280) 32 (350) 40 (620) 70 85 115 135 183 175 237 200 271 250 339 305 414 375 509

PLUGS

ADJUSTABLE

NON-ADJUSTABLE

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

N •m 20 20 20 40 46 80 135 185 235 270 340 415 510

3.23

TRIPLE-LOK FERULOK PIPE FITTINGS lbf•ft N •m (lbf•in) (60) 7 (100) 11 (180) 20 (250) 28 (350) 40 (620) 70 85 115 135 183 175 237 200 271 250 339 305 414 375 509

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

N •m 3.5 6 13.5 19 46 80 135 185 235 270 340 415 510

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

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

Tigercat 215 Loader

Lubrication and Maintenance

EATON Aeroquip

Assembly Torque

Recommended Parallel Connection Assembly torque

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

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

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

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

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

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

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

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

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

ORS

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

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

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

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

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

Swivel Nut Torque lb.-ft.

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

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

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

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

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

Swivel Nut Torque lb.-ft.

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

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

BSPP Straight Adapter or Locknut Torque lb.-ft.

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

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

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

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

3.24

Tigercat 215 Loader

Lubrication and Maintenance

TORQUE CHART LOCATION

THREAD DIAMETER

Cylinders Hoist, Piston nut Hoist, Gland bolts Stick, Piston nut Stick, Gland bolts

M60 M14-2 (10.9) M60 M14-2 (10.9)

2480 111 2480 111

3362 150.5 3362 150.5

M20 - 2.5

275

375

Hoist and Stick boom pin retaining nut

2"-12 UNF (GC)

400

540

Cab securing bolts

M22 - 2.5 (10.9)

400-450

540-610

Swing bearing bolts Swing gearbox mounting bolts

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

7/8"-9 UNC (G8) M16

400-450 160

540-610 225

M22 - 2.5 (10.9) M12-1.75 (10.9) M16 - 2 M10 (12.9)

400-450 40 160 218 40

540-610 54 225 296 54

Pump drive Drive plate to flywheel Bell housing to engine

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

33-36 47

45-49 63

Pump mounting Main Pump to Engine

3/4"-10 UNC (G8)

280

380

Boom joint and cylinder pin retaining bolts

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

3.25

TORQUE (LUBRICATED) lbf·ft N·m

Tigercat 215 Loader

Lubrication and Maintenance

PRESSURE SETTINGS Engine rpm ........................................................................2200 rpm @ Full throttle (no load) ........................................................................1050 rpm @ Idle (no load) Main Valve High Pressure Limiting Control Margin Pressure (‘PX’ - ‘PL’)........................................... 26 bar (375) psi @ Idle Main Pump P.O.R. (‘PX’)............................................. 288 bar (4175) psi @ Full throttle Main Valve Port reliefs Hoist DOWN...............................................................................**Mode 3 Hoist UP.....................................................................................**Mode 3 Stick IN.......................................................................................**Mode 3 Stick OUT...................................................................................**Mode 3 Feed Reducer Grapple OPEN.................................... 172 bar (2500) psi Feed Reducer Grapple CLOSE.................................. 172 bar (2500) psi Feed Reducer Grapple Rotate CCW (See Note 5)..... 121 bar (1750) psi Feed Reducer Grapple Rotate CW (See Note 5 )....... 121 bar (1750) psi * Gauge on 'PL' port ** See Machine Mode Adjustment in section 2 of this manual for details.

6.5 Seconds @ Full throttle 7 Seconds @ Full throttle 5.5 Seconds @ Full throttle 6 Seconds @ Full throttle

NOTES: 1. SYSTEM TO BE AT OPERATING TEMPERATURE WHEN SETTING PRESSURES. 2. ALL PRESSURES MEASURED IN bar (psi). ALL SPEEDS MEASURED IN SECONDS. 3. F - DENOTES PRESSURES SET AT FULL ENGINE rpm.

I - DENOTES PRESSURES SET AT ENGINE IDLE. 4. PORT RELIEFS CANNOT BE ADJUSTED. EACH PORT RELIEF HAS A SPECIFIC SETTING AND SHOULD NOT BE INTERCHANGED WITH OTHER PORT RELIEFS. 5. FOR ROTOBEC HD (HEAVY DUTY) AND HULTDINS GRAPPLES SET ROTATE TO 207 bar (3000 psi).

