Tigercat 2160 LOADER FORWARDER OPERATOR'S MANUAL SN 21600101–21600500 - PDF DOWNLOAD

2160 LOADER FORWARDER

OPERATOR'S MANUAL

SERIAL NUMBER 21600101 – 21600500

ISSUE 1.5, NOVEMBER 2017 Tigercat Industries Inc. P.O. Box 637 Brantford, Ontario Canada N3T 5P9 Tel: (519) 753-2000 Fax: (519) 753-8272

ii

Tigercat 2160 Loader Forwarder TABLE OF CONTENTS INTRODUCTION................................................................................................................................................. v MACHINE IDENTIFICATION AND SERIAL NUMBERS..................................................................................... vi STANDARDS FOR MACHINE OPERATOR PROTECTIVE STRUCTURES.....................................................vii NON-APPROVED FIELD PRODUCT CHANGES.............................................................................................viii REGULATORY INFORMATION.......................................................................................................................... ix WARRANTY – EPA............................................................................................................................................... x 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.

2160 AVAILABLE LITERATURE Operator's Manual (this manual).....................................................................................................Part No. 51953AENG Service Manual................................................................................................................................Part No. 51954AENG Parts Catalog...................................................................................................................................Part No. 51955A Vehicle Moving and Transporting Instructions.................................................................................Part No. 51957AMUL Engine Operation and Maintenance Manual N67 T2......................................................................Part No. 45045AMUL Engine Operation and Maintenance Manual N67 T4f.....................................................................Part No. 42939AMUL iii

iv

INTRODUCTION................................................................................................................................................. v

Tigercat 2160 Loader Forwarder 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 2160 Loader Forwarder.

SERIAL NUMBERS: 2160

21600101 – 21600500

The 2160 Loader Forwarder is designed for loading and transporting cut-to-length trees in millyard facilities.

The Operator's Manual will assist the operator with the techniques of proper and safe operation of the Loader Forwarder. There is also important information regarding the safe operation of optional equipment and attachments.

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 are 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.

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

If the machine in question was built after the release date of this manual and there is a discrepancy, call Tigercat service department.

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

Tigercat Industries Inc.

v

MACHINE IDENTIFICATION AND SERIAL NUMBERS..................................................................................... vi

Introduction

Tigercat 2160 Loader Forwarder

MACHINE IDENTIFICATION AND SERIAL NUMBERS Please record all serial numbers related to this machine below and have ready before calling for assistance.

Engine Identification Label Location

The engine identification label is located on top of the engine beside the oil fill cap.

Engine Date of Manufacture:_______________________ Machine Serial Number Plate Location– Cab

The machine serial number plate is located inside the cab at the top of the side header to the left of the windshield.

Engine Serial Number Plate Location

The engine serial number is also stamped on the side of the engine, between the exhaust manifold and the alternator.

2000174

Machine Serial Number Stamp Location– Upper Frame

The machine serial number is also stamped on the top side of the upper frame between the anti-slip strips immediately to the right of the fuel tank fill cap on the front of the machine.

Engine Serial Number:___________________________

Machine Model Number:__________________________ Machine Serial Number:__________________________ Model Year:____________________________________

vi

STANDARDS FOR MACHINE OPERATOR PROTECTIVE STRUCTURES.....................................................vii

Tigercat 2160 Loader Forwarder

Introduction

STANDARDS FOR MACHINE OPERATOR PROTECTIVE STRUCTURES THIS OPERATOR ENCLOSURE MEETS THE FOLLOWING STANDARDS: • ISO 8082-2:2011 – ROLL OVER PROTECTIVE STRUCTURES (ROPS) • ISO 8083:2006 – FALLING OBJECTS PROTECTIVE STRUCTURES (FOPS), DROP ENERGY LEVEL 11,600J • SAE J2267:2007-OPERATOR FRONT PROTECTIVE STRUCTURE (OFPS) • ISO 8084:2003 – OPERATOR PROTECTIVE STRUCTURES (OPS) • OREGON OSHA 437-007-0775:14a, b, c– PROTECTIVE STRUCTURES FOR OPERATORS

MODIFICATIONS AND REPAIRS The integrity of the structure, and its continued ability to provide the level of protection it was designed for, could be seriously affected by any modifications to the structure, its mounting, or to the chassis to which it is attached.

Tigercat emphasizes the certification of approval of the structure will become void if any such modifications take place.

Tigercat may officially grant approval for modifications only by: • Written approval of repairs or modifications signed by the Tigercat Engineering Manager, or • Approved modifications officially released by Tigercat.

Approval will be granted, provided the work is carried out in the factory approved manner.

Unauthorized modifications and/or repairs made or contributed to by a customer or a Tigercat distributor may result in creating a dangerous situation and therefore the customer or Tigercat distributor will be considered to have assumed the risk involved or be negligent in creating this situation.

Tigercat will not be held responsible for situations arising from having created unauthorized modifications/changes to the structure.

Operator cabs are designed to industry standards so they will withstand force and absorb energy during a roll over (ROPS), when resisting the impact of a falling object (FOPS) and minimize the possibility of operator injury from penetrating objects (OFPS) and (OPS). When a permanent deflection of the structure occurs, the structure can no longer provide the original designed level of protection and should be replaced. Attempts to straighten the structure, particularly by the application of heat, can reduce still further the structures remaining capability to protect.

The mounting and the frame or chassis to which the cab is attached is considered an integral part of the ROPS, FOPS, OFPS, OPS and is included in the design, test and certification of the product.

Contact the Tigercat Service department before attempting any modifications or repair to tip-over protective structures.

Tigercat Industries Inc.

vii

NON-APPROVED FIELD PRODUCT CHANGES.............................................................................................viii

Introduction

Tigercat 2160 Loader Forwarder

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 its 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: • 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.

• 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.

viii

REGULATORY INFORMATION.......................................................................................................................... ix

Tigercat 2160 Loader Forwarder

Introduction

REGULATORY INFORMATION The operator's cab is equipped with standard or optional equipment that is capable of emitting radio frequency fields.

Bluetooth and WiFi exposure limits are significantly less than the maximum permitted for public use.

IMPORTANT! The RemoteLogTM telematics satellite antenna is externally mounted to the operator cab. When transmitting, the external antenna should be separated from personnel by a minimum distance of 20 cm (8 in). Transmissions can be silenced by placing the telematics system in repair mode.

FEDERAL COMMUNICATIONS COMMISSION NOTIFICATIONS TO USER INTERNAL (OPERATOR'S CAB): Telematics Module (WiFi)

Contains FCC ID: VPYLB1CL or NCMOCG2101

IQAN-G11 (Bluetooth)

Contains FCC ID: VPYLBZY

Radio (Bluetooth)

Contains FCC ID: OPDJHD36A

Radio (Bluetooth)

Contains FCC ID: OPDJHD1635BT

Radio (Bluetooth)

Contains FCC ID: OPDJHD3630BT

EXTERNAL: Inmarsat Modem (Satellite)

Contains FCC ID: B92IDP1XX

Iridium Modem (Satellite)

Contains FCC ID: Q639603N

These devices comply with part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.

Changes or modifications not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment.

This equipment complies with FCC radiation exposure limits set forth for an uncontrolled environment and meets the FCC radio frequency (RF) Exposure Guidelines. This equipment has very low levels of RF energy that is deemed to comply without maximum permissive exposure evaluation (MPE).

INDUSTRY CANADA NOTIFICATIONS TO USER INTERNAL (OPERATOR'S CAB): Telematics Module (Wi-Fi)

Contains IC ID: 772C – LB1CL or NCMOCG2101

IQAN-G11 (Bluetooth)

Contains IC ID: VPYLBZY

EXTERNAL: Inmarsat Modem (Satellite)

Contains IC ID: B92IDP1XX

Iridium Modem (Satellite)

Contains IC ID: Q639603N

These devices comply with Industry Canada licence-exempt RSS standard(s). Operation is subject to the following two conditions: (1) this device may not cause interference, and (2) this device must accept any interference, including interference that may cause undesired operation of the device.

This equipment complies with IC radiation exposure limits set forth for an uncontrolled environment and meets RSS102 of the IC radio frequency (RF) Exposure rules. This equipment has very low levels of RF energy that is deemed to comply without maximum permissive exposure evaluation (MPE).

ix

WARRANTY – EPA...............................................................................................................................................

EPA............................................................................................................................................... x

Introduction

Tigercat 2160 Loader Forwarder

US Environmental Protection Agency (EPA) Warranty Certificate Tigercat Industries Inc. (Tigercat) warrants to the ultimate purchaser and each subsequent purchaser that the engine is designed, built and equipped so as to conform with US Environmental Protection Agency (EPA) regulations applicable at the time of manufacture and that it is free from defects in workmanship or material which would cause it not to meet these regulations for a period of:

• 2 years or 1,500 hours of operation, whichever occurs first, for engines less than 19 kW (25 Hp) • 5 years or 3,000 hours of operation, whichever occurs first, for engines greater than or equal to 19 kW (25 Hp) NOTE: This warranty applies to all units operated in the United States or Canada.

Coverage The model year, class of diesel engine, and emission application determination for your engine are identified on the Emission Control Information Label. This label is affixed to one of the following areas of the engine: the top of engine’s rocker arm cover, the right-hand side of the oil pan, and the right-hand side of the engine front gear cover.

The warranty period begins on the date the new equipment is sold to the first retail purchaser. The presence of the emission control label is the indication that the engine conforms to the applicable standards. Any emission control system parts which are proven defective during normal use will be repaired or replaced during the warranty period.

The engine owner has responsibility to perform all the required maintenance listed in the Operation and Maintenance Manual. Tigercat will not deny an emission warranty claim solely because no record of maintenance exists; however, a claim may be denied if failure to perform maintenance resulted in the failure of a warranted part.

It is recommended that replacement parts used for maintenance or repairs be Tigercat Service Parts to maintain the quality originally designed into your emission certified engine. The use of non- Tigercat parts does not invalidate the warranty on other components unless the use of such parts causes damage to warranted parts.

The manufacturer is liable for damages to other engine components caused by the failure of any warranted emission control system part. Tigercat is not responsible for failures resulting from improper repair or the use of parts that are not genuine Tigercat or Tigercat approved parts.

Component coverage New engines certified for sale and registered will have the following items covered by the emission warranty, depending on the emission level of the engine, if the items were first installed on the new engine as original equipment: Fuel injection system

• Fuel injection pump • Fuel injectors • Fuel injection lines Air induction system

• Intake manifold • Turbocharger system (includes exhaust manifold) • Charge air cooler Positive Crankcase Ventilation (PCV) system (if applicable)

• PCV valve • Oil fill cap

x

Tigercat 2160 Loader Forwarder

Introduction

Exhaust after treatment Devices (if applicable)

• Diesel Oxidation Catalyst (DOC) • Diesel Particulate Filter (DPF) • Selective Catalytic Reduction (SCR) • Diesel Exhaust Fluid (DEF) tank and dispensing systems Exhaust Gas Recirculation Systems (EGR)

• EGR valve assembly • EGR cooler Cold Start Enrichment Systems Electronic Control Units, Sensors, Solenoids, and Wiring harnesses used in above systems

Emissions warranty does not cover • Repairs arising from storage deterioration, failure to maintain the equipment, negligence, alteration, improper use of the equipment, collision or other accident, vandalism, or other casualty, or operation beyond rated capacity or specification.

• Repairs arising from abuse or neglect, including but not limited to: operation without adequate coolant or lubricants, adjustments to the fuel system outside equipment specifications, over-speeding, improper storage, starting, warm-up, or shutdown practices, incorrect fuel or contaminated fuel, oil or other fluids.

• Normal maintenance services, such as engine tune-ups, engine fuel system cleaning, checks, adjustments, shimming, etc.

• Items replaced due to customer demand.

• Labor charges performed by anyone except a dealer authorized by contract to repair the equipment, unless they qualify under special provisions (i.e. outside labor).

• Any and all travel costs for items such as towing, service calls, or transporting a unit to and from the place where the warranty service is performed. Unless otherwise specified on the standard engine warranty certificate.

• Normal maintenance costs, including but not limited to: lubricants, coolants, fluids, fuel, filters, and associated labor.

• Claims involving the inspection or reconditioning of units after storage or prior use.

• Repairs arising from service performed by agents not approved by Tigercat.

• Repairs arising from any unauthorized modification to the product or the use of non-Tigercat parts, implements or attachments.

• Removal, replacement, or installation of non-Tigercat optional equipment, attachments or components.

• Premiums charged for overtime labor costs or out of shop expenses.

• Economic loss including lost profits, crop loss, equipment rental, or other expense.

• Unauthorized modification or updating machines without a warrantable failure.

• Any and all costs of dealer shop supplies incurred with repairs, including but not limited to: solvents, cleaners, antiseize lubricants, loctite, sealant, adhesive, oil-dry, shop towels, etc.

• Failure of the machine, its implements or attachments caused by improper field application or loading.

• Any and all costs for coolant, fuel, or lube (oil) analysis including supplies and lab recommendations.

• Cost associated with cleaning of machine in preparation for servicing.

5363-5378-E 0420

xi

Introduction

Tigercat 2160 Loader Forwarder

xii

SAFETY...............................................................................................................................................................1

Tigercat 2160 Loader Forwarder SECTION 1– SAFETY Read and understand the entire contents of this manual, and all manuals for any attachments or accessories associated with this machine, prior to operating or servicing this equipment.

CONTENTS – SECTION 1

ISSUE 1.3, NOVEMBER 2017

A

ARTICULATION LOCK BAR..................................................................................................................................... 1.18 AVOID INJURY FROM BACKOVER ACCIDENTS................................................................................................... 1.8

B

BATTERY DISCONNECT SWITCH......................................................................................................................... 1.12 BATTERY SAFETY...................................................................................................................................................... 1.7

C

CAB EXITS................................................................................................................................................................. 1.10 COOLING SYSTEM.................................................................................................................................................. 1.14

D

DIESEL EXHAUST FLUID (DEF)............................................................................................................................... 1.9

E

EXHAUST FUMES.................................................................................................................................................... 1.14

F

FIRE PREVENTION.................................................................................................................................................. 1.24 AFTER A MACHINE FIRE...................................................................................................................................... 1.26 DRY CHEMICAL CLEANUP PROCEDURES...................................................................................................... 1.27 HOW TO PREPARE FOR A MACHINE FIRE....................................................................................................... 1.25 IN CASE OF A MACHINE FIRE............................................................................................................................. 1.25 WET CHEMICAL CLEANUP PROCEDURES...................................................................................................... 1.27 FLUID INJECTION INJURY...................................................................................................................................... 1.19 FLUID LEAKS............................................................................................................................................................ 1.13

G

GENERAL SAFETY PRECAUTIONS........................................................................................................................ 1.4 GREASE INJECTION INJURY................................................................................................................................. 1.20

H

HYDRAULIC PRESSURE HAZARD........................................................................................................................ 1.13

L

LIGHTNING SAFETY AWARENESS....................................................................................................................... 1.21 LOOSE CLOTHING HAZARD.................................................................................................................................. 1.14

M

MACHINE STABILITY AND TRACTION.................................................................................................................. 1.11

N

NOTICE LABELS....................................................................................................................................................... 1.37

O

OPERATING SAFETY PRECAUTIONS.................................................................................................................... 1.9

P

PARKING THE MACHINE......................................................................................................................................... 1.12 PILOT INTERLOCK SWITCH – LEFT ARMREST.................................................................................................... 1.10 PREPARING THE MACHINE FOR MAINTENANCE.............................................................................................. 1.12 PROTECTIVE CLOTHING.......................................................................................................................................... 1.4

R

RELEASE PILOT SYSTEM PRESSURE................................................................................................................. 1.18

S

SAFETY HAZARDS OPERATING............................................................................................................................................................. 1.7

Safety

Tigercat 2160 Loader Forwarder

VITON SEALS.......................................................................................................................................................... 1.6 SAFETY LABELS...................................................................................................................................................... 1.29 SAFETY PRECAUTIONS GENERAL................................................................................................................................................................. 1.4 OPERATING............................................................................................................................................................. 1.9 SERVICING............................................................................................................................................................ 1.12 SAFETY SIGNAL WORDS.......................................................................................................................................... 1.3 SAFETY SYMBOLS..................................................................................................................................................... 1.3 SERVICING SAFETY PRECAUTIONS.................................................................................................................... 1.12 W

WELDING, PRIOR TO............................................................................................................................................... 1.16 WORKING WITH OIL.................................................................................................................................................. 1.6

1.2

Tigercat 2160 Loader Forwarder

Safety

SAFETY SYMBOLS

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

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

WARNING 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.

NOTICE NOTICE indicates a potentially damaging situation which, if not avoided, may result in property damage and is not related to personal injury.

1.3

Safety

Tigercat 2160 Loader Forwarder

GENERAL SAFETY PRECAUTIONS

WARNING

WARNING 24 VOLT ELECTRICAL SYSTEM 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 must be followed and obeyed.

These safety rules highlight both general and specific measures the operator must 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.

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.

DANGER The safety of persons outside the cab is the responsibility of the machine operator.

• When approaching an operating machine on foot, stay at least 150 m (500 ft) away until the operator recognizes your presence.

NOTE: Opening the cab door or cab side window will NOT stop machine functions.

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

• Use the handrails and steps provided when mounting and dismounting from the machine.

• Follow all instructions from safety inspector and supervisors.

• Do not jump off the machine at any time.

• 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. Do not let untrained persons operate the machine.

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

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

• Do not use the machine foot controls as steps.

• When mounting or dismounting the machine, use the three point technique. Use one hand with two feet or two hands with one foot.

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

1.4

Tigercat 2160 Loader Forwarder

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

WARNING

• 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.

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.

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

• Check all fluid levels.

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

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

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

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

Do not walk on angled steel or irregular shaped surfaces.

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

Maintain these anti-slip surfaces on a regular basis. If the surface shows signs of wear, replace the anti-slip material immediately.

• To reduce risk of fire, completely clean machine of debris daily, particularly around the engine exhaust components. Eliminate hydraulic oil leaks, excess grease, fuel and oil accumulation (including spillage) immediately. Turn OFF the engine and remove the ignition key before cleaning the machine.

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

• Wash machine completely at every major service.

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

1.5

Safety

Tigercat 2160 Loader Forwarder

WORKING WITH OIL

SAFETY HAZARDS – VITON SEALS

Direct contact with oil implies a risk of skin complaints (example: eczema). Observe strict hygiene.

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).

Observe the following when working with oil: • Oils used in this machine may be hot enough to cause serious burns.

• Avoid contact with oil, particularly heated oil.

• Wash off oil on the skin immediately with soap and water.

• Wear protective gloves. Clean hands before putting on gloves. Apply protective cream to the hands to make washing easier.

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

The following procedures are recommended when inspecting equipment subjected to high temperatures such as fire: • Visually inspect any seals or gaskets which have suffered from heat damage. They will appear black and sticky. If these are found, do not touch!

• Don't put oily rags in your pockets.

• Determine the material composition of any seals or gaskets, If fluoroelastomer 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.

• Change oil soiled clothing as soon as possible.

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

• Attend to cuts and abrasions immediately. Clean them and apply first-aid.

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

• Avoid breathing in oil fumes.

• Wash hands and arms frequently, for example, at each meal break or as often as possible.

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

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

1.6

Tigercat 2160 Loader Forwarder

Safety

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.

• Be aware, when performing service and maintenance tasks, 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.

• Do not allow anyone who may be unfit, physically or mentally, or who may be under the influence of alcohol or drugs, to operate the machine.

• When moving the machine, there must be enough clearance is available on all sides and above the machine or any of its attachments. Extra clearance may be required particularly where the ground is uneven.

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

• Read, understand and follow all general safety precautions specified in the ATTACHMENT MANUFACTURER'S DOCUMENTATION.

• 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.

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.

• Maintain a minimum distance of 3 m (10 ft) between the machine, including the boom or attachment, and any power line carrying up to 50,000 V. Add 1.5 m (5 ft) for each 150,000 V increment beyond 50,000 V. For example, if a power line carries 350,000 V, keep back at least 6 m (20 ft).

WARNING

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

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.

• If the machine must be transported, adequately secure it to the transporting vehicle. Refer to the VEHICLE MOVING AND TRANSPORTING INSTRUCTIONS literature supplied with the machine. Refer to the TABLE OF CONTENTS page in THIS MANUAL for the literature part number if required.

• 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 and let run for approximately five 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.

1.7

Safety

Tigercat 2160 Loader Forwarder CAUTION

AVOID INJURY FROM BACKOVER ACCIDENTS

Lead-acid batteries contain sulfuric acid which can severely damage eyes or skin on contact.

Wear a safety face shield, rubber gloves and protective clothing to reduce risk of accidents.

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

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

• Be alert for bystanders moving into the work area.

Use the horn to warn bystanders before moving the machine.

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

• Look around before you back up. Be sure everyone is clear.

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

• Use a signal person when backing up if the view is obstructed. Keep the signal person in view.

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

• Before servicing the machine, remove the negative (−) battery terminal cable (to the starter motor) from the battery.

• Keep all windows, mirrors and lights in good condition.

• When service is complete, connect the negative (−) battery terminal cable and turn ON the battery disconnect switch.

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

• Do not short out the battery terminals for any reason.

Serious burns or an explosion can result.

1.8

Tigercat 2160 Loader Forwarder

Safety

OPERATING SAFETY PRECAUTIONS

FOR TIER 4F MACHINES ONLY

• Turn OFF the engine and remove the ignition key when refuelling. Do not refuel the machine while smoking or near an open flame or sparks.

41581AUNI R0

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

• Diesel Exhaust Fluid (DEF) may irritate eyes or skin.

Do not get in eyes. Do not get on skin.

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

First Aid treatment: DEF Contains Urea. If swallowed call a Poison Control Centre or doctor immediately. Do not induce vomiting. If in the eyes, rinse with water for 15 minutes. If on the skin, rinse well with water. If irritation persists seek medical treatment.

• Sound the machine horn before starting the machine.

WARNING Use only DEF which meets ISO 22241 specifications. Do not fill the DEF tank with any other fluid.

DEF is injected into the exhaust gas stream during normal operation of the Selective Catalytic Reduction (SCR) aftertreatment system.

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

Use of other fluids may cause component damage, or a fire risk which could result in death or serious injury.

• Start the engine according to the instructions in this manual. Refer to OPERATING THE MACHINE in SECTION 2.

WARNING Do not use a liquid starting 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.

• Before operating the machine, all doors, panels, and access covers must be installed properly and secured.

1.9

Safety CAB EXITS

Tigercat 2160 Loader Forwarder PILOT INTERLOCK SWITCH – LEFT ARMREST

Check that all doors, panels, and access covers are properly installed and secured before moving the machine to the work site.

A

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

LEFT 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 pilot interlock switch and if left open will NOT deactivate the pilot system. The left armrest is equipped with a pilot interlock switch that prevents machine operation when the armrest is raised. Refer to PILOT INTERLOCK SWITCH – LEFT ARMREST in THIS SECTION for more details. Turn OFF the engine and raise the left arm rest before using the side door exit.

234-089

A Pilot Interlock Switch in OFF Position – Left Armrest UP

The left arm rest is equipped with a pilot interlock switch to prevent the machine from being operated while the armrest is in the raised position (pilot system is turned OFF).

RIGHT SIDE WINDOW This exit is to be used for emergency exit only if the side door exit becomes blocked. This window is not equipped with a pilot interlock switch and if left open will not deactivate the pilot system. Turn OFF the engine before using the side window as an emergency exit route.

IMPORTANT! The operator of the machine must be familiar with these emergency exits and how to use them.

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

Both exits must be checked frequently to verify they are operational and will function in an emergency.

For additional information, refer to EMERGENCY EXIT in SECTION 2.

A

2000134

C

B 2000117

2000116

A Pilot Interlock Reset Switch B Pilot System OFF (Yellow) C Pilot System ON (Green)

To operate the machine, with the engine running push the left arm rest down and press and release the pilot interlock reset switch. The pilot reset icon on the computer display will change from YELLOW to GREEN. Once the pilot system has been activated, the safety of both the operator and all persons outside the cab becomes the responsibility of the operator.

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

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

1.10

Tigercat 2160 Loader Forwarder

Safety CAUTION

WARNING

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

• When the engine is running, do not allow anyone in areas of the machine where they may be crushed by moving components.

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

• Do not operate the boom or grapple over the heads of bystanders.

WARNING

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

MACHINE STABILITY AND TRACTION When working on slopes, travel straight up or down the slope to reduce the risk of roll-over.

Never travel across a steep slope or side hill: • As logs are added to the wagon, the handling and the stability of the machine will change.

• To avoid tip over, keep the boom and load as low as possible to maintain a low centre of gravity.

• Use only prearranged and approved signalling practices.

• Do not overload the machine as this can create an unstable condition and cause a roll-over.

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

• 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 the seat belt when driving or steering the machine to prevent being thrown from the cab.

• Secure loose items in the cab.

• Prior to commencing work, check all equipment controls to verify the machine responds correctly.

• All safety screens and guards, must be installed and properly secured.

• Rest the grapple on the wagon frame or ground when operation is stopped, regardless if the engine is running or turned OFF. • Operate the machine only from a seated position in the operator seat.

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

• When travelling, position the grapple and the boom to avoid visual impairment.

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

1.11

Safety

Tigercat 2160 Loader Forwarder

PARKING THE MACHINE WARNING To prevent injury, park the machine as outlined below.

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

Before leaving the cab for any reason, lower the grapple onto the wagon frame or ground.

Perform the following steps when parking the machine: 1. Park on level ground with the closed grapple resting firmly on the last bunk of the wagon frame.

NOTE: When the engine is turned off all DEF is pumped back to tank before the engine power system is turned off. This process takes approximately 90 seconds.

Refer to AFTERTREATMENT SYSTEM in SECTION 3 for more information.

NOTE: The aftertreatment system and its related components are applicable to Tier 4f machines only.

IMPORTANT! Only in an emergency use the battery disconnect to turn off a running machine. A fault code will be logged by the engine ECU for improperly shutting and powering down the machine. Wait 90 seconds after the engine is turned OFF before turning OFF the battery disconnect switch. If the battery disconnect is turned OFF before the engine, the ECU (Electronic Control Unit) will register a fault.

PREPARING THE MACHINE FOR MAINTENANCE WARNING To prevent injury, prepare the machine as outlined below prior to performing any maintenance or servicing activities.

• Park the machine as outlined in PARKING THE MACHINE in THIS SECTION.

2000188

2. Set the travel direction switch to the NEUTRAL position.

3. Turn OFF the engine.

SERVICING SAFETY PRECAUTIONS • Conduct maintenance inspections at least as frequently as recommended in SECTION 3.

NOTE: The swing brake is automatically applied when the engine is turned OFF. 4. Remove the ignition key.

A

• Read, understand and follow all operating safety precautions specified in the ATTACHMENT MANUFACTURER'S DOCUMENTATION.

2000159

A Battery Disconnect Switch – OFF

5. Turn OFF the battery disconnect switch if required by the servicing procedure or if the vehicle is to be parked for an extended period of time, such as overnight.

1.12

Tigercat 2160 Loader Forwarder

Safety • Ensure the fan finger guard is in place when the engine is running.

WARNING

A

2000159

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

A Battery Disconnect Switch – OFF

• When servicing or repairing equipment, turn OFF the engine, remove the ignition key, turn OFF the battery disconnect switch and lock out the switch in accordance with local regulations.

• 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).

WARNING • Before servicing the machine, remove the negative (−) battery terminal cable (to the starter motor) from the battery.

• When service is complete, connect the negative (−) battery terminal cable and turn ON the battery disconnect switch.

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

Diesel fuel or hydraulic oil 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.

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

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

• Clean and service the cooler package daily to maintain moderate engine temperatures.

• Exercise care when working in the engine compartment with the engine running. With the FAN CONTROL SWITCH in the AUTO position, the variable-pitch cooling fan will automatically go into CLEAN mode at any time and operate in reverse.

• 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.

1.13

Safety

• Pressure can be maintained in a hydraulic system long after the power source and pump have been shut down. Refer to RELEASE PILOT SYSTEM PRESSURE in SECTION 3 and SECTION 5.

• Lower the grapple to the ground, turn OFF the engine and relieve trapped pressure from pilot system and accumulators before performing work on components, or disconnecting any hoses. For information on relieving pressure, refer to RELEASE PILOT SYSTEM PRESSURE in SECTION 3. The accumulators will self drain within two minutes of turning OFF the engine.

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

Tigercat 2160 Loader Forwarder

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

• Work in a ventilated area. If it is necessary to run an engine in an enclosed area, use an exhaust pipe extension to allow toxic exhaust fumes to be routed outdoors.

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

• 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.

• Turn OFF the engine. Only remove the coolant fill cap when it is cool enough to touch with bare hands.

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

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

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

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

• Be aware of machine pinch points that could cause injury. Do not place body parts within the range of motion of the working parts of the machine.

• When opening or closing the engine compartment doors, watch for personnel in door areas.

1.14

Tigercat 2160 Loader Forwarder

Safety

WARNING

WARNING

Do not operate this machine to lift or move any objects other than what it is designed to lift or move.

Follow the instructions and safety warnings provided by the attachment manufacturer before approaching the attachment head to make adjustments.

• Do not use the boom to service other equipment.

WARNING

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

Do not work below or behind a machine parked on a grade.

• Do not modify the boom system.

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

WARNING

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

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

Maintain a safe operating distance between the machine, the workers and all other personnel. It is the duty of the operator to not allow personnel to approach the machine while in use.

CAUTION

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

Do not open cab doors or window screens when the cab is on a slope. The doors and screens are heavy and could swing out with considerable force. Anyone in the path of the 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 outlined in the ATTACHMENT MANUFACTURER'S DOCUMENTATION.

• Do not stand under an object supported with hydraulics. Use safety stands or a locking device.

1.15

Safety

Tigercat 2160 Loader Forwarder

PRIOR TO WELDING Prior to welding on any part of the machine, clean the repair area and have a fire extinguisher available at the welding location.

Take care in attaching the welding machine grounding clamp so current does not pass through bearings, especially the swing bearing.

This machine is equipped with sensitive electronic control equipment. Prior to welding, follow the steps below:

A

1. Turn OFF the battery disconnect switch.

2. Disconnect the negative (−) battery cable from the batteries.

2000195

A XC21-A2 Expansion Module Multi-Pin Connectors

4. Disconnect all multi-pin connectors from the XC21-A2 expansion module (mounted in the cab fuse and relay panel).

A

A

724G-119

A Cover Fasteners – Two bolts on Bottom and One Screw on Top

3. Disconnect the computer in the cab. Remove the back cover of the computer display held by three socket head screws (one top/two bottom) to access the connectors.

2000058

A Engine ECU Multi-pin Connectors

5. Disconnect the three multi-pin connectors from the engine ECU (front of engine).

1.16

Tigercat 2160 Loader Forwarder

Safety THE AFTERTREATMENT SYSTEM AND ITS RELATED COMPONENTS ARE APPLICABLE TO TIER 4F MACHINES ONLY.

A A

2000066

A MC43-A1 Module Multi-pin Connector

6. Disconnect the multi-pin connectors from the MC43-A1 master module (mounted on the upper structure under the platform).

2000068

A ECU – NH3 Sensor

9. Disconnect the NH3 sensor ECU (mounted in the right rear of the engine compartment).

A A 2000065 2000068

A XA2-A1T Module Multi-pin Connector

7. Disconnect the multi-pin connector from the XA2-A1T expansion module (mounted on the upper structure under the swing pump).

A ECU – Outlet NOx Sensor

10. Disconnect the outlet NOx sensor ECU (mounted in the right rear of the engine compartment).

A A

2000069

A ECU – Inlet NOx Sensor

2000067

A XA2-A2T Module Multi-pin connector

8. Disconnect the multi-pin connector from the XA2-A2T expansion module (mounted on the pedestal frame under the platform).

11. Disconnect the inlet NOx sensor ECU (mounted in the pump compartment).

When welding is complete: 1. Reconnect all multi-pin connectors.

2. Connect the negative ( – ) battery cable.

3. Turn ON the battery disconnect switch.

1.17

Safety

Tigercat 2160 Loader Forwarder

ARTICULATION LOCK BAR A

D

RELEASE PILOT SYSTEM PRESSURE B

Release pressure from the accumulators prior to working on any hydraulic circuit.

Refer to RELEASE PILOT SYSTEM PRESSURE in SECTION 3 for instructions.

D

C

2000175

A B C D

Articulation Lock Bar in Locked Position

Wagon Frame Pedestal Frame Articulation Lock Bar Retaining Pin

To prevent accidental articulation of the machine and injury when working in the centre joint area, install the articulation lock bar between the wagon frame and pedestal frame and hold in place with the retaining pins provided. Refer to ARTICULATION LOCK BAR in SECTION 3 for instructions.

1.18

Tigercat 2160 Loader Forwarder

FLUID INJECTION INJURY

Safety SEARCHING FOR POSSIBLE FLUID LEAKS WARNING

WARNING Diesel fuel or hydraulic oil under pressure can penetrate the skin and could result in serious injury or death. 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.

Never search for leaks with your bare hands.

Wear thick protective gloves.

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.

• Wear safety goggles for eye protection.

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

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.

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

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.

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

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

• Recognize 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 • Turn OFF the engine and relieve all diesel fuel or hydraulic pressure before disconnecting any lines or otherwise working on the system.

IN THE EVENT OF ANY SUSPECTED FLUID INJECTION INJURY

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

• Hoses must be rated for the pressures to which they will be subjected.

• Report the injury to your supervisor immediately.

• Seek professional medical attention immediately.

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

The best defence against suffering the effects of fluid injection is to prevent the accident from occurring.

1.19

Safety

Tigercat 2160 Loader Forwarder

GREASE INJECTION INJURY WHEN USING PNEUMATIC GREASE GUNS Pneumatic grease guns can deliver grease at pressures from 17 – 400 bar (246 – 5801 psi). It takes less than 7 bar (100 psi) to inject a substance through human skin.

Get professional medical treatment immediately after any type of injection injury.

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

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

PRIOR TO USING A HIGH PRESSURE PNEUMATIC GREASE GUN, PERFORM THE FOLLOWING • 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.

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

• Wear proper protective equipment 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.

• Protective shrouds must be installed on all grease gun nozzles as safety devices.

• Remove dirt and grease from the grease fittings prior to greasing.

• Replace any defective grease fittings with new fittings immediately.

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

1.20

Tigercat 2160 Loader Forwarder

Safety

LIGHTNING SAFETY AWARENESS

LIGHTNING SAFETY

WHAT IS A LIGHTNING STRIKE?

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.

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.

Loggers can increase their chances of avoiding a lightning strike by following a few simple safety practices: • Designate a member of your crew to: • Monitor daily weather forecasts • Observe local weather conditions

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.

• Alert all other members of the crew when a possible lightning threat develops • Do not start or continue any work that cannot be stopped immediately, when a storm moves nearby.

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 ft) within the soil around the strike point.

• 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.

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.

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.

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

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

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.

1.21

Safety 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.

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

Heavy forestry equipment such as a skidder, harvester, 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 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.

WHAT TO DO IF YOU ARE OUTSIDE AND SEE LIGHTNING OR HEAR THUNDER IF YOU CAN, GET INSIDE:

Tigercat 2160 Loader Forwarder IF INSIDE A MOTOR VEHICLE OR FULLY ENCLOSED ROPS EQUIPMENT CAB: • 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.

• 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.

IF YOU ARE CAUGHT OUTSIDE AND HAVE NOWHERE TO GO: • Avoid wide-open areas where you project above the surrounding landscape.

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

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

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

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

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

• Avoid entering any small enclosures or shelters.

IF INSIDE A BUILDING:

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

• Do not 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.

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

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

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

• Do not use the telephone except for emergencies.

1.22

Tigercat 2160 Loader Forwarder

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

• 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.

• 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.

WHAT TO DO IF A CO-WORKER HAS BEEN STRUCK BY LIGHTNING: • The victim does not carry any electrical charge.

There is no danger to anyone helping this person.

You can touch him or her immediately.

• Call your local emergency response telephone number immediately.

• If the victim has no pulse, their heart has stopped or they have stopped breathing, call for professional medical help immediately and then begin administering appropriate first aid. Use a portable defibrillator if one is available (as required).

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

• To further increase your awareness about lightning safety, see the following web sites: • National Weather Service Lightning Safety http://www.lightningsafety.noaa.gov • National Lightning Safety Institute http://www.lightningsafety.com

1.23

Safety

FIRE PREVENTION

Tigercat 2160 Loader Forwarder • Steam clean the engine, hydraulic pumps, transmission, brake, fuel and hydraulic oil tank compartments and all machine belly pans at least once each month, or more frequently when working in conditions with high volumes of forest debris • Use only non-flammable solutions for cleaning the machine and components.

When working in a forest environment combustible debris will collect in tight corners of the machine. Left unchecked, this debris may cause a fire; when mixed with fuel, oil, or grease in a hot or confined place, the danger of fire greatly increases.

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.

• Maintain a charged fire extinguisher on the machine at all times. Know how to use it.

• Remove dust and debris regularly from the air intake doors, cooling system components, and A/C condenser to prevent engine and hydraulic system overheating and to maintain efficient operation.

Refer to CLEANING COOLER PACKAGE in SECTION 3 .

• Remove all forest debris and fine organic material around engine intake and exhaust components (turbocharger, exhaust manifold, exhaust pipes, muffler) at the end of each shift, or more frequently when working in conditions with high volumes of combustible forest debris. Check carefully in small pockets and cavities around the engine enclosure where smouldering debris may gather.

NOTE: Minor debris accumulations near hot components can ignite and smoulder. Smouldering debris may shift and cause fire to spread.

• Clean out all accumulated forest debris (twigs, needles, branches, bark, leaves, saw dust, wood chips) and any other combustible materials from inside the machine belly pans, lower machine structures, and engine, hydraulic, and fuel system areas no less frequently than at the completion of each work shift.

• Inspect the machine regularly for evidence of diesel fuel or hydraulic system leakage. Check for worn or damaged hydraulic and fuel lines before turning on the engine.

• Clean up any grease, diesel fuel, or oil spillage (hydraulic or lubricating) immediately.

• Inspect the exhaust system daily for evidence of leakage. Check for worn, cracked, broken, or otherwise damaged pipes or muffler, and missing or damaged bolts or clamps. Make repairs immediately. Engine exhaust leaks can cause fires.

Do not operate the machine until exhaust leaks are repaired.

NOTE: Changes or increases in engine exhaust noise levels often indicate exhaust leaks. Do not ignore these warnings. Shut down the machine immediately and complete repairs.

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

• Never leave the machine parked with the boom raised off the ground. Should the hydraulic cylinder hoses burn through in a fire, hydraulic oil will escape and the boom will fall rapidly to the ground.

• Turn OFF the battery disconnect switch when parking the machine.

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

• Remove the ignition key, and lock the cab and fuel cap at the end of shift to reduce the risk of vandalism or theft.

• Do not smoke in the vicinity of the machine.

• Do not smoke during fuelling operations, when the fuel system is open to the atmosphere, or when servicing the batteries. Exercise caution if smoking in the woods.

• After transporting a machine by road, open all doors and access panels; remove any debris that may have settled around the engine and exhaust system during the journey.

• Before undertaking repair work or welding, clean the surrounding area and place a fire extinguisher within easy reach.

• Store rags and other combustible materials safely in a fireproof location.

• Do not operate the machine near burning timber. Do not use the machine to push burning timber into a pile.

• There is no substitute for fire prevention. Time invested in prevention is repaid through productivity on the job site.

1.24

Tigercat 2160 Loader Forwarder

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

NOTICE Equipment fires undermine productive logging, may increase your insurance premiums dramatically, or prevent you from obtaining insurance coverage. Make fire prevention a priority.

• 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.

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

HOW TO PREPARE FOR A MACHINE FIRE

• Know how to use the fire extinguisher, the pressurized water system (as applicable), and the fire suppression system (as applicable) on your machine. There is no time to read instructions during a fire emergency. Be prepared to act.

• Inspect and maintain all machine systems on a routine basis.

• Maintain fire extinguishers in proper working order. Follow the manufacturer’s instructions for inspection and maintenance (on the label of the fire extinguisher and in the user's manual).

• Keep emergency contact information readily available in case of fire.

• Verify that any pressurized water systems on the machine are charged and in working order. Refer to PRESSURIZED WATER SYSTEM MAINTENANCE as applicable in SECTION 3.

IN CASE OF A MACHINE FIRE If a machine fire occurs:

• Verify the correct types of fire extinguishers are available at the work 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.

1. Lower all working attachments to the ground.

2. Turn OFF the engine.

NOTE: If equipped, use the Emergency Stop Button to override the Hot Engine Shutdown Strategy.

Activate the fire suppression system as applicable.

• Class A fires involve ordinary combustibles such as wood, cloth, paper, rubber and many plastics,

3. Radio or call for help. Report a fire immediately.

• Class B fires occur with flammable liquids such as diesel fuel, oil, and grease.

4. Turn OFF the battery disconnect switch if it safe to do so.

5. Dismount the cab; take the fire extinguisher and pressurized water system hose (if applicable) with you.

• Class C fires apply to energized electrical equipment.

• The nozzles on fires extinguishers and pressurized water systems (if applicable) must fit within the fire extinguisher access ports on the machine doors.

• Keep the fire detection system in working order as applicable. Refer to FIRE DETECTION SYSTEM in SECTION 2.

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

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

• Keep the fire suppression system charged and in working order as applicable. Refer to FIRE SUPPRESSION SYSTEM in SECTION 2.

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

• Know the recommended fire procedures in your organization's emergency action plan.

• Follow all national, state/provincial, and local fire fighting regulations. Regulations will vary from region to region but most will require that: • Workers assigned to fire fighting duties must be physically capable of performing them safely and effectively.

6. Put your personal safety and the safety of other persons first. Approach any fire with extreme caution. All fires are potentially very dangerous and life threatening.

If in doubt about your ability to fight the fire, do not attempt to fight it. Stay well back. Wait for help to arrive.

NOTE: Engine coolant, diesel fuel, or hydraulic hoses may fail during a fire. Hot coolant, fuel, or oil could be ignited, or may spray at high velocity from damaged hoses.

1.25

Safety

Tigercat 2160 Loader Forwarder

When fighting a fire:

AFTER A MACHINE FIRE

1. If possible, use a dry chemical fire extinguisher or fire suppression system first.

Before returning a machine to operations:

2. 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 debris or hot machine components in the area. Water cools the area, reducing the chances of re-ignition.

3. Use the fire extinguisher PASS method: Pull the safety pin at the top of the extinguisher that prevents the discharge lever from being depressed.

Break the plastic seal as the pin is pulled.

Aim the nozzle at the base of the fire. Do not aim the nozzle at the flames. To put out the fire, the fuel must be extinguished, not the flames. Hose nozzles are often clipped to the extinguisher body. Release the hose before taking aim.

1. Determine the cause of the fire.

2. Complete all necessary repairs.

3. Service and recharge the fire suppression and detection systems as applicable.

4. Report the fire to your dealer and/or Tigercat Industries Inc. by completing an incident report (Tigercat form 5101).

NOTE: Fire detection systems are offered as optional installations on some Tigercat product lines. Please disregard any references made to fire detection systems if not installed on your machine.

NOTE: Dry and wet chemical fire suppression systems are offered as optional installations on some Tigercat product lines. Please disregard any references made to fire suppression systems if not installed on your machine.

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

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

822C-190

Typical Fire Extinguisher Access Port

4. Insert the fire extinguisher nozzle into the appropriate access port and discharge the extinguisher.

5. If it is safe to do so, open the access panels in the area of the fire and aim the extinguisher directly at the base of the flames.

6. If it is impossible to reach an access port or to open a panel or door, discharge the extinguisher through mesh screening or any available opening.

7. Monitor the machine after extinguishing a fire in case of re-ignition; remain until help arrives.

1.26

Tigercat 2160 Loader Forwarder

Safety

DRY CHEMICAL CLEANUP PROCEDURES

WET CHEMICAL CLEANUP PROCEDURES

ABC dry chemical fire extinguishers and fire suppression systems discharge a chemical powder. The powder comprises very fine particles that penetrate and cover all components in the vicinity of the discharge.

The wet chemical suppression fluid contains frost protection, rust inhibitor, and film-forming liquids that are broken down by natural organisms. When the fluid dries, the corrosion protection loses its effect. Clean up wet chemical discharges as soon as possible to avoid corrosion on metal parts.

Areas in contact with dry chemical power must be neutralized and cleaned after a fire. Wear protective clothing, safety goggles, and a fine particle dust mask.

1. De-energize electrical systems prior to any cleanup.

2. In areas that remained cool and dry during the fire, the dry chemical remains in powder form.

Clean these areas immediately to prevent residual powder from coming into contact with water or ambient moisture.

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.

Wipe all surfaces with a damp cloth.

3. In areas exposed to moisture during the fire, the dry chemical powder combines with water to form a paste that is mildly acidic. All surfaces covered in dry chemical paste, including electrical contacts, are vulnerable to corrosion.

If the suppression fluid is sucked into the engine air intake, it will not significantly change engine functioning.

However, starting difficulties may occur with diesel engines because the suppression fluid contains water.

The suppression fluid also may cause corrosion damage if the engine is not cleaned soon after a fire.

Clean affected areas promptly to protect electrical system functions and prevent short circuits.

To clean affected areas: 1. Flush the affected area with pressurized fresh water.

2. Use an alkaline washing detergent to remove the film. (Film residue attracts dirt and other impurities on affected surfaces.)

3. Flush affected areas a second time to remove detergent residue.

NOTICE

Neutralize the acidic paste on large surfaces by spraying or washing these areas with a mixture of three parts hot water to one 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.

To protect engines, electrical installations, and other metal parts against corrosion, flush the remains of dried or moist suppression fluid as soon as possible after the release of the piston accumulator (use a high pressure washer if possible).

Clean electrical contacts with a contact cleaner that has no flash or fire point and is non-corrosive and non-conductive, such as CRC Contact Cleaner 2000.

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

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.

When exposed to moisture the caked dry chemical is also mildly acidic. When the breakdown procedure has been completed, follow this immediately with the neutralizing procedure as described in step 3.

1.27

Safety

Tigercat 2160 Loader Forwarder

1.28

Tigercat 2160 Loader Forwarder

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

Safety READ OPERATOR'S MANUAL AND USE THE SEAT BELT AT ALL TIMES

OPERATOR'S MANUAL LOCATION

This label indicates the storage location of the operator's manual in the cab.

This label gives two messages.

The centre panel notifies the operator to 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.

The bottom panel notifies the operator the operator's seat is equipped with lap belt. Use this restraint systems at all times when operating the machine.

1.29

Safety

Tigercat 2160 Loader Forwarder

NO RIDERS

REMOVE IGNITION KEY BEFORE SERVICING THE MACHINE!

No riders inside or outside 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.

Prior to performing any service work or maintenance on the machine, turn OFF the engine, remove the ignition key and store it in a safe place.

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.

1.30

Tigercat 2160 Loader Forwarder

Safety

EMERGENCY EXIT, HAND TIGHTEN ONLY

FIRST AID KIT

This label indicates the escape hatch can also be used as an emergency exit.

This label indicates a location in the cab for storage of a first aid kit.

The label also indicates that escape hatch knobs are to be hand tightened only to allow for easy exit.

Ensure all exit locations are functioning properly.

Refer to CAB EXITS in THIS SECTION. Refer to EMERGENCY EXIT in SECTION 2.

1.31

Safety

Tigercat 2160 Loader Forwarder

KEEP CLEAR

ENTANGLEMENT HAZARD

43424BUNI R0

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

Keep clear of an operating machine.

When approaching an operating machine on foot, stay at least 60 m (200 ft) away until the operator recognizes your presence. Make sure that all equipment has been shut down before advancing to the machine.

Maintain a safe operating distance between the machine and workers and all other personnel. It is the duty of the operator to ensure that no person approach the machine while in use, the risk zone is 60 m (200 ft).

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

This label warns of an entanglement hazard.

The machine is equipped with an exposed driveshaft at the centre joint. Not keeping a safe distance from rotating exposed driveshafts could result in death or serious injury.

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.

1.32

Tigercat 2160 Loader Forwarder CRUSH HAZARD

Safety CRUSH HAZARD

This label warns of the crush hazard caused by the boom when it is not properly supported.

This label warns of the crush zone in the centre joint area. This can occur when the machine steering is used.

Do not work in this area until the articulation lock bar is installed!

Before working in the centre joint area, install the articulation lock bar between the chassis and centre joint to prevent accidental articulation which could result in death or serious injury.

Do not work under or near an unsupported boom or attachment. Contact with a falling boom could result in death or serious injury!

Lower the boom to the ground so the weight of the boom and attachment is resting on the ground. Properly support and brace boom and shut off engine before performing service work.

Refer to ARTICULATION LOCK BAR in SECTION 3 for complete instructions.

1.33

Safety CRUSH HAZARD

Tigercat 2160 Loader Forwarder EXPLOSIVE RELEASE OF HOT COOLING SYSTEM PRESSURIZED FLUID

33952AUNI R0

This label warns of a pressure and fluid spray hazard when the coolant in the radiator is hot.

Do not loosen cap until cool. Explosive release of fluids from pressurized cooling system can cause serious burns.

Turn OFF the engine. Only remove coolant fill cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

This label warns of the crush hazard caused by the cab tilting when machine is equipped with optional cab riser.