3.26

Tigercat 215 Loader

Lubrication and Maintenance

MAIN VALVE ORIENTATION

215-045

MAIN VALVE 3.27

Tigercat 215 Loader

Lubrication and Maintenance

GENERAL TORQUE SPECIFICATIONS

The torque values listed below are for general use only.

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

IMPERIAL

GRADE 5 BOLTS

GRADE 8 BOLTS

IMPERIAL BOLT TORQUE SPECIFICATIONS GRADE 5 BOLTS GRADE 8 BOLTS LUBRICATED lbf-ft Nm 8 - 10 11 - 13 20 - 28 27 - 38 33 - 36 45 - 49 52 - 57 71 - 77 80 - 88 109 - 119 115 - 127 156 - 172 159 - 175 216 - 237 282 - 310 393 - 420 455 - 501 617 - 679 682 - 750 925 - 1016 966 - 1062 1310 - 1441 1360 - 1496 1844 - 2027 LUBRICATED lbf-ft Nm 10 - 13 14 - 17 18 - 25 25 - 33 37 - 41 50 - 55 58 - 64 79 - 86 90 - 99 122 - 134 128 - 141 174 - 191 180 - 198 244 - 268 315 - 347 427 - 470 501 - 550 679 - 745 746 - 821 1012 - 1113 1083 - 1191 1469 - 1613 1509 - 1660 2046 - 2250 4.8

METRIC

DRY LUBRICATED COARSE lbf-ft Nm lbf-ft Nm THREAD 1/4" - 20 7- 8 10 - 11 8 - 10 11 - 13 5/16" - 18 14 - 18 19 - 24 10 - 15 13 - 20 3/8" - 16 31 - 34 42 - 46 23 - 25 31 - 34 7/16" - 14 49 - 54 66 - 73 37 - 41 50 - 55 1/2" - 13 75 - 83 102 - 112 57 - 63 77 - 85 9/16" - 12 109 - 120 148 - 162 82 - 90 111 - 122 5/8" - 11 150 - 165 204 - 223 113 - 124 152 - 168 3/4" - 10 266 - 293 360 - 397 200 - 220 271 - 298 7/8" - 9 394 - 433 535 - 586 296 - 326 402 - 441 1" - 8 591 - 649 802 - 879 443 - 489 601 - 663 1 1/8" - 7 794 - 873 1077 - 1183 596 - 656 808 - 889 1 1/4" - 7 1120 - 1232 1519 - 1670 840 - 924 1139 - 1252 FINE DRY LUBRICATED lbf-ft Nm lbf-ft Nm THREAD 1/4" - 28 9 - 10 12 - 13 9 - 10 12 - 13 5/16" - 24 17 - 22 23 - 29 16 - 20 21 - 27 3/8" - 24 35 - 39 48 - 53 26 - 29 35 - 39 7/16" - 20 55 - 61 75 - 83 41 - 45 56 - 61 1/2" - 20 85 - 94 116 - 127 64 - 70 87 - 95 9/16" - 18 121 - 133 164 - 180 91 - 100 124 - 135 5/8" - 18 170 - 187 231 - 253 128 - 141 174 - 191 3/4" - 16 297 - 327 403 - 443 223 - 245 303 - 332 7/8" - 14 434 - 477 589 - 646 326 - 359 442 - 486 1" - 12 646 - 711 876 - 965 484 - 534 657 - 724 1 1/8" - 12 891 - 980 1208 - 1328 668 - 735 906 - 996 1 1/4" - 12 1240 - 1364 1682 - 1849 931 - 1024 1262 - 1387

8.8

9.8

10.9

4.8

8.8

9.8

10.9

12.9

4.8

8.8

9.8

10.9

12.9

10

5 5

SIZE

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

10

10

5

12.9

10

12.9

12

10

12

METRIC BOLT TORQUE SPECIFICATIONS

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

12.9

12

DRY lbf-ft Nm 11 - 12 15 - 16 26 - 30 35 - 40 44 -48 60 - 65 70 - 77 95 - 104 106 - 117 144 - 158 153 - 168 208 - 228 212 - 233 288 - 316 376 - 414 510 - 561 606 - 667 822 - 904 909 - 1000 1233 - 1355 1288 - 1417 1746 - 1921 1817 - 1999 2464 - 2710 DRY lbf-ft Nm 13 - 14 18 - 19 23 - 28 31 - 38 49 - 54 67 - 73 78 - 86 106 - 116 120 - 132 163 - 179 171 - 188 232 - 255 240 - 264 326 - 358 420 - 462 570 - 626 668 - 735 906 - 996 995 - 1096 1359 - 1486 1445 - 1590 1960 - 2155 2012 - 2213 2728 - 2997