Be sure that all personnel are clear when tilting the cab.

Operating the cab tilt function with personnel in the crush zone could result in death or serious injury!

Keep all personnel clear of the machine before operating the cab tilt function.

1.34

Tigercat 2160 Loader Forwarder

Safety

EXPLOSION HAZARD

STORED ENERGY HAZARD

WARNING

WARNING • EXPLOSION HAZARD. • DO NOT USE ETHER. • ENGINE EQUIPPED WITH HEATER STARTING AID. • USE OF ETHER COULD RESULT IN DEATH OR SERIOUS INJURY. 36782BENG R0

• STORED ENERGY HAZARD

This label warns of an explosion hazard. The engine is equipped with a heater starting aid, do not use ether to assist in starting the engine.

• THE ACCUMULATOR HAS 3000 PSI OF STORED ENERGY. SERVICING THE ACCUMLATOR BEFORE RELEASING PRESSURE COULD RESULT IN DEATH OR SERIOUS INJURY. • DO NOT SERVICE THE ACCUMULATOR BEFORE RELEASING PRESSURE BY APPLYING BRAKES 25 TIMES WITH ENGINE OFF.

Using ether could cause an explosion which could result in death or serious injury!

39945BENG R0

This label warns of a STORED ENERGY HAZARD. The machine is equipped with an accumulator (located in the front chassis). The accumulator has stored energy in the form of hydraulic pressure. Servicing the accumulator or any hydraulic components before releasing pressure could result in death or serious injury.

Do not service accumulator or any hydraulic components before releasing pressure.

Refer to RELEASE PILOT SYSTEM PRESSURE in SECTION 3.

1.35

Safety

Tigercat 2160 Loader Forwarder

FIRE PREVENTION

CHECK DAILY

This label advises operator's of the following:

In addition to the previous label this label 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.

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 the 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.

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.

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

FIRE EXTINGUISHER ACCESS HOLE

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.

1.36

Tigercat 2160 Loader Forwarder

Safety

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

ENGINE COOLANT SHUT-OFF VALVE (MACHINES EQUIPPED WITH ENGINE COOLANT HEATER)

ENGINE IDLE (APPLICABLE TO TIER 4F MACHINES ONLY)

This label informs operators that damage to the engine coolant heater pump may result if the engine coolant heater is operated with the engine coolant shut-off valve closed.

This label informs operators that damage to the emission control system will result when the engine has idled longer than one hour.

LOAD DISTRIBUTION

This label informs operators how to properly distribute the load in the wagon.

1.37

Safety

Tigercat 2160 Loader Forwarder

1.38

CONTROLS AND OPERATION...........................................................................................................................2

Tigercat 2160 Loader Forwarder SECTION 2– CONTROLS AND OPERATION Read and understand the entire contents of this manual, and all manuals for any attachments or accessories associated with this machine, prior to operating or servicing this equipment.

CONTENTS – SECTION 2

ISSUE 1.5, NOVEMBER 2017

A

AIR VENTS, CAB....................................................................................................................................................... 2.27 ALARM....................................................................................................................................................................... 2.23 ALARM LIGHT........................................................................................................................................................... 2.23 ANTI STALL................................................................................................................................................................ 2.78 AUXILIARY POWER SUPPLY, 12 VOLT.................................................................................................................. 2.21

B

BATTERIES................................................................................................................................................................ 2.28 BATTERY BOOSTING.............................................................................................................................................. 2.71 BATTERY DISCONNECT SWITCH......................................................................................................................... 2.28 BRAKES HOLDING BRAKE........................................................................................................................................ 2.15, 2.16 SERVICE BRAKE......................................................................................................................................... 2.15, 2.16 BUNKS....................................................................................................................................................................... 2.80 SETTING BUNK LOCATIONS............................................................................................................................... 2.79

C

CAB CONTROLS JOYSTICK CONTROLS – MACHINES WITH T-BAR (FOOT) SWING............................................................... 2.10 JOYSTICK CONTROLS – MACHINES WITH JOYSTICK SWING AND STEERING......................................... 2.12 FOOT PEDAL CONTROLS – MACHINES WITH T-BAR (FOOT) SWING.......................................................... 2.15 FOOT PEDAL CONTROLS – MACHINES WITH JOYSTICK SWING AND STEERING................................... 2.16 CONTROL PANEL – LEFT ARMREST................................................................................................................... 2.17 CONTROL PANEL – RIGHT ARMREST................................................................................................................ 2.19 MAIN CONSOLE.................................................................................................................................................... 2.21 OVERHEAD CONSOLE – FRONT......................................................................................................................... 2.23 OVERHEAD CONSOLE – RIGHT.......................................................................................................................... 2.22 CAMERAS.................................................................................................................................................................. 2.25 WAGON FRAME..................................................................................................................................................... 2.25 UPPER STRUCTURE............................................................................................................................................ 2.25 VIDEO DISPLAY..................................................................................................................................................... 2.25 PAIRING PROCEDURE......................................................................................................................................... 2.26 COLD WEATHER STARTING................................................................................................................................... 2.82 WARM UP IDLE SPEED ADJUSTMENT.............................................................................................................. 2.83 COMPUTER CONTROL SYSTEM........................................................................................................................... 2.32 ENGINE MENU....................................................................................................................................................... 2.34 ANTI STALL......................................................................................................................................................... 2.37 COLD IDLE FUNCTION..................................................................................................................................... 2.37 ENGINE FUNCTIONS........................................................................................................................................ 2.35 ADJUSTMENT MENU HYDRAULIC OIL GRADE SELECTION............................................................................................................ 2.38 INFORMATION MENU........................................................................................................................................... 2.39 ADDITIONAL INFORMATION SCREEN........................................................................................................... 2.39 TELEMATICS INFORMATION........................................................................................................................... 2.40 UNITS OF MEASURE......................................................................................................................................... 2.39 MAIN MENU............................................................................................................................................................ 2.41 ADJUST MENU COLD IDLE SPEED......................................................................................................................................... 2.44 FAN AUTO CLEAN........................................................................................................................................... 2.45 FAN CLEAN DURATION................................................................................................................................. 2.46

Controls and Operation

Tigercat 2160 Loader Forwarder

FAN CLEAN FREQUENCY............................................................................................................................. 2.45 HOLDING BRAKE............................................................................................................................................ 2.43 IDLE DOWN WAIT TIME................................................................................................................................. 2.42 INFO MENU......................................................................................................................................................... 2.51 MEASURE MENU............................................................................................................................................... 2.46 PREFERENCES MENU...................................................................................................................................... 2.47 HYDRAULIC OIL RETURN FILTERS BYPASSED.............................................................................................. 2.33 MAIN SCREEN....................................................................................................................................................... 2.33 MESSAGES............................................................................................................................................................ 2.53 MESSAGES – ALERT............................................................................................................................................. 2.63 LIST OF MESSAGES.......................................................................................................................................... 2.64 ACCUMULATOR PRESSURE HIGH................................................................................................................. 2.66 ACCUMULATOR PRESSURE LOW.................................................................................................................. 2.66 DIESEL EXHAUST FLUID LEVEL..................................................................................................................... 2.70 DIESEL EXHAUST FLUID QUALITY................................................................................................................. 2.69 DRIVE CHARGE FILTER BYPASSED.............................................................................................................. 2.65 DRIVE PEDAL VOLTAGE LOW......................................................................................................................... 2.66 ENGINE AIR INTAKE FILTER RESTRICTED................................................................................................... 2.65 ENGINE COOLANT TEMPERATURE HIGH – SPN: 62755.............................................................................. 2.68 ENGINE FAULT CODE MESSAGES................................................................................................................. 2.68 ENGINE IDLE AUTOMATICALLY INCREASED............................................................................................... 2.68 ENGINE TORQUE DERATE ACTIVE – SPN: 64911.......................................................................................... 2.68 ENGINE VOLTAGE HIGH – SPN: 4449 OR 4961.............................................................................................. 2.68 ENGINE VOLTAGE LOW – SPN: 8801 OR 9313............................................................................................... 2.68 FUEL LEVEL LOW.............................................................................................................................................. 2.66 HARDWARE FAILURE....................................................................................................................................... 2.67 HARDWARE FAULT............................................................................................................................................ 2.67 HYDRAULIC OIL FILTER RESTRICTED.......................................................................................................... 2.65 JOYSTICK AXIS VOLTAGE LOW...................................................................................................................... 2.66 JOYSTICK TRIGGER VOLTAGE LOW............................................................................................................. 2.66 MACHINE VOLTAGE HIGH................................................................................................................................ 2.66 MACHINE VOLTAGE LOW................................................................................................................................. 2.66 MAIN FUEL FILTER CLOGGED........................................................................................................................ 2.66 MODULE HIGH SUPPLY VOLTAGE – ALERT................................................................................................... 2.67 MODULE HIGH TEMPERATURE...................................................................................................................... 2.67 MODULE LOW SUPPLY VOLTAGE.................................................................................................................. 2.67 SCRUBBER FILTER BYPASSED...................................................................................................................... 2.65 STEERING SLIDER SWITCH VOLTAGE LOW................................................................................................ 2.66 SWING CHARGE FILTER BYPASSED............................................................................................................. 2.65 WATER IN FUEL – SPN 17429............................................................................................................................ 2.68 MESSAGES – CRITICAL........................................................................................................................................ 2.54 LIST OF MESSAGES.......................................................................................................................................... 2.55 AFTERTREATMENT SYSTEM ENGINE IDLE TOO LONG............................................................................ 2.60 AFTERTREATMENT SYSTEM TECHNICAL FAILURE................................................................................... 2.59 ENGINE COOLANT LEVEL LOW...................................................................................................................... 2.56 ENGINE COOLANT TEMPERATURE HIGH.................................................................................................... 2.58 ENGINE COOLANT TEMPERATURE HIGH – ENGINE DERATE................................................................... 2.56 ENGINE FAULT CODE MESSAGES – CRITICAL............................................................................................. 2.58 ENGINE LOCKED OUT...................................................................................................................................... 2.60 ENGINE OIL PRESSURE LOW......................................................................................................................... 2.58 ENGINE OIL PRESSURE LOW – ENGINE DERATE........................................................................................ 2.57 ENGINE OIL TEMPERATURE HIGH................................................................................................................. 2.58 ENGINE STARTS REMAINING UNTIL ENGINE LOCKOUT........................................................................... 2.60 HARDWARE FAULT............................................................................................................................................ 2.57 HYDRAULIC OIL LEVEL LOW........................................................................................................................... 2.57 HYDRAULIC OIL TEMPERATURE HIGH......................................................................................................... 2.57 2.2

Tigercat 2160 Loader Forwarder

Controls and Operation

MAIN FUEL FILTER CLOGGED – ENGINE DERATE....................................................................................... 2.56 PUMP DRIVE GEARBOX TEMPERATURE HIGH........................................................................................... 2.57 MESSAGES – ERROR............................................................................................................................................ 2.61 COMPUTER MODULE BLANK SCREEN......................................................................................................... 2.62 CURRENT OUTPUT ERROR (COUT).............................................................................................................. 2.62 DIGITAL INPUT ERROR (DIN)........................................................................................................................... 2.62 DIGITAL OUTPUT ERROR (DOUT).................................................................................................................. 2.62 MODULE NO CONTACT ERROR...................................................................................................................... 2.61 MODULE VREF ERROR.................................................................................................................................... 2.61 VOLTAGE INPUT ERROR (VIN)........................................................................................................................ 2.62 USB PORT.............................................................................................................................................................. 2.21 COMPUTER DISPLAY.............................................................................................................................................. 2.21 D

DIFFERENTIAL LOCKS............................................................................................................................................ 2.14

E

EMERGENCY EXIT................................................................................................................................................... 2.24 EMERGENCY STOP SWITCH................................................................................................................................. 2.21 ENGINE BLOCK HEATER (OPTIONAL).............................................................................................................................. 2.82 COOLANT SHUT-OFF VALVE.............................................................................................................................. 2.28 IDLE SPEEDS........................................................................................................................................................ 2.18 RESTARTING AFTER ENGINE RUNS OUT OF FUEL....................................................................................... 2.85 STARTING.............................................................................................................................................................. 2.81 STOPPING.............................................................................................................................................................. 2.85

F

FAN CONTROL SWITCH (ENGINE COOLING)..................................................................................................... 2.20 FILTERS CAB AIR.................................................................................................................................................................. 2.27 FIRE EXTINGUISHER.............................................................................................................................................. 2.27 FIRST AID KIT STORAGE........................................................................................................................................ 2.27 FUEL HEATER........................................................................................................................................................... 2.81

H

HEAT AND AIR CONDITIONING CONTROLS........................................................................................................ 2.22 HORN......................................................................................................................................................................... 2.21 HYDRAULIC OIL TANK HEATER (OPTIONAL)...................................................................................................... 2.82

L

LIGHTS INTERIOR CAB...................................................................................................................................................... 2.22 SERVICE................................................................................................................................................................. 2.19 WORK...................................................................................................................................................................... 2.19 LOADING/UNLOADING OPERATIONS.................................................................................................................. 2.87

M

MACHINE PREPARATION....................................................................................................................................... 2.86 SYSTEM TEST AND WARM-UP........................................................................................................................... 2.86 MANUAL CASE, OPERATOR'S............................................................................................................................... 2.27

O

OPERATING THE MACHINE................................................................................................................................... 2.73 OSCILLATION LOCK................................................................................................................................................ 2.14

P

PARKING BRAKE...................................................................................................................................................... 2.19 PICTOGRAMS............................................................................................................................................................. 2.5 PILOT INTERLOCK RESET SWITCH..................................................................................................................... 2.18 PRESTART CHECKS................................................................................................................................................ 2.73

R

2.3

Controls and Operation

Tigercat 2160 Loader Forwarder

RADIOS AM/FM STEREO RADIO/CD................................................................................................................................. 2.22 CB RADIO............................................................................................................................................................... 2.22 REFUELLING............................................................................................................................................................. 2.72 S

SEAT, OPERATOR'S................................................................................................................................................. 2.29 ADJUSTMENTS..................................................................................................................................................... 2.29 CLIMATE CONTROL SWITCHES......................................................................................................................... 2.30 PROBLEMS AND CORRECTIVE ACTIONS........................................................................................................ 2.31 STAKES...................................................................................................................................................................... 2.80 STARTING ENGINE.................................................................................................................................................. 2.81 COLD WEATHER STARTING............................................................................................................................... 2.82 SWITCHES AIR CONDITIONER/HEATER............................................................................................................................... 2.22 EMERGENCY STOP.............................................................................................................................................. 2.21 ENGINE SPEED..................................................................................................................................................... 2.18 FAN CONTROL, ENGINE...................................................................................................................................... 2.20 FAN SPEED, A/C-HEATER.................................................................................................................................... 2.22 HORN...................................................................................................................................................................... 2.19 IGNITION KEY, ENGINE START........................................................................................................................... 2.21 INTERIOR CAB LIGHT.......................................................................................................................................... 2.17 PARKING BRAKE................................................................................................................................................... 2.19 PILOT INTERLOCK RESET.................................................................................................................................. 2.18 SEAT CLIMATE CONTROL................................................................................................................................... 2.31 SERVICE LIGHTS.................................................................................................................................................. 2.19 SWING BRAKE....................................................................................................................................................... 2.19 TEMPERATURE, A/C-HEATER............................................................................................................................. 2.22 VACUUM, HYDRAULIC TANK.............................................................................................................................. 2.17 WINDSHIELD WIPER/WASHER........................................................................................................................... 2.22 WORK LIGHTS....................................................................................................................................................... 2.19

T

TELEMATICS SYSTEM............................................................................................................................................ 2.24 TRAVELLING WITH A LOAD......................................................................................................................................................... 2.88 WITHOUT A LOAD................................................................................................................................................. 2.88

U

USB PORT, COMPUTER.......................................................................................................................................... 2.21

V

VACUUM SWITCHES, HYDRAULIC TANK............................................................................................................. 2.17

W

WAGON COMPONENTS.......................................................................................................................................... 2.79 WINDOWS................................................................................................................................................................. 2.24 WINDSHIELD WASHER FLUID BOTTLE............................................................................................................... 2.28

2.4

Tigercat 2160 Loader Forwarder

Controls and Operation

PICTOGRAM DESCRIPTIONS

= Boom OUT

Diagrams in pictorial form are used to represent machine function operation. They are a simple universal language of symbols or pictograms that illustrate a function or component without the use of words.

= Brake

Examples of these pictograms are the turtle and the rabbit that are often used to describe speed such as SLOW = or FAST = .

= Brake Pedal

= 12V, Auxiliary Power Outlet

= Check, Visually

= 24V, Auxiliary Power Outlet

P

P

= Control Lever Multiple Direction

= Adjustment Menu = Control Lever One Direction = Air Conditioner ON

= Control Lever Two Direction = Critical Message Symbol

= Air Conditioner OFF

= Defrost, Front Window = Air Source FRESH AIR = Diesel Exhaust Fluid (DEF) Tier 4f machines only = Air Source RECIRCULATE = Differential Lock PEDESTAL FRAME AXLE

= Alert Message Symbol = Battery CONNECT

= Differential Lock WAGON FRAME AXLE

= Battery DISCONNECT = Differential Locks PEDESTAL FRAME AND WAGON FRAME AXLES

= Boom DOWN

= Drive Motor Speed

= Boom UP

= Drive Pressure FORWARD

= Boom IN

2.5

Controls and Operation

Tigercat 2160 Loader Forwarder

= Drive Pressure REVERSE

= Engine PERCENTAGE OF LOAD

= Engine Anti Stall

= Engine RUN

= Engine Anti Stall ON

= Engine Speed (rpm)

= Engine Anti Stall OFF

= Engine START

= Engine Boost Pressure = Engine STOP = Engine Charge Air Pressure = Engine WAIT TO START = Engine Charge Air Pressure Filter (Engine Air Intake Filter Restriction)

= Engine WARNING

= Engine Charge Air Temperature = Fan AUTO REVERSING/CLEANING = Engine Cold Idle Function = Fan FULL ON

= Engine Coolant Temperature

= Fan REVERSE/CLEAN

= Engine Diagnostics = Engine Emission Filter

= Fan Speed

= Engine Emission Filter OFF = Fan, Ventilation Blower or

= Engine Emission System Temperature

= Flow Adjustment

= Engine Menu = Fluid Level HIGH = Engine Oil Pressure = Fluid Level LOW = Engine Oil Temperature

2.6

Tigercat 2160 Loader Forwarder

Controls and Operation

= Foot Pedal Control

= Horn

= Fuel Consumption Rate

= Hours MACHINE

= Fuel, Diesel

= Hours ENGINE

= Fuel Heater

= Hydraulic Oil Case Drain

= Fuel Information = Hydraulic Oil Filter Restriction = Fuel Reset and Trip Fuel Information = Hydraulic Oil Grade

= Fuel TEMPERATURE = Fuel WATER IN FUEL

= Hydraulic Oil Level

= Fuel Level LOW

= Hydraulic Oil Level LOW

= Grapple CLOSE

= Hydraulic Oil PRESSURE

= Grapple OPEN

= Hydraulic Oil RETURN

= Grapple ROTATE CLOCKWISE

= Hydraulic Oil Tank

= Grapple ROTATE COUNTERCLOCKWISE

= Hydraulic Oil TEMPERATURE

= Hydraulic Oil TEMPERATURE HIGH

= Grapple Tilt DOWN

= Hydraulic System Pressure LOAD SENSE

= Grapple Tilt UP

= Hydraulic Oil Tank Vacuum = Grapple Tilt FLOAT = Imperial/Metric Toggle Symbol

2.7

Controls and Operation

Tigercat 2160 Loader Forwarder = Remote Hydraulic Cylinder EXTEND

= Information Menu Icon

= Remote Hydraulic Cylinder RETRACT = Information Message Symbol = Saw, Grapple, CUT = Information – More Symbol

= Serial Number = Speed CREEP or VERY SLOW

= Instrument Test

= Speed FAST or HIGH

= Joystick and Switches

= Speed SLOW or LOW = Lights SERVICE

= Steer RIGHT

= Lights INTERIOR (Cab) = Lights REAR

= Steer LEFT

= Lights WORK

= Swing brake

= Oil Cooler BYPASS = Swing CLOCKWISE = Operator

= Swing COUNTERCLOCKWISE = Switch ON

= Oscillation Lock

= Switch OFF

= Parking Brake

= Telematics

= Pilot System ON (Reset)

= Telematics, Connectivity = Pilot System OFF

= Telematics, Messages Sent/ Recorded

= Pump Drive Gearbox Temperature 2.8

Tigercat 2160 Loader Forwarder

Controls and Operation

= Telematics, Latitude = Telematics, Longitude

= Temperature

= Travel Direction

= Travel Direction PEDESTAL

= Travel Direction WAGON

= Travel Speed

= Transmission

= Transmission Oil Level

= Transmission Temperature = Vacuum = Variable Speed = Ventilation Blower Fan = Windshield Washer

2.9

Controls and Operation

Tigercat 2160 Loader Forwarder

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.

JOYSTICK CONTROLS – MACHINES WITH T-BAR (FOOT) SWING NOTE: All joystick and foot pedal controls require the pilot system to be activated for the controls to function. Refer to PILOT INTERLOCK RESET SWITCH in THIS SECTION.

JOYSTICK – LEFT A

B

JOYSTICK SWITCHES AND BUTTONS MACHINE DIRECTION ROCKER SWITCH • Press the TOP button on the rocker switch to drive the machine in the direction of the PEDESTAL frame.

• Press the BOTTOM button on the rocker switch to drive the machine in direction of the WAGON frame.

• Position both buttons of the rocker switch UP to set the transmission in NEUTRAL. TRAVEL SPEED CONTROL SLIDER SWITCH • Push the slider FORWARD to INCREASE machine travel speed.

• Ease the slider BACK to DECREASE machine travel speed.

2000209

A Machine Direction Rocker Switch B Travel Speed Control Slider Switch

NOTE: The travel speed control slider switch performs the same function as the travel speed control pedal.

85464BUNI 85464BUNI R0R0 CONTROLS Refer to CAB CONTROLS – FOOT PEDAL in THIS SECTION.

MAIN BOOM – UP/DOWN • Move the joystick BACK to raise the main boom UP. • Move the joystick FORWARD to lower the main boom DOWN.

GRAPPLE – OPEN/CLOSE • Move the joystick to the LEFT to OPEN the grapple arms.

• Move the joystick to the RIGHT to CLOSE the grapple arms.

2.10

Tigercat 2160 Loader Forwarder JOYSTICK – RIGHT

Controls and Operation JOYSTICK SWITCHES AND BUTTONS

A

STEERING SLIDER SWITCH

B

• Slide the switch to the LEFT or RIGHT to articulate the pedestal and wagon in the desired direction.

C

DIFFERENTIAL LOCK BUTTON– PEDESTAL FRAME AXLE • Press and release the button to turn ON the pedestal frame axle differential lock to provide driving torque to all pedestal frame axle wheels.

D

• Press and release the button again to turn OFF. DIFFERENTIAL LOCK BUTTON – WAGON FRAME AXLE • Press and release the button to turn ON the wagon frame axle differential lock to provide driving torque to all wagon frame axle wheels.

• Press and release the button again to turn OFF.

2000208

85464BUNI R0 Differential Lock Button – Wagon Frame 85464BUNI R0 Axle

A B Differential Lock Button – Pedestal Frame Axle C Oscillation Lock Button D Steering Slider Switch

OSCILLATION LOCK BUTTON • Press and release the button to turn ON the oscillation lock.

STICK BOOM – IN/OUT

• Press and release the button again set oscillation to AUTO mode.

• Move the joystick BACK to move the stick boom OUT away from the machine.

• Move joystick FORWARD to move the stick boom IN toward the machine.

GRAPPLE – ROTATE • Move the joystick to the RIGHT to rotate the grapple CLOCKWISE. • Move the joystick to the LEFT to rotate the grapple COUNTERCLOCKWISE.

2.11

Controls and Operation

Tigercat 2160 Loader Forwarder

JOYSTICK CONTROLS– MACHINES WITH JOYSTICK SWING AND STEERING (ISO BOOM CONTROL) NOTE: All joystick and foot pedal controls require the pilot system to be activated for the controls to function. Refer to PILOT INTERLOCK RESET SWITCH in THIS SECTION.

JOYSTICK – LEFT A

B

JOYSTICK SWITCHES AND BUTTONS MACHINE DIRECTION ROCKER SWITCH • Press the TOP button on the rocker switch to drive the machine in the direction of the PEDESTAL frame.

• Press the BOTTOM button on the rocker switch to drive the machine in direction of the WAGON frame.

• Position both buttons of the rocker switch UP to set the transmission in NEUTRAL.

C

TRAVEL SPEED CONTROL SLIDER SWITCH • Push the slider FORWARD to INCREASE machine travel speed.