10

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

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

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

M6 M8 M10

4.8 12.0 23.0

3.5 8.5 17.0

6.0 15.0 29.0

4.5 11.0 21.0

9.0 22.0 43.0

6.5 16.0 32.0

11.0 28.0 55.0

8.5 20.0 40.0

13.0 32.0 63.0

9.5 24.0 47.0

17.0 40.0 80.0

12.0 30.0 60.0

15.0 37.0 75.0

11.5 28.0 55.0

19.0 47.0 95.0

14.5 35.0 70.0

M12 M14 M16

40.0 63.0 100.0

29.0 47.0 73.0

50.0 80.0 125.0

37.0 60.0 92.0

75.0 120.0 190.0

55.0 88.0 140.0

95.0 150.0 240.0

70.0 110.0 175.0

110.0 175.0 275.0

80.0 130.0 200.0

140.0 225.0 350.0

105.0 165.0 225.0

130.0 205.0 320.0

95.0 150.0 240.0

165.0 260.0 400.0

120.0 190.0 300.0

M18 M20 M22

135.0 190.0 260.0

100.0 140.0 190.0

175.0 240.0 330.0

125.0 180.0 250.0

260.0 375.0 510.0

195.0 275.0 375.0

330.0 475.0 650.0

250.0 350.0 475.0

375.0 530.0 725.0

275.0 400.0 540.0

475.0 675.0 925.0

350.0 500.0 675.0

440.0 625.0 850.0

325.0 560.0 460.0 800.0 625.0 1,075.0

410.0 580.0 800.0

M24 M27 M30

330.0 490.0 675.0

250.0 360.0 490.0

425.0 625.0 850.0

310.0 650.0 450.0 950.0 625.0 1,300.0

M33 900.0 M36 1,150.0

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

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

3.28

Tigercat 215 Loader

Lubrication and Maintenance

Tigercat wire colour code chart applicable to all products manufactured by Tigercat Industries Inc. COLOUR Red Black White Blue Purple

Tan

FUNCTION EXAMPLE Power........................................ (fused and unfused) Ground Engine control........................... (fuel shut-off, start aid) Propulsion Control..................... (transmission/reverser solenoids) Monitor, electrical and mechanical systems.................. (air cleaner, alternator, wheel speed, engine speed) Electrical and electromechanical control.......... (park brake, alternator excitation)

(power door motor, backup alarm) Yellow Monitors..................................... (flow, pressure, temperature, level) Grey Standard monitor system.......... (logic module to monitor) Brown Lights Green Electro-hydraulic control............ (pilot solenoids) Orange Accessories............................... (horn, A/C, heater) COMMON CONVERSIONS To Convert

Into

Multiply By

bar .................................. psi ....................... 14.5 cm3 .................................. in3 ........................ 0.06102 °C ...................................°F ......................... (°C x 9/5) + 32 kg .................................... lb ......................... 2.205 kW .................................. hp........................ 1.341 L ...................................... US gal ................. 0.2642 mm .................................. in ......................... 0.03937 N • m ................................ lbf • ft .................... 0.7375 N ..................................... lbf ........................ 0.22481

To Convert

.Into

.Multiply By

in3 .................................... cm3 ..................... 16.39 °F .................................... °C ....................... (°F - 32) / 1.8 US gal ............................. L .......................... 3.785 hp ................................... kW ...................... 0.7457 in ..................................... mm ..................... 25.4 lb ..................................... kg ........................ 0.4535 lbf • ft ................................ N • m .................... 1.356 psi ................................... bar ...................... 0.06896 in Hg ............................... psi ....................... 0.4912 in H2O ............................. psi ....................... 0.03613 lb ..................................... N ......................... 4.4482

3.29

Tigercat 215 Loader

Lubrication and Maintenance

Weights of Commercial Wood

Species

kg/m3

lb/ft3

Species

kg/m3

lb/ft3

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

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

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

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

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

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

Note: The values shown here are green weights.

3.30