• Ease the slider BACK to DECREASE machine travel speed.

NOTE: The travel speed control slider switch performs the same function as the travel speed control pedal. Refer to CAB CONTROLS – FOOT PEDAL CONTROLS in THIS SECTION.

2000209

A Machine Direction Rocker Switch B Travel Speed Control Slider Switch C Grapple OPEN/CLOSE Slider Switch

MAIN BOOM – UP/DOWN • Move the joystick BACK to raise the main boom UP.

GRAPPLE OPEN/CLOSE SLIDER SWITCH • Push the slider LEFT to OPEN the grapple arms.

• Push the slider RIGHT to CLOSE the grapple arms.

• Move the joystick FORWARD to lower the main boom DOWN.

SWING • Move the joystick to the LEFT to SWING the upper structure COUNTERCLOCKWISE. • Move the joystick to the RIGHT to SWING the upper structure CLOCKWISE. NOTE: Swing brake must be turned OFF to perform swing functions. Refer to SWITCHES – SWING BRAKE in THIS SECTION.

2.12

Tigercat 2160 Loader Forwarder JOYSTICK – RIGHT

Controls and Operation JOYSTICK SWITCHES AND BUTTONS

A

DIFFERENTIAL LOCK BUTTON– PEDESTAL FRAME AXLE • Press and release the button to turn ON the pedestal frame axle differential lock to provide driving torque to all pedestal frame axle wheels.

B C

• Press and release the button again to turn OFF.

D

DIFFERENTIAL LOCK BUTTON – WAGON FRAME AXLE

E

• Press and release the button to turn ON the wagon frame axle differential lock to provide driving torque to all wagon frame axle wheels.

• Press and release the button again to turn OFF. OSCILLATION LOCK BUTTON • Press and release the button to turn ON the oscillation lock.

2000208

A B C D E

Differential Lock Button – Wagon Frame Axle Differential Lock Button – Pedestal Frame Axle Oscillation Lock Button Grapple Rotate COUNTERCLOCKWISE Grapple Rotate CLOCKWISE

• Press and release the button again set oscillation to AUTO mode.

GRAPPLE ROTATE COUNTERCLOCKWISE BUTTON • Press and hold the button to rotate the grapple COUNTERCLOCKWISE.

STICK BOOM – IN/OUT • Move the joystick FORWARD to move the stick boom OUT away from the machine.

GRAPPLE ROTATE CLOCKWISE BUTTON • Press and hold the button to rotate the grapple CLOCKWISE.

• Move joystick BACK to move the stick boom IN toward the machine.

STEERING • Move the joystick to the LEFT or RIGHT to articulate the pedestal and wagon in the desired direction.

2.13

Controls and Operation

Tigercat 2160 Loader Forwarder

DIFFERENTIAL LOCKS

OSCILLATION LOCK

This machine is equipped with 100% engagement differential locks in both the pedestal frame and wagon frame axles.

When the engine is running and the machine is NOT travelling, the centre joint oscillation between the wagon frame and pedestal frame is automatically locked to stabilize the machine during loading and unloading operations. This is the default mode when the machine is turned on.

IMPORTANT! Use differential locks sparingly for brief periods and ONLY when additional traction is required. Do not continuously drive the machine with differential locks turned on. Damage to the axles will result.

NOTE: Differential locks will automatically turn OFF two minutes after being turned on.

When machine travel is commenced, the centre joint oscillation is automatically unlocked.

The oscillation lock switch is used to lock the oscillation between the wagon frame and pedestal frame if additional machine stability is required when travelling.

WARNING A

Risk of machine roll over if the oscillation lock is off during loading or unloading operations.

2000119

A Differential Lock Icon – Pedestal Frame Axle ON

When the pedestal frame axle differential lock is turned ON, the pedestal frame axle differential lock icon on the computer display will illuminate green.

Machine instability is increased with a load in the grapple when the wagon is empty or near empty while steered and extending the boom.

WARNING Risk of machine roll over if the machine is positioned on uneven ground during loading or unloading operations.

A

TRAVELLING WITH OSCILLATION LOCK

2000120

A Differential Lock Icon – Wagon Frame Axle ON

When the wagon frame axle differential lock is turned ON, the wagon frame axle differential lock icon on the computer display will illuminate green.

A 2000118

A Oscillation Lock Icon – ON A 2000121

A Differential Lock Icon – Both Axles ON

The pedestal and wagon frame axle differential locks can be ON simultaneously if maximum driving torque is required.

When the oscillation lock is turned ON, the oscillation lock icon on the computer display will illuminate green.

NOTE: When the oscillation lock is engaged, the travel speed of the machine is automatically limited to 3.2 km/h (2 mph). If the oscillation lock button is pressed during travel, the oscillation lock will NOT engage until travel speed is reduced to 3.2 km/h (2 mph) or below.

NOTE: Both differential locks will automatically turn OFF two minutes after being turned on.

2.14

Tigercat 2160 Loader Forwarder

Controls and Operation

FOOT PEDAL CONTROLS – MACHINES WITH T-BAR SWING C

A

B

SERVICE BRAKE PEDAL Pressing the foot pedal applies the service brakes in both axles.

D

HOLDING BRAKE The holding brake feature automatically applies the service brakes when the machine comes to a complete stop. This feature may be turned OFF to avoid brake release delays in cold weather. Refer to COMPUTER– MAIN MENU – ADJUST MENU – HOLDING BRAKE in THIS SECTION.

2000359

A B C D

Service Brake Pedal Travel Speed Control Pedal Swing Counterclockwise (CCW) Swing Clockwise (CW)

NOTE: As a safety precaution use the service brake pedal to release pilot system pressure before working on or around the machine. Refer to RELEASE PILOT SYSTEM PRESSURE in SECTION 3.

TRAVEL SPEED CONTROL PEDAL Press the pedal to move the machine FORWARD or REVERSE. Travel speed is determined by how far the pedal is pressed.

The position of the foot pedal is directly proportional to the requested speed of the machine.

NOTE: The travel speed control pedal performs the same function as the travel speed control slider switch on the left joystick. Using the slider switch instead of the pedal permits swinging the boom while driving.

SWING Press the left side of the T-bar to SWING the upper structure COUNTERCLOCKWISE. Press the right side of the T-bar to SWING the upper structure CLOCKWISE. NOTE: Swing brake must be turned OFF to perform swing functions. Refer to SWITCHES – SWING BRAKE in THIS SECTION.

2.15

Controls and Operation

Tigercat 2160 Loader Forwarder

FOOT PEDAL CONTROLS – MACHINES WITH JOYSTICK SWING A

B

SERVICE BRAKE PEDAL Pressing the foot pedal applies the service brakes in both axles.

HOLDING BRAKE The holding brake feature automatically applies the service brakes when the machine comes to a complete stop. This feature may be turned OFF to avoid brake release delays in cold weather. Refer to COMPUTER– MAIN MENU – ADJUST MENU – HOLDING BRAKE in THIS SECTION.

2000371

A Service Brake Pedal B Travel Speed Control Pedal

NOTE: As a safety precaution use the service brake pedal to release pilot system pressure before working on or around the machine. Refer to RELEASE PILOT SYSTEM PRESSURE in SECTION 3.

TRAVEL SPEED CONTROL PEDAL Press the pedal to move the machine FORWARD or REVERSE. Travel speed is determined by how far the pedal is pressed.

The position of the foot pedal is directly proportional to the requested speed of the machine.

NOTE: The travel speed control pedal performs the same function as the travel speed control slider switch on the left joystick. Using the slider switch instead of the pedal permits swinging the boom while driving.

2.16

Tigercat 2160 Loader Forwarder

Controls and Operation

CONTROL PANEL – LEFT ARMREST

VACUUM SWITCH IN ENGINE COMPARTMENT

A

A

B

C

D

2000134

A B C D

Interior Cab Light Switch Vacuum Switch – Hydraulic Oil Tank Pilot Interlock Reset Switch Engine Speed Switch

The control panel is located in the left armrest on the seat. The following machine functions are controlled by switches located on this control panel:

2000159

A Vacuum Switch – Engine Compartment

This switch is located in the front engine compartment.

It is 'unswitched' and will function with the battery disconnect switch in the OFF position. Push the right side of the switch to put it in the ON position to activate the vacuum pump.

INTERIOR CAB LIGHT SWITCH This is a two-position switch to turn the interior cab light ON and OFF.

VACUUM SWITCH – HYDRAULIC OIL TANK The machine is equipped with a vacuum pump to 'hold' the oil in the hydraulic oil tank when work is being done on the hydraulic system. This eliminates the need to drain the hydraulic oil tank before servicing pumps and other hydraulic components.

This switch will NOT function if the battery disconnect switch is turned OFF. Push the top of the switch to put it in the ON position to activate the vacuum pump.

2.17

Controls and Operation

Tigercat 2160 Loader Forwarder

PILOT INTERLOCK RESET SWITCH This switch is used to turn ON the pilot system after it has been deactivated by raising the left armrest or by turning the ignition switch to the OFF position. This system prevents accidental or improper use of the controls from anywhere but the operator's seat.

NOTE: When the left armrest is raised the parking brake is automatically applied.

Press and hold this switch in the bottom position to decrease engine speed. Release switch at desired speed or continue to hold to set engine speed to LOW.

MAINTAINING CORRECT ENGINE SPEED It is important the LOW and HIGH speeds of the engine be correct at all times.

LOW • Pilot System OFF: 900 rpm • Pilot System ON: 1400 rpm

C

B 2000117

2000116

A Pilot System OFF (Yellow) B Pilot System ON (Green)

With the engine running, push the left armrest down and press and release the pilot interlock reset switch to turn ON the pilot system. The Pilot System On icon on the computer display will change from YELLOW to GREEN.

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

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

WARNING The pilot interlock switch (Refer to PILOT INTERLOCK SWITCH in SECTION 1) and the pilot interlock reset switch are safety features and their function must not be defeated in any way.

ENGINE SPEED SWITCH

When the pilot interlock reset switch is pressed, the engine speed will automatically increase to 1400 rpm. This engine speed is adequate for most loading functions.

When the pilot system is deactivated by raising the left armrest, engine speed will automatically reset to 900 rpm.

NOTE: At start-up with the pilot system OFF, engine speed defaults to 900 rpm.

HIGH • 2100 rpm max. (No Load) The above speeds are with the hydraulic oil and engine oil at normal operating temperatures and no functions activated. These values are preset into the engine ECU and cannot be adjusted without the proper electronic programming software equipment.

NOTE: Engine speed will increase above set speed if additional power is required when the travel speed controls are being operated. When travel speed is reduced, engine speed will return to the set speed.

AUTO IDLE DOWN If engine speed is set to run above LOW and no functions are activated for 10 seconds (factory default), engine speed will automatically return to LOW. The engine will return to the selected speed when a function is activated.

This is a momentary switch used to decrease or increase engine speed between the LOW and HIGH speed set points.

Refer to COMPUTER – MAIN MENU – IDLE DOWN WAIT TIME in THIS SECTION to adjust the idle down wait time.

NOTE: Press the pilot interlock reset switch before increasing engine speed.

NOTE: During cold weather the computer limits HIGH speed until the hydraulic oil has reached a specific temperature based on the hydraulic oil grade selected.

Refer to COLD WEATHER STARTING in THIS SECTION.

Press and hold this switch in the top position to increase engine speed. Release switch at desired speed or continue to hold to set engine speed to HIGH.

2.18

Tigercat 2160 Loader Forwarder

Controls and Operation

CONTROL PANELS – RIGHT ARMREST

The control panels are located in the right armrest on the seat. The following machine functions are controlled by switches located on this control panel:

HORN SWITCH Press this switch to sound the horn.

PARKING BRAKE SWITCH D

This is a two-position switch that manually applies the parking brake.

A C

2000135

E

2000156

F

A Parking Brake Icon – ON (Red)

Press the top of the switch (ON) to apply the parking brake. The parking brake icon on the computer display will illuminate RED.

B

Press the bottom of this switch (OFF) to release the parking brake.

SWING BRAKE SWITCH A

2000136

A B C D E F

Horn Switch Parking Brake Switch Fan Control Switch Swing Brake Switch Service Lights Switch Work Lights Switch

This is a two position ON/OFF switch. Place this switch in the ON position to apply the swing brake and prevent the upper structure from turning.

The swing brake is also automatically applied when the pilot system is deactivated (left armrest in the raised position) or when the swing has not been activated for four seconds.

As an added safety precaution, apply the swing brake with this switch before leaving the cab.

SERVICE LIGHTS SWITCH This switch controls the service light located in the engine compartment.

WORK LIGHTS SWITCH This switch controls the work lights located on the front of the cab, the left side and rear of the upper structure, the stick boom and the wagon and pedestal frames.

2.19

Controls and Operation

Tigercat 2160 Loader Forwarder

FAN CONTROL SWITCH A B C

NOTE: When the switch is in the AUTO 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.

FULL ON POSITION 724G-011

A Full ON B Auto C Clean (Purge)

This is a three-position momentary switch, FULL ON/ AUTO/CLEAN. This switch controls the operation of the Flexxaire® variable-pitch cooling fan.

The cooling fan blade pitch is hydraulically varied to control the flow and direction of air through the cooler package.

AUTO POSITION

A

A 2000123

A Fan Icon – 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 AUTO position for optimal cooling. The FULL ON position is intended for use in the event of a temporary failure of the control system.

CLEAN POSITION

2000087

A Fan Icon – Auto Position

AUTO is the normal operating position for the fan control switch. When the switch is in the AUTO position, the fan will operate completely in automatic mode. The computer control system will automatically control the fan pitch to minimize system energy losses and improve performance 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 the 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 cooler package and air conditioning systems. In low temperature operating conditions fan air flow is reduced, as less cooling is required for efficient operation of the cooler package.

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

The fan auto clean cycle is adjustable through the computer control system menu. Refer to COMPUTER – MAIN MENU – ADJUST MENU – FAN AUTO CLEAN in THIS SECTION.

A 2000122

A Fan Icon – 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 by overheating. Ensure 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.

It is also important to manually clean debris from the machine on a regular basis to maintain low machine operating temperatures. Refer to CLEANING COOLER PACKAGE in SECTION 3.

2.20

Tigercat 2160 Loader Forwarder

Controls and Operation

MAIN CONSOLE

IGNITION KEY SWITCH This is a 3-position switch with STOP/RUN/START positions.

F

E

G

STOP POSITION All electrical power through the ignition key switch is turned OFF. Electrical power is still available for the horn, auxiliary power, 2-way radio, cab dome light, work lights and service lights.

RUN POSITION

D C

A

The batteries are connected to all functions. Used for normal machine operation.

START POSITION Turn the switch to this position to start the engine. The batteries are connected to the start relay. The switch will return to RUN position when released.

12 VOLT AUXILIARY POWER B 234B-013

A B C D E F G

Emergency Stop Switch Ignition Key Switch 12 Volt Auxiliary Power Mobile Device Holder Computer Display USB Port– Computer Radio Auxiliary IN Port (On Console Behind Computer Display)

Two 12 volt outlets with 20 A capacity for portable devices such as phones.

MOBILE DEVICE HOLDER An adjustable mobile device holder.

COMPUTER DISPLAY Refer to COMPUTER CONTROL SYSTEM in THIS SECTION for more details.

EMERGENCY STOP SWITCH

USB PORT – COMPUTER

Press the emergency stop switch DOWN, to immediately turn OFF all electrical power and turn OFF the engine and hydraulic systems.

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

The parking brake is automatically applied when the emergency stop switch is pressed.

IMPORTANT! This USB connection is to be used only by a trained service technician.

To turn the power back ON, turn the knob clockwise and allow it to pop back up.

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

RADIO AUXILIARY IN PORT Port to plug auxiliary devices into the radio.

2.21

Controls and Operation

Tigercat 2160 Loader Forwarder

OVERHEAD CONSOLE – RIGHT A

B

C

A

D

234B-011

A B C D

HEAT AND AIR CONDITIONING CONTROLS

CB Radio (Optional) Interior Cab Light AM/FM Stereo Radio/CD Windshield Wiper/Washer Switch

CB RADIO Refer to the manufacturer's manual for operation instructions.

B

C

234B-011

A Fan Speed Rotary Switch B Temperature Rotary Switch C Air Conditioner Switch

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

FAN SPEED ROTARY SWITCH

INTERIOR CAB LIGHT

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

The interior cab light is turned ON or OFF by the switch in the left armrest control panel.

TEMPERATURE CONTROL ROTARY SWITCH

Refer to the manufacturer's manual for operation instructions.

This is a variable, rotary switch to adjust the air temperature of the cab by controlling the flow of engine coolant through the heater core. Make sure this control is set to the MAX COLD position when using the air conditioning.

WINDSHIELD WIPER/WASHER SWITCH

AIR CONDITIONER (A/C) SWITCH

The wiper/washer rotary switch controls the windshield wiper. Turn the dial one setting clockwise, to operate wiper on intermittent speed which is adjustable.

This is a 2-position ON/OFF power switch.

AM/FM STEREO RADIO/CD

Turn the dial a setting further clockwise to set the wiper to low speed. Turn the dial a setting further clockwise to set 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 and hold the dial.

This function sprays washer fluid on the windshield.

2.22

Tigercat 2160 Loader Forwarder

Controls and Operation

OVERHEAD CONSOLE – FRONT

A

B

234-107

A Alarm Light B Master Alarm

ALARM LIGHT The alarm light is a visual warning indicator that is activated by the computer system when a system fault occurs.

MASTER ALARM The master alarm is an audible warning indicator that is activated by the computer system when a system fault occurs.

NOTE: The computer will automatically perform a test at engine startup to ensure the alarm and light are functioning.

2.23

Controls and Operation

Tigercat 2160 Loader Forwarder

TELEMATICS SYSTEM

WINDOWS B A

234T-031

A Sliding Window Handle B Window Screen Hand Knob

The right window and cab door window slide to open.

To open, push on the handle and slide the window. To close, slide the window firmly until it stops and latch the handle to the frame.

Both windows are equipped with an exterior screen to provide personal protection of the operator. Each screen is held closed with two hand knobs, one inside the cab and one outside the cab. Removing either hand knob will open the window screen.

Telematics is a tool used by owners, operators, or service technicians to monitor a machine or fleet of machines. Monitoring the location, movements, fuel status, fault codes or a variety of other parameters is done using a web enabled device.

IMPORTANT! All window screen hand knobs should be hand-tight only at all times.

EMERGENCY EXIT

NOTE: Leave the ignition key switch in the RUN position for several minutes to allow the telematics module to fully power up after it has been powered off.

RIGHT SIDE WINDOW The right side window serves as an emergency exit if the side door exit becomes blocked.

Refer to TELEMATICS SYSTEM in SECTION 6 for additional information.

1. Turn OFF the engine before using this exit.

2. Push the sliding window handle and slide the window fully open.

3. Turn the inside hand knob counterclockwise and remove.

4. Push the window screen out.

B

234T-031

A

2000199

A Window Screen Hand Knob – Outside Cab B Window Screen Hand Knob – Inside Cab

2.24

Tigercat 2160 Loader Forwarder

CAMERAS

Controls and Operation VIDEO DISPLAY – CAMERAS

CAMERA 1 – WAGON FRAME

A B C D E

A

F 2000198

G

A Camera 1 – Wagon Frame

2000192

A digital wireless camera, mounted low on the end of the wagon frame provides the operator with a better view of obstacles beyond the wagon frame.

A B C D E F G

CAMERA 2 – UPPER STRUCTURE

Display Screen Power Camera Select Menu Selection Up Selection Down Light Sensor

Press the camera select button to display Camera 1 or Camera 2.

Press the menu button to display menu 1. Press and hold the menu button to display menu 2.

A

To change the language: 1. Press and hold the menu button to display menu 2.

2. Press the selection down button to highlight advanced menu 5.

3. Press the menu button to select it.

2000177

A Camera 2 – Upper Frame

A digital hard-wired camera, mounted above the rear engine compartment door provides the operator with a better view of obstacles behind the upper structure.

4. Press the menu button to select item 1 Language.

5. Select the language desired and press the menu button.

The light sensor automatically adjusts the monitor brightness.

NOTE: When the cab is facing away from the wagon, both cameras are facing the same direction.

2.25

Controls and Operation

Tigercat 2160 Loader Forwarder

CAMERA PAIRING PROCEDURE

RECEIVER CONTROLLER LED INDICATOR

If the wagon frame camera becomes unpaired, the camera video display will show the message 'Manual Pairing Required'.

B

Perform the following steps:

A

RECEIVER CONTROLLERS A

2000014

A Control Button B LED Indicator

• Red: Power on, NOT paired.

234B-011

A Receiver Controller Location – Heat and A/C Control Panel

The receiver controller(s) for the camera receiver(s) in the cab are mounted on the back of the Heat and Air Conditioning Controls panel located on the upper right side of the cab.

• Flashing green: Pairing in progress.

• Solid green: Pairing complete.

• Off: No power to transmitter.

Remove the six screws on the panel to gain access to the receiver controller(s).

CAMERA 1 INPUT – WAGON FRAME 1. Turn the key switch to the RUN position. The camera system will power up.

2. Press and hold the control button on the receiver controller until the LED indicator begins to flash green. When the pairing is complete the indicator will be solid green.

CAMERA 2 INPUT – UPPER STRUCTURE The upper structure camera is hard-wired and does not require pairing.

NOTE: The power connectors for the receivers are clearly identified with wire markers as 1 and 2.

2.26

Tigercat 2160 Loader Forwarder

CAB AIR FILTERS

A

Controls and Operation

FIRE EXTINGUISHER

B

A

234-093

A Air Conditioner Recirculation Filter B Cab Fresh Air Filter

Two filters are provided with the A/C heater unit. The A/C recirculation filter is located at the bottom of the A/C heater unit. The cab fresh air filter is located adjacent to the A/C heater unit.

Both filters require regular servicing. Refer to AIR CONDITIONING SYSTEM– CAB AIR FILTERS in SECTION 3.

CAB AIR VENTS

2000016

A Check Fire Extinguisher

A portable fire extinguisher is located in operator's cab.

Check the extinguisher daily to verify that it is charged.

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

FIRST AID KIT STORAGE A

B

A

234-094

A Air Vents

The heating and A/C unit has 10 ventilation outlets. Six are shown here, one is located under the seat and three at the bottom of the front windshield.

2000015

A First Aid Kit Storage Pouch B Manual and Document Storage Box

A storage pouch for a first aid kit is located on the inside of the cab door.

OPERATOR'S MANUAL CASE A manual and document storage box is located on the inside of the cab door.

2.27

Controls and Operation

Tigercat 2160 Loader Forwarder

ENGINE COOLANT SHUT-OFF VALVE

BATTERY DISCONNECT SWITCH

B A

A

2000159

2000052

A Hose to A/C Heater Unit B Engine Coolant Shut-Off Valve

A Battery Disconnect Switch – Front Engine Compartment

To maximize the efficiency of the air conditioning, the temperature control must be rotated to the MAX COLD position (fully counterclockwise). During times when cab heating is not required, close the coolant shut-off valve (on the heater hose from the engine) to prevent warm engine coolant from seeping through the A/C unit, thereby reducing the effect of the cooling.

The coolant shut-off valve is accessible through the engine compartment rear access door.

WINDSHIELD WASHER FLUID BOTTLE A

This switch is located just inside the engine compartment front access panel. In the OFF position (shown), it completely disconnects all electrical circuits (see notes below) on the machine from the batteries. It is good practice to turn this switch to OFF when the machine is left idle for an extended period of time, such as overnight.

IMPORTANT! Only use the battery disconnect switch to shut off a running machine in an emergency. A fault code will be logged by the engine ECU for improper shut down.

NOTE: On Tier 4 machines, when the engine is stopped, all DEF solution is pumped back to tank before the engine power system is turned OFF. This process takes approximately 90 seconds. Refer AFTERTREATMENT SYSTEM in SECTION 3.

NOTE: The aftertreatment system and its related components are applicable to Tier 4f machines only.

BATTERIES Two 12 volt batteries are located in the rear of the engine compartment. The batteries are wired in series to produce a 24 volt supply. Access to the batteries is through the engine compartment rear access door.

Refer to BATTERY BOOSTING in THIS SECTION and BATTERY CARE in SECTION 3 for more information.

2000210

A Windshield Washer Fluid Bottle

The bottle is located in the DEF tank compartment.

Loosen the hand knob and swing open the access cover on the front left of the upper structure. In cold climates, fill with an anti-freeze washer fluid. To avoid scratching the windshield, do not operate wipers on a dry windshield.

2.28

Tigercat 2160 Loader Forwarder

Controls and Operation

OPERATOR’S SEAT – AIR RIDE

A

A

B

B D

E

C

C

E

D

G

F

N

H

M

H

L

I

I

K J 2000413

A B C D E F G

Headrest Backrest Seat Belt, Lap and Shoulder Harness Left Armrest Right Armrest Backrest Angle Adjustment Lever Lumbar Horizontal Adjustment Lever

SEAT ADJUSTMENTS WARNING Use the lap and shoulder harness belt at all times when operating the machine. Failure to do so can result in death or serious injury.

HEIGHT ADJUSTMENT The spring-assisted height adjustment is controlled by the height adjustment control bar located on the front of the seat frame.

To raise the seat, lift up on the control bar while partially lifting body weight from the seat. When the seat is at the desired height, release the lever and sit down.

H I J K L M N

Armrest Fore/Aft Adjustment Wing-Bolt Handle Armrest Up/Down/Angle Adjustment Wing-Bolt Handle Seat Fore/Aft Slide Adjustment Lever Seat Climate Control Switches Air Ride Adjustment Knob Seat Height Adjustment Control Bar Seat Cushion

RIDE ADJUSTMENT After adjusting the seat height, the ride adjustment can be made by pulling or pushing the seat ride adjustment knob.

To stiffen the ride, push the knob to inflate the air spring to obtain the desired firmness.

To soften the ride, pull the knob to deflate the air spring to obtain the desired firmness.

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

To lower the height of the seat, lift up on the control bar while applying body weight to the seat. When the seat is at the desired height, release the lever and sit normally.

2.29

Controls and Operation

Tigercat 2160 Loader Forwarder

LUMBAR ADJUSTMENT

ARMREST ADJUSTMENT Each armrest has three adjustments to place it in the required position.

NOTE: The wing-bolt handles on the following adjustments can be pulled outwards and repositioned to work like a ratchet.

FORE AND AFT ADJUSTMENT

A

Loosen the armrest fore/aft adjustment wing-bolt handle to allow the armrest to slide forward or back.

UP, DOWN AND ANGLE ADJUSTMENT

B

Loosen the armrest up/down/angle adjustment wing-bolt handle to allow the armrest to slide up and down or to adjust the angle of the armrest.

C

WIDTH ADJUSTMENT

2000415

Right Side of Seat

A Lumbar Horizontal Adjustment Lever B Armrest Up/Down/Angle Adjustment Wing-Bolt Handle C Armrest Fore/Aft Adjustment Wing-Bolt Handle

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

A

BACK ANGLE ADJUSTMENT

B

A 2000416

B

C 2000414

Underside of Armrest

A Armrest (Right Shown) B Armrest Width Adjustment Bolts – Both Armrests

Loosen the two width adjustment bolts on the underside of the armrest with a 9/16 inch wrench to adjust the width and angle of the armrest in relation to the seat.

Left Side of Seat

A Backrest Angle Adjustment Lever B Armrest Up/Down/Angle Adjustment Wing-Bolt Handle C Armrest Fore/Aft Adjustment Wing-Bolt Handle

To place backrest at the desired angle, push down the backrest angle adjustment lever. Release the lever when the desired angle is reached.

2.30

Tigercat 2160 Loader Forwarder SEAT CLIMATE CONTROL SWITCHES A

B

Controls and Operation PROBLEMS AND CORRECTIVE ACTIONS RIDE IS 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 the height adjustment lever to raise the seat.

RIDES TOO SOFT OR BOTTOMS OUT AND PINCHES OPERATOR

200182

A Heater/Ventilation Switch B Low-Medium-High Switch

The seat is equipped with electric heating and venting modes. Two switches located at the front of the seat control these operations.

The heater/ventilation switch is a three-position switch.

The up position 'H' turns ON the seat heater and the down position 'V' turns ON the seat vent. The middle position turns OFF seat climate control.

The low-medium-high switch is a three-position switch that adjusts the heat level or ventilation fan speed depending on the mode selected on the heater/ ventilation switch.

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.

SEAT TOO HIGH/SEAT TOO LOW There are several things which can cause improper seat height. Adjust the seat to the desired position. If the proper height cannot be reached using one of the 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 too low into the seat.

2.31

Controls and Operation

Tigercat 2160 Loader Forwarder

COMPUTER CONTROL SYSTEM

A

B

234-107

J

K

C

2000075

A B C D E F

F

G

H

I

UP Arrow Button OK Button DOWN Arrow Button Menu Button Back Button F1 Button

E

D G H I J K

F2 Button F3 Button F4 Button Alarm Light – Front Overhead Console Master Alarm – Front Overhead Console

Navigation buttons that are used to scroll through selections on a menu page.

The buttons are configured by program software to bring up a display screen, bring up an adjustment group or act as a virtual input.

A

• OK button.

Pushing this button equals 'Enter'. It saves the value or confirms the selection you have made.

• Menu button.

Displays the Main menu. It is not programmable.

234B-013

A Computer Display

• Back button.

The computer and display is the operator interface with the electronic control system. The computer is the central unit in the control system that functions as both a master controller and a display unit.

The front of the computer consists of a control panel with a display and nine buttons:

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

• F1 – F4 function buttons.

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

• UP and DOWN arrow buttons.

2.32

Tigercat 2160 Loader Forwarder

Controls and Operation

COMPUTER DISPLAY MAIN SCREEN A

B

C

D

E

F

G

H

I

L

M

J

N

O

K

P

Q

R

S

2000076

A B C D E F G H I J

Pilot System – ON/OFF Anti Stall – ON/OFF Cold Idle Function Indicator Hydraulic Oil Return Filter Bypass * Engine Air Intake Filter Restriction Fan Indicator – AUTO/FULL ON/CLEAN Parking Brake – ON/OFF Differential Locks – ON/OFF Oscillation Lock – ON/Auto Engine Speed – rpm

K L M N O P Q R S

Engine Coolant Temperature Gauge *** Fuel Level Gauge ** DEF Level Indicator Hydraulic Oil Temperature Gauge *** Hydraulic Oil Grade Engine Menu – Press F1 to Select Adjustment Menu – Press F2 To Select Information Menu – Press F3 To Select Alarm Indicators – Press F4 To Select

* HYDRAULIC OIL RETURN FILTER BYPASS

** FUEL LEVEL GAUGE SYMBOL

GREY – Hydraulic oil is not bypassing return filters.

YELLOW– Fuel level is low.

YELLOW– Hydraulic oil is below operating temperature and is bypassing return filters. Allow hydraulic oil to warm to operating temperature.

*** TEMPERATURE GAUGE SYMBOL

RED – Hydraulic oil is at operating temperature and is bypassing return filters. STOP the machine and change the return filters immediately.

Refer to FILTERS– HYDRAULIC OIL RETURN in SECTION 3 for more information.

BLUE – Temperature range is LOW. WHITE– Temperature range is NORMAL. RED – Temperature range is HIGH. IMPORTANT! To prevent damage to the machine, do not run the attachment circuit or work the machine hard when the hydraulic oil temperature gauge symbol is BLUE. 2.33

Controls and Operation

Tigercat 2160 Loader Forwarder

ENGINE MENU

The engine functions displayed are: Charge Air Temperature – °C or °F Engine Coolant Temperature – °C or °F Engine Oil Temperature – °C or °F Fuel Temperature – °C or °F Engine Speed – rpm Turbocharger Boost Pressure – kPa or psi Engine Oil Pressure – kPa or psi Engine Load – %

2000087

Engine Hours – h

Press the F1 button from the main screen to select the Engine menu.

Battery Voltage – V Fuel Rate – US gph or L/h (instantaneous) Press the back button to return to the main screen.

2000124

2.34

Tigercat 2160 Loader Forwarder

Controls and Operation

ENGINE FUNCTIONS

CHARGE AIR TEMPERATURE This display indicates the charge air temperature reading.

If temperature rises above the recommended temperature a message is sent to the computer display and an alarm will sound. Check for the following: • Plugged cooler package access door screen.

• Plugged charge air cooler.

Do not continue to operate the machine.

Refer to CLEANING COOLER PACKAGE in SECTION 3 and COMPUTER – MESSAGES in THIS SECTION. 2000124

ENGINE COOLANT TEMPERATURE This display indicates the current engine coolant temperature.

If temperature rises above the recommended temperature a message is sent to the computer display and an alarm will sound. Check for the following: • Plugged cooler package access door screen.

• Plugged radiator.

Do not continue to operate machine Refer to CLEANING COOLER PACKAGE in SECTION 3 and COMPUTER – MESSAGES in THIS SECTION. A

B

C

A Engine Temperature Low B Engine Temperature Normal C Engine Temperature High

NOTE: Coolant temperature can also be monitored using the engine coolant temperature gauge on the main screen. The changes in gauge symbol colour indicate temperature range (BLUE=low, WHITE=normal, RED=high).

2.35

Controls and Operation

Tigercat 2160 Loader Forwarder ENGINE LOAD

ENGINE OIL TEMPERATURE This display indicates the current engine oil temperature.

If temperature rises above the recommended temperature a message is sent to the computer display and an alarm will sound. Check for the following: • Plugged cooler package access door screen.

• Plugged radiator.

This display indicates the percentage of maximum engine load currently in use.

ENGINE HOURS This display indicates the total number of hours the engine has run.

VOLTAGE

Do not continue to operate machine.

IMPORTANT!

Refer to CLEANING COOLER PACKAGE in SECTION 3 and COMPUTER – MESSAGES in THIS SECTION. FUEL TEMPERATURE This display indicates the fuel temperature.

ENGINE SPEED This display indicates engine speed in rpm.

24 VOLT ELECTRICAL SYSTEM This display indicates engine voltage levels.

Normal operating range for the electrical system is between 20 and 30 volts.

If the engine voltage goes outside the normal range a message is sent to the computer display and an alarm will sound.

Refer to COMPUTER – MESSAGES in THIS SECTION. A reading in excess of 30 volts indicates a possible faulty voltage regulator.

A reading less than 20 volts indicates a possible faulty battery or alternator.

FUEL RATE (INSTANTANEOUS)

NOTE: Engine speed can also be monitored using the engine speed gauge (tachometer) shown on the main screen.

This display indicates the current rate of fuel consumption.

Refer to SWITCHES– ENGINE SPEED in THIS SECTION for speed settings.

TURBOCHARGER BOOST PRESSURE This display indicates air intake manifold boost pressure. This reading is an absolute value and includes atmospheric pressure.

ENGINE OIL PRESSURE This display indicates engine oil pressure.

If oil pressure falls too low a message is sent to the computer display and an alarm will sound.

Refer to COMPUTER – MESSAGES in THIS SECTION.

2.36

Tigercat 2160 Loader Forwarder

Controls and Operation

COLD IDLE FUNCTION

UNITS OF MEASURE

A

2000077

A Cold Idle Function Indicator

Press the F1 button to turn the cold idle function ON or OFF.

2000124

Press the F3 button to toggle between metric and Imperial units of measure.

The cold idle function indicator will illuminate YELLOW on the computer display when the cold idle function is turned ON.

ANTI STALL

2000078

Press the F2 button to access the Anti Stall ON/OFF selection. Press the UP or DOWN arrow buttons to turn Anti Stall ON or OFF. Press the OK button to confirm the selection.

2.37

Controls and Operation

Tigercat 2160 Loader Forwarder

ADJUSTMENT MENU

HYDRAULIC OIL GRADE SELECTION

2000087

Press the F2 button from the main screen to select the Adjustment menu.

2000080

Press the F2 button to select the Oil Grade menu.

Press the UP or DOWN arrow buttons to select the desired hydraulic oil grade.

Press the OK button to confirm the selection.

Press the back button to return to the main screen.

2000079

The adjustment selections are: Hydraulic Oil Grade Selection

2.38

Tigercat 2160 Loader Forwarder

Controls and Operation

INFORMATION MENU

ADDITIONAL INFORMATION SCREEN

A

B

C

D

E

2000082

2000087

A B C D E

Press the F3 button from the main screen to access the Information menu.

Engine Load Indicator – % Travel Speed – Km/h or MPH Trip Distance – Km or miles Fuel Rate (Instantaneous) – L/h or US gph Fuel Consumption; (Trip) – L/h or US gph

The additional information screen provides a second level of digital readout gauges that can be used to instantaneously monitor machine functions when travelling.

Press the F1 button to toggle between metric and Imperial units of measure.

Press the F2 button to reset the trip average fuel rate and trip fuel used functions.

Press the F3 button to display the Telematics information.

2000081

When selected, the information functions displayed are: Serial Number Machine Hours – h Hydraulic Oil Temp – °C or °F Hydraulic Oil Pressure, Load Sense Total Fuel Information Trip Fuel Information Press the F2 button to reset the trip average fuel rate and trip fuel used functions.

Press the F3 button to display the additional information screen.

2.39

Controls and Operation

Tigercat 2160 Loader Forwarder

TELEMATICS INFORMATION (OPTIONAL)

2000083

Telematics Symbol Telematics, Connectivity Telematics, Messages Sent/Recorded Telematics, Latitude Telematics, Longitude

2.40

Tigercat 2160 Loader Forwarder

Controls and Operation

MAIN MENU

ADJUST MENU 2000074

2000087

Press the menu button the Main menu.

from the main screen to view

Press the F1 button to access the Adjust menu.

2000084

2000074

The following selections are displayed: • Adjust – Press F1

The following menu items can be selected.

• Machine Parameters • Engine

• Measure – Press F2

• Fan

• Preferences – Press F3

• Engine Operations

• Info– Press F4 Press the back button to return to the main screen.

2.41

Controls and Operation

Tigercat 2160 Loader Forwarder

MACHINE PARAMETERS

IDLE DOWN WAIT TIME 2000084

2000085

Press the UP or DOWN arrow buttons to select Machine Parameters.

Press the UP or DOWN arrow buttons to select Idle Down Wait Time.

Press the OK button to make the selection.

Press the OK button to make adjustments.

2000086

2000085

The following menu items can be selected: • Anti Stall • Oil Grade (Hydraulic Oil) • Idle Down Wait Time • Holding Brake ANTI STALL Refer to COMPUTER – ENGINE MENU – ANTI STALL in THIS SECTION for setting instructions.

OIL GRADE Refer to COMPUTER – ADJUSTMENT MENU – HYDRAULIC OIL GRADE SELECTION in THIS SECTION for selection instructions.

The setting value can be adjusted between 2 seconds and 60 seconds. The factory default is 10 seconds.

If the engine is set to run above LOW and no functions are activated for the set time, engine speed will automatically go to LOW. The engine will return to the set speed when a function is activated.

Press the UP or DOWN arrow buttons to select the desired value.

Press the OK button to set the value. The screen will automatically return to the Machine Parameters menu.

Press the back button to return to the Adjust menu or the F1 button to return to the Main menu.

Press the back button from the Main menu to return to the main screen.

2.42

Tigercat 2160 Loader Forwarder

Controls and Operation ENGINE

HOLDING BRAKE 2000092

Press the UP or DOWN arrow buttons to select Holding Brake.

Press the OK button to make adjustments.

2000094

Press the UP or DOWN arrow buttons to select Engine.

Press the OK button to make the selection.

2000093

Press the UP or DOWN arrow buttons to select OFF or ON. Press the OK button to set the value. The screen will automatically return to the Machine Parameters menu.

Press the back button to return to the Adjust menu or the F1 button to return to the Main menu.

Press the back button from the Main menu to return to the main screen.

2.43

Controls and Operation

Tigercat 2160 Loader Forwarder FAN

COLD IDLE SPEED

2000139

2000095

Press the UP or DOWN arrow buttons to select Cold Idle Speed.

Press the OK button to make adjustments.

Press the UP or DOWN arrow buttons to select Fan. Press the OK button to make the selection.

2000096

The Cold Idle Speed can be adjusted between 1000 rpm and 1400 rpm.

Press the UP or DOWN arrow buttons to select the desired value.

Press the OK button to set the value. The screen will automatically return to the Engine menu.

Press the back button to return to the Adjust menu or the F1 button to return to the Main menu.

Press the back button from the Main menu to return to the main screen.

2.44

Tigercat 2160 Loader Forwarder

Controls and Operation

FAN AUTO CLEAN

FAN CLEAN FREQUENCY 2000142

2000140

Press the UP or DOWN arrow buttons to select Fan Auto Clean.

Press the UP or DOWN arrow buttons to select Fan Clean Frequency.

Press the OK button to make adjustments.

Press the OK button to make adjustments.

2000141

Press the UP or DOWN arrow buttons to select OFF or ON. Press the OK button to set the value. The screen will automatically return to the Fan menu.

2000143

The setting value can be adjusted between 1 minute and 420 minutes. This is the setting for auto reverse of the cooling fan to go into the clean mode (reverse/clean).

The factory default setting is every 30 minutes.

Press the back button to return to the Adjust menu or the F1 button to return to the Main menu.

Press the UP or DOWN arrow buttons to select the desired value.

Press the back button from the Main menu to return to the main screen.

Press the OK button to set the value. The screen will automatically return to the Fan menu.

Press the back button to return to the Adjust menu or the F1 button to return to the Main menu.

Press the back button from the Main menu to return to the main screen.

2.45

Controls and Operation

Tigercat 2160 Loader Forwarder MEASURE MENU

FAN CLEAN DURATION 2000144

Press the UP or DOWN arrow buttons to select Fan Clean Duration.

2000074

Press the F2 button to access the Measure menu.

2000099

Press the OK button to make adjustments.

2000145

The setting value can be adjusted between 5 seconds and 20 seconds. This is the time the cooling fan remains in the clean (reverse/clean) mode. The factory default is 15 seconds.

Press the UP or DOWN arrow buttons to select the desired value.

Press the OK button to set the value. The screen will automatically return to the Fan menu.

Press the back button to return to the Adjust menu or the F1 button to return to the Main menu.

This menu is used by Tigercat service technicians.

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

Press the UP or DOWN arrow buttons to select the menu item.

Press the OK button to view the information from the menu item.

Press the back button to return to the Measure menu or press the F1 button to return to the Main menu.

Press the back button from the Main menu to return to the main screen.

Press the back button from the Main menu to return to the main screen.

2.46

Tigercat 2160 Loader Forwarder

Controls and Operation

PREFERENCES MENU

DISPLAY ADJUSTMENT 2000101

2000074

Press the F3 button to access the Preferences menu.

2000100

Press the F1 button from the Preferences menu to display the Display adjustment screen with the following selections: • Return to Main menu – Press F1 • Backlight – Press F2 • Screen saver – Press F3 BACKLIGHT ADJUSTMENT 2000102

The Preferences menu displays the following selections: • Display – Press F1 • Date/Time – Press F2 • Language – Press F3

Press the F2 button to select the Backlight adjustment.

The range is 10 – 100. The default setting is 100. The lower the number, the longer the life of the display unit.

Press the UP or DOWN arrow buttons to select the desired value.

Press the OK button to set the value.

2.47

Controls and Operation

Tigercat 2160 Loader Forwarder DATE/TIME ADJUSTMENT

SCREEN SAVER ADJUSTMENT 2000103

Press the F3 button to view the Screen saver adjustment screen.

2000104

2000105

Press the F2 button from the Preferences menu to display the Date/Time adjustment screen with the following selections: • Date – Press F1 • Time – Press F2

Press the UP and DOWN arrow buttons to scroll through the choices: • Screen Saver Off, Dimmed or Black • Dimmed • Timeout: 5 – 600 seconds • Dimmed light: 0 – 60 seconds • Black – Timeout 5 – 600 seconds Press the UP or DOWN buttons to make a selection.

Press the OK button to make the selection and go to the next selection.

Press the back button to return to the Preferences menu.

2.48

Tigercat 2160 Loader Forwarder

Controls and Operation

DATE ADJUSTMENT

2000108 2000106

Press the F1 button from the Date/Time Adjustment screen to set the date. Year is automatically highlighted.

When the month has been confirmed the day is highlighted.

Press the UP or DOWN arrow buttons to select the day.

Press the UP or DOWN arrow buttons to select the year.

Press the OK button to confirm day selected.

Press the OK button to confirm year selected.

2000105 2000107

When the year has been confirmed the month is highlighted.

Press the UP or DOWN arrow buttons to select the month.

The display will return to the Date/Time adjustment screen.

Press the F2 button from the Date/Time Adjustment screen to set the time.

Press the OK button to confirm month selected.

2.49

Controls and Operation

Tigercat 2160 Loader Forwarder

TIME ADJUSTMENT

LANGUAGE ADJUSTMENT 2000137

2000109

Hour is automatically highlighted.

Press the UP or DOWN arrow buttons to select the hour.

Press the OK button to confirm hour selected.

2000110

Press the F3 button from the Preferences menu to view Language selection screen. The languages available for selection will be shown.

Press the UP or DOWN arrow buttons to select the language.

Press the OK button to confirm language selected. The display will return to the Preferences menu.

Press the back button to return to the Main menu.

Press the back button again to return to the main screen.

When the hour has been confirmed the minute is highlighted.

Press the UP or DOWN arrow buttons to select the minute.

Press the OK button to confirm minute selected. The display will return to the Date/Time menu.

Press the back button to return to the Preferences menu.

2.50

Tigercat 2160 Loader Forwarder

Controls and Operation

INFO MENU

MODULES 2000112

2000111

Press the F4 button from the Main menu to view the Info menu.

2000111

Press the F1 button from the Info menu to select the Modules menu. This menu provides information on the following machine modules: • MD3 (Computer) • Valve Module MC43-A1 Press the UP or DOWN arrow buttons to select a module. Press the OK button to select the module.

2000113

The Info menu displays the following selections: This screen also provides access to: • Modules – Press F1 • Logs – Press F3 The machine ID information is also displayed on the screen.

Press the OK button to view the details of the module.

2.51

Controls and Operation

Tigercat 2160 Loader Forwarder 2000114

LOGS 2000115

Specific information for the module 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 three times to return to the Info menu or press the F1 button to return to the Main menu.

Press the F3 button from the Info menu to select the Logs menu.

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

Press the UP or DOWN arrow buttons to select the log.

Press the OK button to view the events of the log.

2000138

Press the UP or DOWN arrow buttons to scroll through the list of events.

The events are a list of all the fault occurrences in each log. Events cannot be cleared by operators.

This menu is used by Tigercat service technicians. Refer to SECTION 6 of the SERVICE MANUAL for more information.

Press the back button or the F1 button to return to the Main menu.

2.52

Tigercat 2160 Loader Forwarder

Controls and Operation

MESSAGES, COMPUTER The computer displays messages and activates the master alarm and alarm light when a system fault occurs.

Message Header Message Text

NOTE: The computer control system will automatically perform a test at engine start up to verify 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 – RED header • ERROR MESSAGE – RED header

Message Header

• ALERT MESSAGE – YELLOW header

Message Text

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, turn OFF the engine and repair the problem causing the message.

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

Message Header Message Text

2.53

Controls and Operation

Tigercat 2160 Loader Forwarder

CRITICAL MESSAGES (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 it is hidden by the operator.

2000131

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

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

2000125

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, turn OFF the engine 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 turn OFF the engine before serious machine damage can occur!

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

2.54

Tigercat 2160 Loader Forwarder

Controls and Operation

LIST OF CRITICAL MESSAGES Critical Message

Message Header

Message Text

Engine Coolant Level Low

Engine Coolant

Level Low

Engine Coolant Temperature High – Engine Derate

Engine Coolant

Temperature High - Engine Derate

Main Fuel Filter Clogged – Engine Derate

Main Fuel Filter

Clogged - Engine Derate

Pump Gearbox Temperature High

Gearbox Temperature

High. Service machine to correct.

Hydraulic Oil Level Low

Hydraulic Oil

Level low.

Hydraulic Oil Temperature High

Hydraulic Oil

Temperature High.

Engine Oil Pressure Low – Engine Derate

Engine Oil

Pressure Low - Engine Derate

Hardware Fault

Hardware Fault - (Module Name)

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

Engine Fault Code Messages – Critical

SPN: #####

Contact dealer.

Engine Oil Pressure Low

SPN: 9939

Engine Oil Pressure Low.

Engine Coolant Temperature High

SPN: 63011

Engine coolant temperature high.

Engine Oil Temperature High

SPN: 7123

Engine oil temperature high.

Aftertreatment System Technical Failure *

After Treatment System

Technical failure severe. Engine lockout will occur after full torque derate and 3 engine restarts.

Engine Restarts Remaining Until Engine Lockout *

Engine

Number of restarts remaining.

Engine Locked Out *

Engine

Engine locked out. Engine derate to 0% Torque and 850 rpm. Contact dealer.

Aftertreatment System Engine Idle Too Long *

After Treatment System

Engine idle too long. Shut down engine to prevent damage to emission control system.

* NOTE: The aftertreatment system and its related components are applicable to Tier 4f machines only.

2.55

Controls and Operation

Tigercat 2160 Loader Forwarder

ENGINE COOLANT LEVEL LOW

Safely stop the machine, set engine speed to LOW and turn the A/C off. If the engine coolant temperature reading does not return to normal operating levels, turn OFF the engine and perform further cooling system checks. Refer to COMPUTER – MESSAGES – CRITICAL – ENGINE OIL TEMPERATURE HIGH in THIS SECTION for recommended corrective action. If engine coolant temperature does not return to normal operating levels contact dealer for service.

This message will be displayed, alarm light will flash and alarm will sound when the coolant level drops below a safe operating level. The sensor is located in the surge tank.

If this light comes on when the engine is running, turn OFF the engine immediately and correct the fault. With engine running, top up the surge tank using correct solution of engine coolant.

Refer to SERVICE AND LUBRICATION POINTS in SECTION 3.

WARNING

Do not remove the radiator fill cap when the engine is hot, release of pressurized coolant can cause serious burns.

Turn OFF the engine. Only remove the radiator fill cap when cool enough to touch with bare hands.

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

ENGINE COOLANT TEMPERATURE HIGH – ENGINE DERATE This message will be displayed, alarm light will flash and alarm will sound when an engine derate is activated due to high engine coolant temperature. This message may be accompanied by Engine Fault Code Messages related to coolant temperature.

• When coolant temperatures fall below 106°C (223°F) for more than 5 seconds this message will be turned off and engine speed will automatically ramp up at 5% per second to full operating speed.

NOTE: An ENGINE TORQUE DERATE ACTIVE message will also be activated as the engine begins to derate. Refer to COMPUTER – MESSAGES– ALERTS– ENGINE TORQUE DERATE ACTIVE.

MAIN FUEL FILTER CLOGGED – ENGINE DERATE This message will be displayed, alarm light will flash and alarm will sound when an engine derate is activated due to a clogged main fuel filter. This message may be accompanied by Engine Fault Code Messages.

When a main fuel filter clog is detected a message will be displayed to alert the operator.

This message results in the following derate sequence: • When a fuel filter clog continues for more than 5 minutes this message will be shown and engine speed will immediately begin to derate at 5% per second to a set creep speed allowing the operator to safely stop the machine.

Change engine fuel filter as soon as possible to correct. Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for engine fuel filter replacement instructions. If the problem continues contact dealer for service.

This message results in the following derate sequence: • When coolant temperature rises to 106°C (223°F) for more than 5 seconds the critical symbol will flash.

• When coolant temperature rises to 110°C (230°F) for more than 5 seconds this message will be shown and engine speed will immediately begin to derate at 5% per second to a set creep speed allowing the operator to safely stop the machine. Do not continue to operate machine.

• When a fuel filter clog condition is no longer detected for more than 5 seconds this message will be turned off and engine speed will automatically ramp up at 5% per second to full operating speed.

NOTE: An ENGINE TORQUE DERATE ACTIVE message will also be activated as the engine begins to derate. Refer to COMPUTER – MESSAGES– ALERTS– ENGINE TORQUE DERATE ACTIVE in THIS SECTION.

2.56

Tigercat 2160 Loader Forwarder PUMP DRIVE GEARBOX TEMPERATURE HIGH This message will be displayed, alarm light will flash and alarm will sound to inform the operator the pump drive gearbox temperature is high.

Stop the machine immediately when this alarm is activated and check the pump drive gearbox for proper operation.

Controls and Operation Refer to COMPUTER – ADJUSTMENT MENU – HYDRAULIC OIL GRADE SELECTION in THIS SECTION for hydraulic oil grade selection settings information.

Refer to APPROVED HYDRAULIC OILS in SECTION 3 for hydraulic oil operating range information.

HYDRAULIC OIL LEVEL LOW

Refer to COMPUTER – INFORMATION MENU in THIS SECTION for hydraulic oil temperature information display.

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

ENGINE OIL PRESSURE LOW – ENGINE DERATE

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

This message will be displayed, alarm light will flash and alarm will sound when and engine derate is activated due to low engine oil pressure. This message may be accompanied by Engine Fault Code Messages related to engine oil pressure.

When this alarm is activated turn OFF the engine and look for signs of broken hoses or other leaks. Repair leaks and refill the hydraulic oil tank to FULL mark on the hydraulic oil level sight gauge. Restart engine and inspect for leaks.

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

If the temperature rises above the recommended operating range for the type of hydraulic oil in use check the following: • Plugged cooler package access door screen.

• Malfunction in the 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 screen, together with the HYDRAULIC OIL OPERATING RANGE chart in SECTION 3 to prevent damage to the hydraulic system.

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

Operating outside the recommended operating range shortens hydraulic component life.

This message results in the following derate sequence: When engine oil pressure readings fall below 1.2 bar (17 psi) for more than 5 seconds this message will be shown and engine speed will immediately begin to derate at 5% per second to a set creep speed allowing the operator to safely stop the machine. Do not continue to operate machine.

Safely stop the machine and turn OFF the engine. Refer to COMPUTER– MESSAGES– CRITICAL – ENGINE OIL PRESSURE LOW in THIS SECTION for recommended corrective action. If the problem continues contact dealer for service.

When engine oil pressure readings rise above 1.4 bar (20 psi) for more than 5 seconds this message will be turned off and engine speed will automatically ramp up at 5% per second to full operating speed.

NOTE: An ENGINE TORQUE DERATE ACTIVE message will also be activated as the engine begins to derate. Refer to COMPUTER – MESSAGES– ALERTS– ENGINE TORQUE DERATE ACTIVE.

HARDWARE FAULT This message will be displayed, alarm light will flash and alarm will sound when a critical active hardware fault related to the MD3, MC43-A1, XA2-A1T, XA2-A2T, and XC21-A2 modules and the engine has been hidden.

To recall the original active fault(s) the operator must turn the key OFF and ON. A VREF (modules reference voltage) error is an example of the type of hardware fault (original active fault) that activates this message.

2.57

Controls and Operation

Tigercat 2160 Loader Forwarder

ENGINE FAULT CODE MESSAGES – CRITICAL

WARNING

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

They provide the SPN code (suspect parameter number) 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.

NOTE: Some less common engine fault codes will appear without a message describing the fault. Make a note of the SPN code and contact service for more information.

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for specific information regarding the engine and aftertreatment system.

NOTE: Contact your Tigercat dealer to obtain an Engine Fault Codes chart. An up to date copy should be kept in the manual box (in the cab). The chart is updated regularly by the engine manufacturer, so it is important to check periodically with the Tigercat dealer to ensure that you have a current copy of the Engine Fault Codes chart.

ENGINE OIL PRESSURE LOW – SPN: 9939 This message will be displayed, alarm light will flash and alarm will sound when engine oil pressure falls below 0.7 bar (10 psi).

Do not remove the radiator fill cap when the engine is hot, release of pressurized coolant can cause serious burns.

Turn OFF the engine. Only remove the coolant fill cap when it is cool enough to touch with bare hands.

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

ENGINE OIL TEMPERATURE HIGH – SPN: 7123 This message will be displayed, alarm light will flash and alarm will sound when engine oil temperature exceeds recommended engine temperature.

Check the cooler package and fan for proper operation and run a clean cycle if the machine is equipped with a variable pitch fan. It is also important to manually clean debris from the machine on a regular basis to maintain low machine operating temperatures. Refer to CLEANING COOLER PACKAGE in SECTION 3 Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for code information.

Turn OFF the engine when this alarm is activated. Check engine oil level.

Refer to STARTING ENGINE in THIS SECTION for more information.

ENGINE COOLANT TEMPERATURE HIGH – SPN: 63011 This message will be displayed, alarm light will flash and alarm will sound when the engine temperature exceeds recommended engine temperature.

When this alarm is activated check for: • Plugged cooler package access door screen.

• Plugged radiator.

• Malfunction of the cooling fan.

Refer to CLEANING COOLER PACKAGE in SECTION 3.

2.58

Tigercat 2160 Loader Forwarder

Controls and Operation 4. The engine continues to operate at 35% of rated torque for approximately 50 minutes.

THE AFTERTREATMENT SYSTEM AND ITS RELATED COMPONENTS ARE APPLICABLE TO TIER 4F MACHINES ONLY.

5. Engine torque reduces to minimum value as engine speed reduces to LOW over the next 30 minutes.

AFTERTREATMENT SYSTEM TECHNICAL FAILURE

Some less severe technical faults can be fixed after the engine has been fully derated to LOW.

This message will be displayed, alarm light will flash and alarm will sound when an aftertreatment technical fault is detected. Take immediate action to avoid affecting engine performance and damage to the diesel oxidation catalyst /selective catalytic reduction (DOC/SCR) aftertreatment system components.

More severe technical faults will result in an engine lockout when engine speed has derated to LOW and there have been 3 restarts. Once locked out, the engine will only operate at LOW. The original cause(s) of the lockout must be corrected before the engine can be reset. Contact dealer to reset engine lockout for normal operation.

The following engine derate sequence occurs immediately after the Aftertreatment System– Technical failure severe message:

Refer to COMPUTER – MESSAGES– CRITICAL – ENGINE LOCKED OUT and COMPUTER – MESSAGES– CRITICAL – ENGINE STARTS REMAINING UNTIL ENGINE LOCKOUT in THIS SECTION.

1. Engine torque reduces to 75% of rated torque over the next 25 minutes.

2. The engine continues to operate at 75% of rated torque for approximately 65 minutes.

Identify the cause of the technical failure and take action to correct the problem.

derate – technical failure to and35% tampering 3. Engine Engine torque reduces of rated torque over the next 40 minutes.

100%

MIN

C

.

80%

A ≈ 25

90%

B

70%

≈ 65 MIN.

0M

≈4

60% 50%

I N.

TORQUE

Refer also to AFTERTREATMENT SYSTEM in SECTION 3 for more information.

40%

D

30%

≈ 50 MIN.

≈ 30

20%

MIN .

10% 0%

E

F

0

60

1000010

180

120

240

300

MINUTES

A Critical Message: Aftertreatment System– Technical Failure Severe.

Engine torque begins to reduce.

B Engine torque reduced to 75% after 25 minutes.

C Engine torque begins to reduce further after 65 minutes.

2.59

D

Engine torque reduced to 35% after 40 minutes.

E

Engine torque begins to reduce further after 50 minutes.

F

Engine speed reduced to LOW after 30 minutes.

Controls and Operation

Tigercat 2160 Loader Forwarder

ENGINE STARTS REMAINING UNTIL ENGINE LOCKOUT

AFTERTREATMENT SYSTEM ENGINE IDLE TOO LONG

This message will be displayed, alarm warning light will flash and alarm will sound to inform the operator of the number of restarts available before the engine is locked out.

This message will be displayed, alarm light will flash and alarm will sound when this engine has idled for more than one hour. Shutdown engine to prevent damage to the emission control system.

Note that an engine is locked out after several other critical aftertreatment system messages regarding the cause of the problem and this message regarding the number of restarts until engine lockout.

IMPORTANT! Engine should not idle longer than one hour.

Damage to the emission control system will result.

When this machine idles for an extended period, excess hydrocarbon buildup is created in the SCR aftertreatment system. Burn off of excess hydrocarbon at full load immediately after a long idle period will generate excess heat which will cause damage to emission control system components. It will take 45 minutes at 40% load (or an SCR exhaust outlet temperature of 320°C (608°F) to burn off the hydrocarbon that accumulates during a long idle.

Refer to COMPUTER – MESSAGES– CRITICAL – ENGINE LOCKED OUT in THIS SECTION.

ENGINE LOCKED OUT This message will be displayed, alarm warning light will flash and alarm will sound when an engine is locked out by the computer system to prevent further damage to the engine and aftertreatment system.

Note that an engine is locked out after several other critical aftertreatment system messages regarding the cause of the problem and additional messages regarding the number of restarts until engine lockout.

Once locked out, the engine will only operate at 850 rpm.

The original cause(s) of the lockout must be corrected before the engine can be reset. Contact dealer to reset engine lockout for normal operation.

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL. Refer to COMPUTER – MESSAGES– CRITICAL – ENGINE STARTS REMAINING UNTIL ENGINE LOCKOUT in THIS SECTION.

2.60

Tigercat 2160 Loader Forwarder ERROR MESSAGES (RED) Error messages advise the operator that a machine fault is about to occur or a system fault has occurred.

Controls and Operation A list of some types of ERROR MESSAGES is as follows: • Module No Contact Error • Module VREF Error

Error messages are computer system generated and are generally activated by computer system error and fault related conditions.

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

Error messages are activated when a fault, such as an electrical connection, is broken/disconnected. Most error messages are due to computer system hardware or connection faults.

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

• Voltage Input Error (VIN) • Digital Input Error (DIN) • Digital Output Error (DOUT) • Current Output Error (COUT) NOTE: Not all error messages are shown.

MODULE NO CONTACT ERROR The module no contact error message will be displayed to indicate a loss of communication with or power to a module. The module is identified on the display screen.

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

When a module loses contact all machine functions controlled by that module cease and all messages associated with that module are activated. If the problem is with the CAN wires all modules beyond the problem module will also be affected.

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.

NOTE: If the computer display module has a loss of power or other malfunction the screen may go blank and all machine functions controlled by the computer system will be affected.

However, if the machine cannot be stopped immediately for safety reasons, the operator can hide the message.

In this instance, the machine should only be operated long enough to move the machine to a safe location then stop machine operation and shut the engine off before serious machine damage can occur!

Once acknowledged, this message will be replaced with a hardware fault message for the corresponding module when active faults are recalled to the screen. Refer to COMPUTER – MESSAGES – CRITICAL – HARDWARE FAULT in THIS SECTION.

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

The module VREF message will be displayed to indicate a problem related to the 5V reference signal coming from the module.

Error messages flash the Critical symbol or the Alert above the F4 button when active messages are hidden depending on the type of error message. The symbol will continue to flash until the problem is resolved and the fault becomes inactive.

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

MODULE VREF ERROR

The module is identified on the display screen.

This message indicates a problem with a sensor, connecting wires or the 5V reference signal itself.

Once acknowledged this message will be replaced with a hardware fault message for the corresponding module when active faults are recalled to the screen. Refer to COMPUTER – MESSAGES– CRITICAL – HARDWARE FAULT in THIS SECTION.

2.61

Controls and Operation

Tigercat 2160 Loader Forwarder

VOLTAGE INPUT ERROR (VIN)

CURRENT OUTPUT ERROR (COUT)

Voltage input error messages will be displayed to indicate a problem with a voltage input signal to a computer system module.

Current output error messages will be displayed to indicate a problem with a current output signal from a computer system module.

The module and pin number are identified on the display screen.

The module and pin number are identified on the display screen.

The heading identifies the signal source and the text indicates the type of error.

The heading identifies the signal destination and the text indicates the type of error.

An example of a voltage input error message is shown above.

The display is similar to the voltage input error message shown above.

DIGITAL INPUT ERROR (DIN)

Once acknowledged these message will be replaced with a hardware failure message for the corresponding module when active faults recalled to the screen. Refer to COMPUTER– MESSAGES– ALERT– HARDWARE FAILURE in THIS SECTION.

Digital input error messages will be displayed to indicate a problem with a digital input signal to a computer system module.

The module and pin number are identified on the display screen.

COMPUTER MODULE BLANK SCREEN

The heading identifies the signal source and the text indicates the type of error.

The display is similar to the voltage input error message shown above.

DIGITAL OUTPUT ERROR (DOUT) Digital output error messages will be displayed to indicate a problem with a digital output signal from a computer system module.

The module and pin number are identified on the display screen.

The heading identifies the signal destination and the text indicates the type of error.

The display is similar to the voltage input error message shown above.

The computer module is the central unit in the computer control system, which works as both a master and a display unit. Faults or failure in this unit will affect all other computer components.

Likely causes are: • Power – Fuse (Computer) • Ground • LCD display settings too light to read • Faulty computer

2.62

Tigercat 2160 Loader Forwarder ALERT MESSAGES (YELLOW)

Controls and Operation

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

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.

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

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.

There are two types of alert messages: 1. Alert programmed messages. The messages are generally initiated by machine function related conditions.

2. Alert computer system messages. These messages which are generally initiated by computer system errors and fault related conditions.

When an alert message is displayed, the audible alarm and warning light will sound and flash on and off three times alerting the operator of the message. The alert message remains on the screen until the operator hides it by pressing the F2 button (Hide).

2000126

All alert messages 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.

NOTE: Active hardware fault alert messages are acknowledged by pressing the F2 button (OK). To recall these messages turn ignition key switch OFF and ON. On screen messages will indicate to the operator that an active hardware fault has been hidden.

2000130

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

2.63

Controls and Operation

Tigercat 2160 Loader Forwarder

LIST OF ALERT MESSAGES Critical Message

Message Header

Message Text

Engine Air Filter Restricted

Engine Air Filter

Restricted. Service machine.

Drive Charge Filter Bypassed

Drive Charge Filter

Bypassed. Service machine to correct.

Swing Charge Filter Bypassed

Swing Charge Filter

Bypassed. Service machine to correct.

Scrubber Filter Bypassed

Scrubber Filter

Bypassed. Service machine to correct.

Hydraulic Oil Filter Restricted

Hydraulic Oil Filter

Restricted. Service machine.

Main Fuel Filter Clogged

Main Fuel Filter

Clogged. Replace filter to prevent engine derate.

Fuel Level Low

Fuel

Level Low.

Drive Pedal Voltage Low

Drive Pedal

Low Voltage

Left Hand Joystick Trigger Voltage Low

LH Joystick Trigger

Low Voltage

Joystick Axis Voltage Low

## Joystick ## Axis

Low Voltage

Steering Slider Switch Voltage Low

Steer Slider

Low Voltage

Machine Voltage High

Machine Voltage

High. Service machine to correct.

Machine Voltage Low

Machine Voltage

Low. Service machine to correct.

Accumulator Pressure High

Accumulator

Pressure High. Service machine to correct.

Accumulator Pressure Low

Accumulator

Pressure Low. Service machine to correct.

Hardware Fault

Hardware Fault - (Module Name)

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

Hardware Failure

Hardware Failure -

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

Module High Temperature

(Module name)

High temperature

Module High Supply Voltage

(Module name)

High supply voltage.

Module Low Supply Voltage

(Module name)

Low supply voltage.

Engine Fault Code Messages – Alert

SPN: #####

Contact dealer.

Engine Coolant Temperature High

SPN: 63011

Engine coolant temperature high.

Engine Torque Derate Active

SPN: 64911

Engine torque derate active.

Water in Fuel

SPN: 17429

Water in fuel.

Engine Voltage Low

SPN: 8801 or 9313

Engine voltage low.

Engine Voltage High

SPN: 4449 or 4961

Engine voltage high.

Diesel Exhaust Fluid Quality *

SPN: 19402 or 19658

DEF quality low.

Diesel Exhaust Fluid Level – Below 10% *

SPN: 61839

DEF Level below 10%

Diesel Exhaust Fluid Level – Below 5% *

SPN: 62095

DEF Level below 5%

Diesel Exhaust Fluid Level – Empty *

SPN: 64191

DEF tank empty.

* NOTE: The aftertreatment system and its related components are applicable to Tier 4f machines only.

2.64

Tigercat 2160 Loader Forwarder

Controls and Operation

ENGINE AIR INTAKE FILTER RESTRICTED

SCRUBBER FILTER BYPASSED

This message will be displayed when a signal is received from the restriction indicator sensor on the engine air cleaner.

This message will be displayed when an oil flow restriction in excess of 3.5 bar (50 psi) is encountered at the scrubber filter. This pressure build up opens the bypass valve in the filter head allowing oil to bypass the filter element and return to the hydraulic oil tank.

When this happens the filter requires immediate service.

2000157

A

A Engine Air Intake Filter Restriction Icon – ON (Yellow)

The engine air intake filter restriction icon on the computer display will also illuminate YELLOW. When this happens the engine air cleaner requires immediate service.

Refer to AIR INTAKE SYSTEM– AIR CLEANER in SECTION 3.

DRIVE CHARGE FILTER BYPASSED

If alarm sounds during cold start-ups, engine speed should be reduced and the warm up procedure continued. Note the bypass message will only be displayed when hydraulic oil temperature is above 29°C (85°F) and the filter is in bypass mode.

HYDRAULIC OIL FILTER RESTRICTED This message will be displayed when an oil flow restriction in excess of 1.4 bar (20 psi) is encountered at the hydraulic oil return filters. If pressure continues to build up to 1.7 bar (25 psi) the bypass valve in the filter head opens allowing oil to bypass the filter elements and return to the hydraulic oil tank .

This message will be displayed when an oil flow restriction in excess of 3.5 bar (50 psi) is encountered at the drive charge filter. This pressure build up opens the bypass valve in the filter head allowing oil to bypass the filter element and return to the hydraulic oil tank.

2000126

When this happens the filter requires immediate service.

If alarm sounds during cold start-ups, engine speed should be reduced and the warm up procedure continued. Note the bypass message will only be displayed when hydraulic oil temperature is above 29°C (85°F) and the filter is in bypass mode.

SWING CHARGE FILTER BYPASSED This message will be displayed when an oil flow restriction in excess of 3.5 bar (50 psi) is encountered at the swing charge filter. This pressure build up opens the bypass valve in the filter head allowing oil to bypass the filter element and return to the hydraulic oil tank.

A

A Hydraulic Oil Filter Restricted Icon – ON (Red)

The hydraulic oil filter restriction icon on the computer display will also illuminate RED. If this message appears, replace all four hydraulic oil return filters to prevent contamination to the hydraulic system which could lead to damage to hydraulic components.

Refer to HYDRAULIC SYSTEM – FILTERS, HYDRAULIC OIL RETURN in SECTION 3.

When this happens the filter requires immediate service.

If alarm sounds during cold start-ups, engine speed should be reduced and the warm up procedure continued. Note the bypass message will only be displayed when hydraulic oil temperature is above 29°C (85°F) and the filter is in bypass mode.

2.65

Controls and Operation

Tigercat 2160 Loader Forwarder

MAIN FUEL FILTER CLOGGED

STEERING SLIDER SWITCH VOLTAGE LOW

This message will be displayed when a main fuel filter clog is detected.

This message will be displayed when a fault has been detected in the voltage output from the steering slider switch on the right joystick.

Replace engine fuel filter to prevent engine derate.

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for engine fuel filter replacement instructions.

When a fuel filter clog continues for more than 5 minutes a critical message will be shown and the engine will immediately begin to derate. Refer to COMPUTER – MESSAGES– CRITICAL – MAIN FUEL FILTER CLOGGED– ENGINE DERATE in THIS SECTION.

FUEL LEVEL LOW This message will be displayed when the fuel level falls below 5% of full.

When this alarm is activated investigate the cause immediately.

MACHINE VOLTAGE HIGH This message will be displayed when machine voltage readings of greater than 30 volts are detected.

Machine voltage readings indicate voltage levels in the electrical system.

When this alarm is activated investigate the cause immediately.

MACHINE VOLTAGE LOW This message will be displayed when machine voltage readings of less than 20 volts are detected.

A 2000173

A Fuel Icon – Low (Yellow)

The fuel icon will also illuminate yellow when the fuel level is low.

Refer to REFUELLING PROCEDURE in SECTION 3.

DRIVE PEDAL VOLTAGE LOW This message will be displayed when a fault has been detected in one of the voltage outputs from the drive pedal.

Machine voltage readings indicate voltage levels in the electrical system.

When this alarm is activated investigate the cause immediately.

ACCUMULATOR PRESSURE HIGH This message will be displayed when the accumulator pressure rises above 207 bar (3000 psi).

When this message is activated check the function of the pressure switch or solenoid that activates the switch.

ACCUMULATOR PRESSURE LOW

When this alarm is activated investigate the cause immediately.

This message will be displayed when the accumulator pressure falls below 83 bar (1200 psi).

JOYSTICK TRIGGER VOLTAGE LOW

When this message is activated check for leaks in the brake circuit and the pilot system. If no leaks are found check for proper operation of the accumulator.

This message will be displayed when a fault has been detected in the voltage output from the LH joystick trigger.

When this alarm is activated investigate the cause immediately.

JOYSTICK AXIS VOLTAGE LOW This message will be displayed when a fault has been detected in one or more of the voltage outputs from the joystick axis. The message will indicate if the fault is in the left or right joystick and with the X or Y axis.

When this alarm is activated investigate the cause immediately.

2.66

Tigercat 2160 Loader Forwarder

Controls and Operation

HARDWARE FAULT

MODULE HIGH TEMPERATURE

This message will be displayed when an alert level active hardware fault related MD3, MC43-A1, XA2-A1T, XA2-A2T, and XC21-A2 modules and the engine has been hidden.

Module high temperature alert message will be displayed to indicate the computer control system has detected high temperature readings in a system module.

To recall the original active fault(s) the operator must turn the ignition key switch OFF and ON.

The module is identified on the display screen. The temperature reading value is also displayed.

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 activate this message.

Once acknowledged this message will be replaced with a hardware fault message for the corresponding module when active faults are recalled to the screen. Refer to COMPUTER – MESSAGES – ALERT – HARDWARE FAULT in THIS SECTION.

HARDWARE FAILURE

MODULE HIGH SUPPLY VOLTAGE

This message will be displayed when an error message for the any of the following conditions has been hidden.

Module high supply voltage alert message will be displayed to indicate the computer control system has detected high supply voltage readings in a system module.

• CURRENT OUTPUT • DIGITAL INPUT • DIGITAL OUTPUT • VOLTAGE INPUT To recall the original active fault(s) the operator must turn the key OFF and ON.

The module is identified on the display screen. The voltage reading value is also displayed.

Once acknowledged this message will be replaced with a hardware fault message for the corresponding module when active faults are recalled to the screen. Refer to COMPUTER – MESSAGES – ALERT – HARDWARE FAULT in THIS SECTION.

MODULE LOW SUPPLY VOLTAGE Module low supply voltage alert message will be displayed to indicate the computer control system has detected low supply voltage readings in a system module.

The module is identified on the display screen.

Once acknowledged this message will be replaced with a hardware fault message for the corresponding module when active faults are recalled to the screen. Refer to COMPUTER – MESSAGES – ALERT – HARDWARE FAULT in THIS SECTION.

2.67

Controls and Operation

Tigercat 2160 Loader Forwarder

ENGINE FAULT CODE MESSAGES – ALERT

ENGINE TORQUE DERATE ACTIVE– SPN: 64911

Alert engine fault message(s) are displayed, the alarm light flashes and the alarm sounds when an alert engine fault message is received from the engine electronic control module.

This message will be displayed, alarm light will flash and alarm will sound when the engine ECU has derated the engine. This code is activated by a high NOx emission reading.

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

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for code information to identify the cause(s) of engine derating and more information regarding failure cause and repair.

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.

NOTE: Some less common engine fault codes will appear without a message describing the fault. Make a note of the SPN code and contact service for more information.

WATER IN FUEL – SPN 17429 This message will be displayed when water is detected in the fuel.

When this alarm is activated check the fuel filter/water separator.

ENGINE VOLTAGE LOW – SPN: 8801 OR 9313

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for specific information regarding the engine.

This message will be displayed when engine voltage readings of less than 20 volts are detected.

ENGINE COOLANT TEMPERATURE HIGH – SPN: 62755

When this alarm is activated investigate the cause immediately.

This message will be displayed, alarm light will flash and alarm will sound when engine temperature exceeds recommended engine temperature.

ENGINE VOLTAGE HIGH – SPN: 4449 OR 4961

When this alarm is activated check for: • Plugged cooler package access door screen.

• Plugged radiator.

This message will be displayed when engine voltage readings of greater than 30 volts are detected.

When this alarm is activated investigate the cause immediately.

• Malfunction of the cooling fan.

Refer to CLEANING COOLER PACKAGE– SECTION 3.

Refer to COMPUTER – MESSAGES– ALERT– ENGINE COOLANT TEMPERATURE HIGH in THIS SECTION.

2.68

Tigercat 2160 Loader Forwarder

Controls and Operation To correct the DEF quality problem, clean the area around the DEF tank then drain and refill the tank with clean DEF which meets ISO 22241 specifications.

Additional messages from the DENOX 2.2 Module will also be displayed. Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for code information.

THE AFTERTREATMENT SYSTEM AND ITS RELATED COMPONENTS ARE APPLICABLE TO TIER 4F MACHINES ONLY.

DIESEL EXHAUST FLUID QUALITY This message will be displayed, alarm light will flash and alarm will sound when a diesel fluid quality problem is detected. Take immediate action to correct the problem to avoid affecting engine performance and damage to the aftertreatment system components.

NOTE: An ENGINE TORQUE DERATE ACTIVE message will also be displayed as the engine begins to derate. Refer to COMPUTER – MESSAGES– ALERTS– ENGINE TORQUE DERATE ACTIVE. Refer to DIESEL EXHAUST FLUID TANK – DRAINING AND CLEANING in SECTION 3.

This message results in the following derate and engine lockout sequence if no action is taken to correct the problem:

Refer also to AFTERTREATMENT SYSTEM in SECTION 3 for information regarding the use of DEF and its function in the aftertreatment system.

1. Beginning approximately 50 minutes after a DEF quality low message, engine speed ramps down to 1320 rpm and engine torque reduces to 35% of rated torque over the next 40 minutes.

WARNING Use only diesel exhaust fluid (DEF) which meets ISO 22241 specifications. Do not fill the DEF tank with any other fluid.

2. After operating for two hours at derated engine speed and torque, engine speed reduces to LOW and engine torque reduces to its minimum value over the next 30 minutes.

DEF is injected into the exhaust gas stream during normal operation of the Selective Catalytic Reduction (SCR) aftertreatment system.

A total of three restarts are allowed after any derate has started. Refer to COMPUTER – MESSAGES– CRITICAL – ENGINE LOCKED OUT and COMPUTER – MESSAGES– CRITICAL – ENGINE STARTS T4f Engine derate – poor DEF quality REMAINING UNTIL ENGINE LOCKOUT in THIS SECTION.

100%

A

Use of other fluids may cause component damage, or a fire risk which could result in death or serious injury.

B

≈ 50 MIN.

90% 80% 70% ≈ 40

TORQUE

M IN.

60% 50% 40%

D

30%

≈ 120 MIN.

C

≈ 30

20%

MIN

0%

.

10%

E

0

1000009

A Alert Message: Poor DEF quality detected.

B Engine torque begins to reduce.

C Engine torque reduced to 35% after 40 minutes.

120

60

180

240

300

MINUTES

D Engine torque begins to reduce further after 120 minutes.

E Engine speed reduced to LOW after 30 minutes.

2.69

Controls and Operation

Tigercat 2160 Loader Forwarder

DIESEL EXHAUST FLUID LEVEL

Beginning immediately after a DEF Level below 5% message, engine speed ramps down to 1320 rpm and engine torque reduces to 35% of rated torque over the next 40 minutes.

There are three levels of diesel exhaust fluid level messages generated by the DENOX 2.2 Module.

DIESEL EXHAUST FLUID LEVEL BELOW 10% This message will be displayed, alarm light will flash and alarm will sound when a diesel exhaust fluid level below 10% is detected. Take immediate action to correct DEF levels to avoid affecting engine performance and damage to the aftertreatment system components.

The engine will continue to operate normally for approximately one hour after this message is displayed.

Fill the DEF tank and restart the engine to clear the message.

Refer to DIESEL EXHAUST FLUID TANK – FILLING in SECTION 3.

DIESEL EXHAUST FLUID LEVEL BELOW 5% This message will be displayed, alarm light will flash and alarm will sound when a diesel exhaust fluid level below 5% is detected. Take immediate action to correct DEF levels to avoid affecting engine performance and T4f Engine derate low DEF level damage to the–aftertreatment system components.

100% 90%

A

Fill the DEF tank and restart the engine to clear the message.

Refer to DIESEL EXHAUST FLUID TANK – FILLING in SECTION 3.

DIESEL EXHAUST FLUID LEVEL EMPTY This message will be displayed, alarm light will flash and alarm will sound when diesel exhaust fluid level empty is detected. Take immediate action to correct DEF levels to avoid affecting engine performance and damage to the aftertreatment system components.

Beginning immediately after a DEF tank empty message, engine speed reduces to LOW and engine torque reduces to its minimum value over the next 30 minutes.

Fill the DEF tank and restart the engine to clear the message. Refer to DIESEL EXHAUST FLUID TANK – FILLING in SECTION 3.

NOTE: An ENGINE TORQUE DERATE ACTIVE message will also be displayed as the engine begins to derate. Refer to COMPUTER – MESSAGES– ALERTS– ENGINE TORQUE DERATE ACTIVE.

≈ 60 MIN.

B

80% 70% ≈ 40 MIN

60%

.

TORQUE

50% 40% ≈ 20 MIN.

30%

C

D 0M

≈3

20%

1000008

.

0%

IN

10% <10%

<5%

≈ 1.8%

E

0

DEF LEVEL

A Alert Message: DEF Level Below 10%.

B Alert Message: DEF Level Below 5%. Engine torque begins to reduce.

C Engine torque reduced to 35% after 40 minutes.

2.70

D E

DEF tank empty. Engine speed begins to reduce to LOW. Engine speed reduced to LOW after 30 minutes.

Tigercat 2160 Loader Forwarder

Controls and Operation

BATTERY BOOSTING

A

NOTICE This machine has a 24 volt starting system. Only use the same voltage when boosting with an auxiliary battery. Using a higher or lower voltage will cause serious damage to the electrical system. Only a compatible (same) voltage is permissible.

B A

2000035

A Positive Battery Terminal (Red) B Negative Battery Terminal (Black)

B

7. Connect the other clamp of the red jumper cable to the positive (+) terminal of the good battery.

8. Connect the clamp of the black jumper cable to the negative ( – ) terminal of the good battery.

2000186

9. Connect the other clamp of the black jumper cable to the negative ( – ) terminal of the dead battery.

A Battery Cover B Batteries

10. Start the engine of the machine with the good battery.

The batteries are located in the rear of the engine compartment.

BATTERY BOOSTER CABLE WITH CLAMPS

11. Start the engine of the machine with the dead battery.

1. Bring the machines as close as possible, make sure the machines do not touch.

12. Disconnect the clamp of the black jumper cable from the negative ( – ) terminal of the dead battery.

13. Disconnect the clamp of the black jumper cable from the negative (-) terminal of the good battery.

WARNING 24 VOLT ELECTRICAL SYSTEM

14. Disconnect the clamp of the red jumper cable from the positive (+) terminal of the good battery.

2. Make sure the machine with the good battery uses a 24 volt system.

15. Disconnect the clamp of the red jumper cable from the positive (+) terminal of the dead battery.

3. Turn OFF the ignition of both machines.

16. Replace the protective covers on the battery terminals.

4. Remove the battery cover and locate the red positive (+) and black negative ( – ) battery terminals.

5. Remove the protective covers from the battery terminals.

If the batteries require charging, refer to BATTERY CARE in SECTION 3.

6. Connect the clamp of the red jumper cable to the positive (+) terminal of the dead battery.

2.71

Controls and Operation

REFUELLING WARNING

Tigercat 2160 Loader Forwarder THE AFTERTREATMENT SYSTEM AND ITS RELATED COMPONENTS ARE APPLICABLE TO TIER 4F MACHINES ONLY.

Do not refuel while smoking or while near an open flame or sparks.

S≤15 mg/kg ULTRA LOW SULFUR FUEL ONLY 36686AUNI R0

Refuelling of the machine is a critical component of proper operation. It is important to follow the proper procedures based on the refuelling options available for your machine. It is also important to verify the proper type and grade of fuel is used in your machine. Refer to REFUELLING PROCEDURES in SECTION 3 for complete details.

IMPORTANT! Do not idle the engine longer than one hour. Damage to the emission control system will result. When this machine idles for an extended period, excess hydrocarbon buildup is created in the DOC/SCR aftertreatment system. Burn off of excess hydrocarbon, at full load, immediately after a long idle period, generates excess heat which causes damage to emission control system components.

2.72

Tigercat 2160 Loader Forwarder

Controls and Operation

OPERATING THE MACHINE

A

The appropriate lubrication and maintenance schedule must been performed prior to operating the machine.

Refer to SCHEDULED MAINTENANCE in SECTION 3.

Refer to the ENGINE OPERATION AND MAINTENANCE MANUAL supplied with the machine.

B

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

PRESTART CHECKS 1. Unlock cab door.

2000016

A

A Charge Gauge B Portable Fire Extinguisher

4. Check portable fire extinguisher for sufficient charge.

A 234-106

B

A Ignition Key Switch-OFF

2. Set the ignition key switch to the OFF position.

A

2000133

A Fuel Level Gauge B DEF Level Indicator

2000136

A Parking Brake Switch

5. Turn the ignition key switch to the RUN position to check fuel and DEF levels on the computer display main screen. Fill fuel and DEF to the required levels.

Refer to REFUELLING PROCEDURE and DIESEL EXHAUST FLUID TANK – FILLING in SECTION 3.

NOTE: The DEF level indicator is applicable to Tier 4f machines only.

3. Check the parking brake for proper operation and apply the parking brake.

2.73

Controls and Operation

Tigercat 2160 Loader Forwarder

A A

2000148

A Pump Drive Gearbox Dipstick 2000147

A Hydraulic Oil Tank Sight Gauge

8. Check the pump drive gearbox oil level. Dipstick is located in the front engine compartment.

6. Check the hydraulic oil level. The sight gauge is viewable through the engine compartment front access door.

The level of the oil must be between the ADD and FULL marks on the dipstick. Refer to PUMP DRIVE GEARBOX in SECTION 3.

The level should be between the HIGH and LOW marks on the level gauge with all cylinders fully retracted. Refer to REFILLING THE HYDRAULIC SYSTEM in SECTION 3.

A

A 2000164

A Transmission Dipstick

9. Check the transmission oil level. Dipstick is located at the front of the pedestal frame.

The level of the oil must be between the ADD and FULL marks on the dipstick. Refer to TRANSMISSION in SECTION 3.

2000058

A Engine Oil Level Dipstick

A

7. Check the engine oil level. Dipstick is located in the front engine compartment.

The level of the oil must be between the ADD and FULL marks on the dipstick. Refer to the ENGINE OPERATION AND MAINTENANCE MANUAL.

2000158

A Swing Drive Gearbox Oil Bottle

10. Check swing drive gearbox oil level. The bottle is located under a cover to the left of the main boom.

Half fill bottle with recommended oil as specified in SECTION 3.

2.74

Tigercat 2160 Loader Forwarder

Controls and Operation

A

A

2000153

2000210

A Windshield Washer Bottle

A Air Intake Filter Restriction Indicator

11. Check windshield washer fluid level. The windshield washer bottle is located in the left front corner of the upper structure.

13. Check the air filter restriction indicator. Service to the air filter is required when the restriction indicator shows RED. Refer to AIR INTAKE SYSTEM– AIR FILTER RESTRICTION INDICATOR in SECTION 3.

A

A 2000055 2000162

A Engine Air Precleaner – Top of Engine Compartment

12. Check the air intake precleaner. Remove any blockages or obstructions. Refer to AIR INTAKE SYSTEM– ENGINE AIR PRECLEANER in SECTION 3.

A Air Cleaner Unloader Valve

14. Check the air cleaner unloader valve. The valve is located in the front engine compartment. Refer to AIR INTAKE SYSTEM– AIR CLEANER UNLOADER VALVE in SECTION 3.

2.75

Controls and Operation

Tigercat 2160 Loader Forwarder A

B

B

A

C

C

D

2000163

A B C D

2000057

A Engine Coolant Surge Tank B Engine Coolant Fill Cap C Engine Coolant Level Sight Glass

Vent Plug Hand Primer Pump Fuel Filter/Water Separator Engine Fuel Filter

15. Check the fuel filter/water separator and drain any accumulated water into a bowl and clean up any spills. Refer to FILTERS– FUEL FILTER/WATER SEPARATOR in SECTION 3.

17. Check the engine coolant level in the surge tank. Fill as required. Coolant level must be visible in the sight glass.

NOTE: A low level sensor warns the operator if the coolant level falls below an acceptable level.

WARNING

B A

Do not remove the radiator fill cap when the engine is hot, release of pressurized coolant can cause serious burns.

Turn OFF the engine. Only remove the radiator fill cap when cool enough to touch with bare hands.

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

2000025

A Serpentine Fan Belt (Fan not shown) B A/C Compressor Belt

16. Check the condition and tension of the engine serpentine belt and the A/C compressor belt. Refer to BELTS, ENGINE in SECTION 3.

2.76

Tigercat 2160 Loader Forwarder A

B

C

Controls and Operation D

2000187

A B C D

Radiator A/C Condenser Charge Air Cooler Hydraulic Oil Cooler

18. Clean the cooler package if required. Refer to CLEANING COOLER PACKAGE in SECTION 3.

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

25. If cab has been tilted, verify that it is secured to the frame with the locking bolts. Refer to CAB TILT in SECTION 3.

20. Fasten all doors covers and access panels securely.

21. Check tire pressure. Refer to TIRE PRESSURES in SECTION 3.

22. Check wheel bolts for tightness.

23. Check all exits.

24. Inspect all windows daily and immediately after any impacts. Refer to WINDOWS – INSPECTION AND MAINTENANCE in SECTION 3.

2.77

Controls and Operation ANTI STALL

Tigercat 2160 Loader Forwarder

CENTRE JOINT

Selecting Anti Stall ON turns on an electronic load control system which automatically prevents overloading of the engine when several high load functions are in use at the same time. Turn Anti Stall ON during normal machine operation and OFF only when performing service checks on the machine.

If engine stalling occurs, check: • That Anti Stall function is ON. • For a malfunction of the Anti Stall system.

A

B

D

C

2000167

A B C D

Pedestal Frame Centre Joint Wagon Frame Check for Movement in this Joint Area

Do not operate the machine if there is any looseness in the centre joint bearings.

Refer to CENTRE JOINT in SECTION 3 for inspection steps.

2000087

Press the F1 button from the computer display main screen to select the Engine menu.

For additional information regarding adjustment and maintenance of the centre joint refer to CENTRE JOINT in SECTION 11 of the SERVICE MANUAL.

2000078

Press the F2 button again to access the Anti Stall ON/ OFF selection. Press the UP or DOWN arrow buttons to turn Anti Stall ON or OFF. Press the OK button to confirm the selection.

2.78

Tigercat 2160 Loader Forwarder

Controls and Operation

WAGON COMPONENTS B

2000031

A

C

A Bunk B Stake C Wagon Frame

SETTING BUNK LOCATIONS

A

A

2000034

A Bunk Positioning Holes in Wagon

The wagon is fitted with multiple holes to accommodate numerous bunk locations. Install all bunks supplied with the machine whenever possible.

A crane or similar lifting device is required to reposition a bunk. Typical bunk weight is approximately 454 kg (1000 lb).

Change the location of the bunks on the wagon to suit log lengths and to provide sufficient access for the grapple.

2.79

Controls and Operation

Tigercat 2160 Loader Forwarder

BUNKS

STAKES

A bunk can be installed at any location using the holes provided in the wagon frame.

Install all stakes in the bunks. Do not operate the machine with missing stakes. Replace damaged stakes promptly.

A A B

C B

C

D

D

E

2000032

A B C D E

Bunk Bolt Spacer Washer Nut

2000033

A B C D

Install the spacers provided when fastening a bunk to the frame. Install all four fasteners per bunk.

Once bunks are in the desired location, tighten and torque the bolts (M24 – 3.0 Grade 10.9) to 790 – 869 N-m (583 – 641 lbf-ft).

Stake Bolt Washer (QTY 2) Nut

WARNING To prevent the stakes from falling out, secure the stake with the bolt, nut and both washers.

Do not rely on the end-stop to hold the stake in place.

2.80

Tigercat 2160 Loader Forwarder

Controls and Operation

STARTING ENGINE

CAUTION

1. Perform all PRESTART CHECKS. Refer to OPERATING THE MACHINE – PRESTART CHECKS in THIS SECTION.

Do not attempt to start the engine by shorting across the starter terminals as personal injury could occur. Start engine only from the operator's seat.

2. Apply the parking brake.

3. Check that all personnel are clear of the machine.

4. Insert the ignition key and turn ignition key switch to the RUN position. The WAIT TO START icon below will appear on the display during the 'key ON' engine preheat 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 automatically turns OFF.

A

WARNING Do not use ether! The engine is equipped with an electrical starting aid. Use of ether can cause an explosion and severe injury.

IMPORTANT! Allow a cold engine to warm up at LOW for at least five minutes before applying any load. Check all measured values on the computer display often during the warm-up period.

FUEL HEATER

2000132

A WAIT TO START Icon

A

5. Sound the horn to warn personnel of machine startup.

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

B

7. When the engine starts, release the ignition key switch to the RUN position.

NOTE: If the engine does not start after three attempts, check the fuel supply system.

2000168

8. Set engine speed to LOW and wait three to five minutes before operating with a load.

9. Increase engine speed slowly to provide adequate lubrication to the bearings and allow oil pressure to stabilize.

If the engine stalls while operating the machine, turn the ignition key switch to the OFF position and repeat steps 1 through 8.

A Fuel Filter/Water Separator B Fuel Heater (Bottom of Clear Bowl)

The fuel heater is incorporated into the fuel filter/water separator and is controlled electronically by the engine ECU.

2.81

Controls and Operation

COLD WEATHER STARTING WARNING Do not use ether! The engine is equipped with an electrical starting aid. Use of ether may cause an explosion and severe injury.

IMPORTANT! Cold start-ups can result in pump failure. Refer to APPROVED HYDRAULIC OILS in SECTION 3 for recommended oil viscosity and temperature ranges.

Tigercat 2160 Loader Forwarder 2. During the engine warm-up period constantly monitor the engine coolant temperature and the engine oil pressure. Turn OFF the engine if any pressure or temperature does not meet the specification.

3. Continue with MACHINE PREPARATION – SYSTEM TEST AND WARM-UP in THIS SECTION. 4. Start the engine and keep speed at LOW. • Do not activate the pilot system.

• The Hydraulic Oil Return Filter Bypass icon must be OFF before proceeding to the next step.

NOTE: Cold temperatures require the use of an engine block heater and a hydraulic oil tank heater. Preheating of the hydraulic oil is recommended as standard procedure in cold weather.

• The engine coolant temperature must reach 60°C (140°F) before proceeding to the next step.

• The hydraulic oil temperature must reach −7°C (20°F) before proceeding to the next step.

• Check the cooling fan is turning before proceeding to next step.

NOTE: At a starting temperature of −18°C (0°F), it will take approximately thirty minutes to complete he above step.

5. Activate the pilot system and turn ON the saw.

A

• The Hydraulic Oil Return Filter Bypass icon must be OFF.

B

6. Begin slow boom movements.

• Operate the main boom to raise the grapple.

• Operate the stick boom slowly IN and OUT. 2000207

Optional 120V Heater Electrical Connections A Engine Block Heater B Hydraulic Oil Tank Heater

The connectors for the optional 120V heater electrical connections are located in the front engine compartment.

1. Follow the STARTING ENGINE instructions for this COLD WEATHER STARTING procedure, paying attention to the WAIT TO START icon on the computer display.

This message will be ON during the key RUN engine preheat time. The engine must not be started until this message automatically turns OFF. NOTE: If at any time during the warming procedure, the Hydraulic Oil Filter Restricted message appears on the computer display, return engine speed to LOW.

7. Swing the upper structure 360° to the left, then 360° to the right.

8. Steer the machine to the left and right. It may be necessary to drive the machine either towards the wagon frame or the pedestal frame to allow it to steer fully.

9. Observe the hydraulic oil temperature. Do not begin any work until temperature reaches 10°C (50°F).

10. Do not fully push the travel speed control slider on the joystick or fully press the travel speed control pedal until the hydraulic oil temperature reaches 32°C (90°F). Loading may begin but work very slowly. The machine functions will seem to operate much slower until the systems are warmed up.

Avoid operating the boom functions quickly until the hydraulic oil is above 32°C (90°F). Work the machine for thirty minutes.

11. When the hydraulic oil reaches 32°C (90°F) and the machine has been operated for 30 minutes, it is safe to increase engine speed to HIGH.

2.82

Tigercat 2160 Loader Forwarder WARM UP IDLE SPEED ADJUSTMENT

Controls and Operation ADJUST COLD IDLE SPEED

The COLD IDLE function is provided to adjust engine speed to assist in warming the engine and cab temperature in cold weather conditions.

2000074

TURN ON COLD IDLE FUNCTION

Press the menu button

to go to the Main menu.

2000094

2000087

Press the F1 button from the main screen to select the Engine menu.

A

Press the F1 button to access the Adjust menu.

Press the UP or DOWN arrow buttons to select Engine.

Press the OK button to make the selection.

2000077

A Cold Idle Function Indicator

Press the F1 button to turn the cold idle function ON. The cold idle function indicator will illuminate YELLOW on the computer display when the cold idle function is turned ON. Press the BACK button display.

to return to the engine

2.83

Controls and Operation

Tigercat 2160 Loader Forwarder 2000095

Press the UP or DOWN arrow buttons to select Cold Idle Speed.

TURN OFF COLD IDLE FUNCTION

2000087

Press the F1 button to select the engine display.

Press the OK button to make adjustments.

2000096

2000124

The Cold Idle Speed can be adjusted between 1000 rpm and 1400 rpm.

When engine and cab have warmed to the desired temperature, press the F1 button ( ) to turn off the Cold Idle function.

Press the UP or DOWN arrow buttons to select the desired value.

Press the OK button to set the value. The screen will automatically return to the Engine menu.

Press the back button to return to the Adjust menu or the F1 button to return to the Main menu.

Press the back button from the Main menu to return to the main screen.

2.84

Tigercat 2160 Loader Forwarder

ENGINE, RESTARTING AN ENGINE THAT HAS RUN OUT OF FUEL 1. Fill the fuel tank completely.

2. Bleed the system according to the procedures in the ENGINE OPERATION AND MAINTENANCE MANUAL.

Controls and Operation

STOPPING ENGINE IMPORTANT! 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. The important benefits are: • Extended life of engine, cooling and exhaust systems.

WARNING Do not use ether! The engine is equipped with an electrical starting aid. Use of ether may cause an explosion and severe injury.

3. Crank the engine until it starts. If it fails to start after 20 seconds, stop and wait for two minutes before trying again.

IMPORTANT! To prevent damage to the starter, do not engage the starter motor for more than 15 – 20 seconds. Wait two minutes between each attempt to start the engine. If the engine fails to start, refer to ENGINE OPERATION AND MAINTENANCE MANUAL.

• Reduced risk of post shutdown fires.

• Interior of machine cools significantly reducing risk of touching hot surfaces.

1. Find a clear and level area, a least 15 m (50 ft) from any other equipment, to park the machine.

2. Park on level ground with the grapple resting firmly on the wagon frame.

3. Apply the swing brake.

4. Raise the left armrest to deactivate the pilot system.

Engine speed will automatically reset to LOW. Let the engine run at LOW for approximately three minutes (minimum) to allow 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.

Do not increase engine speed before turning the engine OFF. 5. Turn OFF the engine.

6. Remove the ignition key.

NOTE: For Tier 4f machines, when the engine is stopped, all DEF solution is pumped back to tank before the engine power system is turned off. This process takes approximately 90 seconds. Refer to AFTERTREATMENT SYSTEM in SECTION 3 for more information.

NOTE: The aftertreatment system and its related components are applicable to Tier 4f machines only.

7. Turn OFF the battery disconnect switch if required by the servicing procedure or if the vehicle is to be parked for an extended period of time, such as overnight.

8. Perform EVERY 8 HOURS maintenance at the end of the shift (greasing, clean engine compartment, etc.). This allows the machine time to cool down while under the watchful eye of the operator.

2.85

Controls and Operation

Tigercat 2160 Loader Forwarder

MACHINE PREPARATION SYSTEM TEST AND WARM-UP Prior to commencing operations follow steps 1 – 14 to accomplish the following: • Warm up the hydraulic system.

• Test all systems for proper operation.

• Inspect for hydraulic oil leaks.

IMPORTANT! 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.

1. Perform PRESTART CHECKS and STARTING ENGINE procedures in THIS SECTION. 2. Sound the horn to warn personnel of machine startup.

3. Start the engine. Refer to STARTING ENGINE in THIS SECTION.

8. Slowly raise and lower the stick boom and the hoist boom, and check for proper operation. If any operations are not operating as they should, take the necessary steps to correct the problem.

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

10. With the stick boom and hoist boom raised and retracted for the grapple to clear the wagon and bunks, swing the upper structure to the left and right.

11. Steer the machine to the left and right. It may be necessary to drive the machine either towards the wagon frame or the pedestal frame to allow it to steer fully.

12. 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.

13. Rest the grapple on the wagon or stable ground ensuring grapple and booms are fully supported.

14. Apply the parking brake and the swing brake.

15. Raise the left armrest to set engine speed to LOW. 16. 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

B

234-107

A Alarm Light B Master Alarm

4. Controller display alarm light must indicate normal operating conditions.

5. Check that all personnel are clear of the machine.

6. Lower the left armrest and press and release the pilot interlock reset switch. Engine speed will automatically increase to 1400 rpm.

NOTE: The computer has a warm-up mode function which limits engine speed and applies the Anti Stall function during cold starts.

Do not 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.

7. Grapple and boom must not be attached, chained or clamped around trailer or any other stationary object.

2.86

Tigercat 2160 Loader Forwarder

Controls and Operation

LOADING/UNLOADING OPERATIONS DANGER Do not operate this machine to lift or move any objects other than logs.

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

1. Operate the swing, boom and grapple functions to pick up the load, and place it where desired. Refer CONTROLS – JOYSTICK CONTROLS in THIS SECTION for specific information on boom and grapple operating controls. Grip the logs near the middle to keep them balanced.

2. When loading is complete, raise the main boom and bring the stick boom towards the cab and park the grapple clear of the wagon.

2.87

Controls and Operation

Tigercat 2160 Loader Forwarder

TRAVELLING

TRAVELLING WITH A LOAD

TRAVELLING WITHOUT A LOAD

Follow the steps outlined in TRAVELLING – WITHOUT A LOAD in THIS SECTION.

1. Raise the main boom and bring the stick boom towards the cab and raise the grapple to be clear of the wagon.

A loaded machine may be less stable due to a higher centre of gravity.

2. Set the machine direction rocker switch on the left joystick.

Adjust the travel speed to suit the terrain, ground conditions and the size of the load

3. Operate the travel speed control pedal or the travel speed control slider switch on the left joystick to move the machine.

When travelling downhill with a load do not operate the machine at maximum travel speed. Swing the cab to face the wagon and travel with the wagon ahead of the cab.

4. Steer the machine using the steering slider switch on the right joystick or by moving the right joystick side to side.

Refer to CAB CONTROLS – JOYSTICK CONTROLS and CAB CONTROLS – FOOT PEDAL CONTROLS in THIS SECTION.

When travelling uphill swing the cab to face away from the wagon and travel with the wagon behind the cab.

IMPORTANT! Use differential locks sparingly for brief periods and ONLY when additional traction is required. Do not continuously drive the machine with differential locks turned on. Damage to the axles will result.

NOTE: Differential locks will automatically turn OFF two minutes after being turned on.

2.88

LUBRICATION AND MAINTENANCE.................................................................................................................3

Tigercat 2160 Loader Forwarder SECTION 3– LUBRICATION AND MAINTENANCE Read and understand the entire contents of this manual, and all manuals for any attachments or accessories associated with this machine, prior to operating or servicing this equipment.

CONTENTS – SECTION 3 A

ISSUE 1.4, NOVEMBER 2017

ACCESS DOORS AND COVERS............................................................................................................................ 3.22 AFTERTREATMENT SYSTEM (TIER 4F MACHINES ONLY)............................................................................... 3.75 APPROVED ANTI-SEIZE PASTES FOR SENSORS.......................................................................................... 3.99 CATALYTIC CONVERTER.................................................................................................................................... 3.95 DEF QUALITY SENSOR........................................................................................................................................ 3.79 DEF SUPPLY LINES, HEATED............................................................................................................................. 3.86 DEF SUPPLY MODULE......................................................................................................................................... 3.88 DENOX 2.2 DOSING SYSTEM............................................................................................................................. 3.87 DIESEL EXHAUST FLUID (DEF).......................................................................................................................... 3.84 DIESEL OXIDATION CATALYST (DOC)............................................................................................................... 3.88 DOSING MODULE (DEF INJECTOR).................................................................................................................. 3.94 EXHAUST FLAP..................................................................................................................................................... 3.87 HEATER VALVE..................................................................................................................................................... 3.86 HUMIDITY AND TEMPERATURE SENSOR........................................................................................................ 3.96 MIXER TUBE.......................................................................................................................................................... 3.94 NH3 SENSOR......................................................................................................................................................... 3.97 NOX SENSOR........................................................................................................................................................ 3.98 SYSTEM COMPONENTS...................................................................................................................................... 3.76 TANK, DIESEL EXHAUST FLUID......................................................................................................................... 3.79 TEMPERATURE SENSORS................................................................................................................................. 3.96 AIR CONDITIONING SYSTEM................................................................................................................................ 3.55 CAB AIR FILTERS.................................................................................................................................................. 3.58 COMPRESSOR...................................................................................................................................................... 3.55 CONDENSER......................................................................................................................................................... 3.55 ENGINE BELTS...................................................................................................................................................... 3.60 EVAPORATOR, HEATER CORE AND BLOWERS.............................................................................................. 3.57 INSPECTION.......................................................................................................................................................... 3.59 RECEIVER-DRIER................................................................................................................................................. 3.56 AIR INTAKE SYSTEM............................................................................................................................................... 3.72 AIR CLEANER........................................................................................................................................................ 3.73 IMPROPER SERVICING.................................................................................................................................... 3.73 OVER SERVICING............................................................................................................................................. 3.73 AIR CLEANER UNLOADER VALVE..................................................................................................................... 3.74 AIR FILTER RESTRICTION INDICATOR............................................................................................................. 3.74 AIR FILTER RESTRICTION SENSOR................................................................................................................. 3.74 AIR INTAKE TUBING AND JOINTS...................................................................................................................... 3.72 CHANGING FILTER ELEMENTS.......................................................................................................................... 3.73 ENGINE AIR PRECLEANER................................................................................................................................. 3.72 ANTI-CORROSION SPRAY, REMOVAL................................................................................................................ 3.109 APPROVED HYDRAULIC OILS............................................................................................................................... 3.20 ARTICULATION LOCK BAR..................................................................................................................................... 3.21 AXLES, BOGIE.......................................................................................................................................................... 3.34 DRAINING AND REFILLING................................................................................................................................. 3.34 OIL LEVEL CHECK................................................................................................................................................ 3.34 SLEW BEARING INSPECTION............................................................................................................................ 3.35 SLEW BEARING LUBRICATION.......................................................................................................................... 3.35

B

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

BATTERY CARE........................................................................................................................................................ 3.64 BRAKE, PARKING..................................................................................................................................................... 3.27 C

CAB TILT CAB TILT PUMP..................................................................................................................................................... 3.39 LOCKING BOLT STORAGE.................................................................................................................................. 3.41 TILTING PROCEDURE.......................................................................................................................................... 3.39 CARE OF THE MACHINE....................................................................................................................................... 3.103 CASE DRAIN STRAINER......................................................................................................................................... 3.53 CENTRE JOINT......................................................................................................................................................... 3.30 ARTICULATION BEARINGS LUBRICATION....................................................................................................... 3.30 ARTICULATION MAINTENANCE AND INSPECTION........................................................................................ 3.31 OSCILLATION BEARING MAINTENANCE AND INSPECTION......................................................................... 3.31 OSCILLATION LOCK CYLINDER ENDS LUBRICATION................................................................................... 3.30 CLEANING COOLER PACKAGE........................................................................................................................... 3.105 COMMERCIAL WOOD, WEIGHTS........................................................................................................................ 3.118

D

DIAGNOSTICS CONNECTION................................................................................................................................ 3.63 DIESEL EXHAUST FLUID (DEF) (TIER 4F MACHINES ONLY)............................................................................ 3.84 DISPOSAL.............................................................................................................................................................. 3.80 HANDLING AND STORAGE................................................................................................................................. 3.85 PROPER HANDLING PRACTICES...................................................................................................................... 3.85 DIESEL EXHAUST FLUID TANK DEF QUALITY SENSOR........................................................................................................................................ 3.79 DRAINING AND CLEANING................................................................................................................................. 3.80 FILLING................................................................................................................................................................... 3.83 REMOVING THE DEF TANK AND SENDING UNIT............................................................................................ 3.81 SENDING UNIT...................................................................................................................................................... 3.79 STRAINER, CLEANING......................................................................................................................................... 3.82 DRIVESHAFT INSTALLATION................................................................................................................................. 3.33 DRIVESHAFT SLIP SPLINE LUBRICATION.......................................................................................................... 3.32

E

EMERGENCY EXITS.................................................................................................................................................. 3.9 EMERGENCY STOP SWITCH............................................................................................................................... 3.101 ENGINE ACCESS DOORS................................................................................................................................................... 3.22 AIR PRECLEANER................................................................................................................................................ 3.72 BELTS..................................................................................................................................................................... 3.60 REMOVAL AND REPLACEMENT...................................................................................................................... 3.60 COOLANT, ADDING............................................................................................................................................... 3.38 COOLANT, DRAINING........................................................................................................................................... 3.38 DIAGNOSTICS CONNECTION............................................................................................................................. 3.63

F

FILTERS CAB AIR.................................................................................................................................................................. 3.58 DEF DOSING MODULE......................................................................................................................................... 3.89 DRIVE CHARGE.................................................................................................................................................... 3.51 ENGINE OIL............................................................................................................................................................ 3.65 FUEL FILTERS....................................................................................................................................................... 3.65 FUEL FILTER/WATER SEPARATOR.................................................................................................................... 3.67 HYDRAULIC OIL RETURN.................................................................................................................................... 3.48 SCRUBBER............................................................................................................................................................ 3.52 SWING CHARGE................................................................................................................................................... 3.51 FIRE PREVENTION.................................................................................................................................................. 3.10 FLUID ANALYSIS PROGRAM.................................................................................................................................... 3.6 FLUID ANALYSIS KITS............................................................................................................................................ 3.6 3.2

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

FLUID SAMPLING PROGRAM.................................................................................................................................. 3.7 FLUID SAMPLING COLLECTION PROCEDURES............................................................................................... 3.7 FUEL HEATER........................................................................................................................................................... 3.68 FUEL, REFUELLING................................................................................................................................................. 3.71 FUEL TANK................................................................................................................................................................ 3.69 CAPACITY............................................................................................................................................................... 3.69 FUEL FILL CAP...................................................................................................................................................... 3.69 INTANK FUEL STRAINER..................................................................................................................................... 3.70 FUSES AND RELAYS CAB......................................................................................................................................................................... 3.61 ENGINE COMPARTMENT..................................................................................................................................... 3.62 G

GRAFFITI REMOVAL.............................................................................................................................................. 3.108

H

HEATER, FUEL.......................................................................................................................................................... 3.68 HYDRAULIC OIL OPERATING RANGE CHART.................................................................................................... 3.20 HYDRAULIC OIL TANK............................................................................................................................................. 3.43 ADDING OIL........................................................................................................................................................... 3.46 CLEAN OUT COVER............................................................................................................................................. 3.45 DRAINING............................................................................................................................................................... 3.45 LOW LEVEL SWITCH............................................................................................................................................ 3.43 OIL LEVEL SIGHT GAUGE................................................................................................................................... 3.43 RETURN DIFFUSER/STRAINERS....................................................................................................................... 3.54 TEMPERATURE SENDING UNIT......................................................................................................................... 3.43 VACUUM................................................................................................................................................................. 3.44 HYDRAULIC SYSTEM.............................................................................................................................................. 3.42 CASE DRAIN STRAINER...................................................................................................................................... 3.53 FILTER CHANGE PROCEDURES CHARGE AND SCRUBBER FILTERS............................................................................................................... 3.52 RETURN FILTERS.............................................................................................................................................. 3.50 FILTER RESTRICTION PRESSURE SWITCH.................................................................................................... 3.48 FILTERS, HYDRAULIC OIL RETURN.................................................................................................................. 3.48 REFILLING.............................................................................................................................................................. 3.47 RETURN FILTER RESTRICTION INDICATOR................................................................................................... 3.49

L

LUBRICATION POINTS AXLE INPUT YOKE BEARING – PEDESTAL FRAME......................................................................................... 3.28 AXLE INPUT YOKE BEARING – WAGON FRAME.............................................................................................. 3.29 CENTRE JOINT...................................................................................................................................................... 3.30 CENTRE JOINT OSCILLATION BEARING.......................................................................................................... 3.28 DRIVESHAFT FLANGE BEARING – PEDESTAL FRAME................................................................................... 3.29 DRIVESHAFT FLANGE BEARING – WAGON FRAME........................................................................................ 3.29 DRIVESHAFT HANGER BEARING – WAGON FRAME....................................................................................... 3.29 DRIVESHAFTS....................................................................................................................................................... 3.32 PEDESTAL FRAME BULKHEAD.......................................................................................................................... 3.28 ROTARY MANIFOLD SEAL................................................................................................................................... 3.28 STEERING CYLINDER ENDS – CENTRE JOINT................................................................................................ 3.29 STEERING CYLINDER ENDS – WAGON FRAME............................................................................................... 3.29 SWING BEARING AND SWING PINION.............................................................................................................. 3.28 SWING DRIVE........................................................................................................................................................ 3.28 WAGON FRAME BULKHEAD............................................................................................................................... 3.29

N

NEW MACHINE MAINTENANCE FIRST 125 HOUR INSPECTION REPORT............................................................................................................ 3.5 INITIAL PRE-DELIVERY INSPECTION................................................................................................................. 3.5 TIGHTENING POINTS............................................................................................................................................. 3.5 3.3

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

P

PARKING BRAKES, RELEASING............................................................................................................................ 3.27 PRESSURE AND SPEED SETTINGS................................................................................................................... 3.110 PRESSURE WASHING........................................................................................................................................... 3.104 PREVENTIVE MAINTENANCE SCHEDULE............................................................................................................ 3.5 PUMP DRIVE GEARBOX......................................................................................................................................... 3.37 CHECKING OIL LEVEL......................................................................................................................................... 3.37 DRAINING AND REFILLING................................................................................................................................. 3.37

R

REFILLING THE HYDRAULIC SYSTEM................................................................................................................. 3.47 REFRIGERANT SPECIFICATION........................................................................................................................... 3.55 REFUELLING PROCEDURE................................................................................................................................... 3.71 RELEASE PILOT SYSTEM PRESSURE................................................................................................................. 3.25

S

SCHEDULED MAINTENANCE GENERAL................................................................................................................................................................. 3.8 FREQUENTLY........................................................................................................................................................ 3.11 2 YEARS................................................................................................................................................................. 3.17 8 HOURS................................................................................................................................................................. 3.12 48 HOURS............................................................................................................................................................... 3.13 125 HOURS............................................................................................................................................................. 3.13 250 HOURS............................................................................................................................................................. 3.14 500 HOURS............................................................................................................................................................. 3.14 1000 HOURS........................................................................................................................................................... 3.15 2000 HOURS........................................................................................................................................................... 3.16 SEASONAL............................................................................................................................................................. 3.17 SERVICE AND LUBRICATION POINTS.................................................................................................................. 3.18 STARTUP PROCEDURE AFTER MAJOR MACHINE MAINTENANCE.............................................................. 3.100 STRAINERS CASE DRAIN.......................................................................................................................................................... 3.53 FUEL TANK............................................................................................................................................................. 3.70 HYDRAULIC OIL RETURN.................................................................................................................................... 3.54

T

TIRE PRESSURES................................................................................................................................................. 3.117 TORQUE CHART, GENERAL................................................................................................................................. 3.113 TORQUE CHART, SPECIFIC................................................................................................................................. 3.112 TORQUE, FLUID CONNECTIONS........................................................................................................................ 3.114 TOWING INSTRUCTIONS....................................................................................................................................... 3.25 TRANSMISSION........................................................................................................................................................ 3.36 CHECKING OIL LEVEL......................................................................................................................................... 3.36 DRAINING AND REFILLING................................................................................................................................. 3.36

W

WINDOWS............................................................................................................................................................... 3.106 CARE OF POLYCARBONATE WINDOWS........................................................................................................ 3.106 CAUTIONS........................................................................................................................................................ 3.108 CLEANING INSTRUCTIONS........................................................................................................................... 3.107 CONCEALING HAIRLINE SCRATCHES........................................................................................................ 3.108 FIRE PRECAUTIONS....................................................................................................................................... 3.108 GRAFFITI REMOVAL........................................................................................................................................ 3.108 INSPECTION AND MAINTENANCE............................................................................................................... 3.106 RESISTANCE TO CHEMICALS....................................................................................................................... 3.107 RESISTANCE TO WATER................................................................................................................................ 3.107 WINDOW SCREENS.......................................................................................................................................3.9, 3.109

3.4

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL and ATTACHMENT MANUFACTURER'S DOCUMENTATION for additional required maintenance at this scheduled time period.

NEW MACHINE MAINTENANCE

IMPORTANT! When installing wheels, remove all paint from the mating surfaces of both the wheel and the axle flange to ensure metal to metal contact.

INITIAL PRE-DELIVERY INSPECTION Perform the initial pre-delivery inspection using Tigercat form numbers 5414 and 5347: PDI and 125 hour inspection report.

Refer to SECTION 8 of the SERVICE MANUAL for more information.

FIRST 125 HOUR INSPECTION AND SERVICE REPORT

WARNING

With the owner's mechanic present, perform an inspection and service according to the Tigercat form numbers 5414 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.

WARNING, HOT FLUIDS AND HOT MACHINE SURFACES CAN CAUSE SERIOUS BURNS! • Before servicing the machine, allow the engine cooling system, fuel system, exhaust system, hydraulic system and machine surfaces to cool down.

TIGHTENING POINTS All hydraulic connections

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

Hose clamps All cylinder and boom pin retainers Centre joint pin securing bolts

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

Transmission securing bolts Check swing bearing bolt torque Engine mounting bolts

CAUTION

Pump mounting bolts

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

Bogie axle mounting bolts Wheel retaining bolts Swing gearbox mounting bolts Swing motor mounting bolts Cab securing bolts Bunk retaining bolts Pin retainers Any other loose nut, bolt or fitting NOTE: Use of filters other than genuine Tigercat replacement filters is not recommended.

3.5

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

TIGERCAT FLUID ANALYSIS PROGRAM

TIGERCAT FLUID ANALYSIS KITS

Using the Tigercat Advanced Fluid Analysis Program on a regular basis is an excellent preventative maintenance tool.

Each kit includes a Prepaid Sample Bottle and Sample Information Form. Preprinted 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.

Studies have shown that it is possible to receive a 10 to 1 payback when looking at the amount saved on repair costs in relation to the amount invested in a scheduled fluid analysis program. Some of the benefits of a sampling program include:

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

• Detecting problems early and before they become major catastrophic failures.

• Better ability to schedule downtime and forecast cost of repairs.

• Monitoring maintenance schedules and practices and confirming the required maintenance is being done on time.

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

Contact your Tigercat Dealer Parts Department to order kits.

• Increase used equipment value by providing proof of proper maintenance.

This Program uses the most modern technology available to analyze all fluid samples. Most test results are available within 24 hours after receipt of the sample and are supplied in an easy to understand report, which calls for specific action and makes detailed recommendations. The report is available as a mailed or faxed hardcopy, sent via e-mail or it can be viewed on the Internet.

This program will provide Tigercat machine owners access to an Advanced Fluid Analysis Program for all major machine components including Engines, Hydraulic Circuits, Axles, Final Drives, Gearboxes, etc.

Tigercat Fluid 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 follow-up fluid samples.

Refer to FLUID SAMPLING PROGRAM in THIS SECTION for sample valve and drain plug locations.

2160 Series Location

First Sample

Follow-up Samples

Hydraulic Oil

125 hrs

Every 1000 hrs or 6 Months

Swing Drive Gearbox

125 hrs

Every 500 hours or 3 Months

Pump Drive Gearbox

125 hrs

Every 250 hours or 1.5 Months

Transmission

125 hrs

Every 250 hours or 1.5 Months

Bogie Axle Housings

125 hrs

Every 1000 hours or 6 Months

3.6

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

TIGERCAT FLUID SAMPLING PROGRAM

HYDRAULIC OIL SAMPLES

FLUID SAMPLING COLLECTION PROCEDURES Fill out the Sample Information Form (SIF) completely and accurately. When taking multiple fluid samples, fill out all of the required SIF`s in their entirety, prior to taking any fluid samples. Then, immediately package each completed SIF together with the matching fluid 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`s and fluid samples. Incorrectly identified samples could result in a false warning alarm.

A

The accuracy of the lab analysis results is very dependent on the quality of the fluid sample taken.

Collection of clean fluid samples that are representative of the main body of fluid 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 followup samples should be consistently taken from the same location using the same techniques as all previous samples.

2000191

A Oil Sampling Connector

• 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 bleed hose before taking a representative oil sample. Drain a minimum of 90 – 120 ml (3 – 4 oz) of oil into a separate container and discard this oil using approved recycling methods.

• All sample valves and drain plugs must be clean and free of debris.

• Remove the bleed hose and replace the dust cover on the sample valve immediately after taking the oil sample and sealing the sample bottle.

• Remove the dust cover from the sample valve and attach the bleed hose (supplied with the machine) to the sample valve connection.

TRANSMISSION, AXLE AND PUMP DRIVE GEARBOX SAMPLES

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

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

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

• To obtain a representative oil sample, the oil must be warm and must not have settled (within 30 minutes of shutdown).

• Avoid contamination of the sample – replace the sample bottle cap immediately after filling the bottle to approximately ¾ full.

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

All samples taken should be immediately forwarded to the lab for processing.

• 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 fluid samples must be pumped or otherwise drawn out of a tank or housing, a hand operated fluid suction pump is also available from your Tigercat dealer.

3.7

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

GENERAL

• When welding, secure ground connection as close to working position as possible to prevent arcing across machined surfaces or through bearings.

CAUTION

• Clean away all branches, bark and chips. Clean up all traces of oil to avoid fires.

All handles, steps and platforms must be kept free of grease, oil, fuel, mud, snow, ice and forest debris.

• 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. Repair all exhaust leaks or defective parts immediately. Engine exhaust leaks can cause fires. Do not operate the machine until the exhaust leak is repaired.

• Clean around fill caps before checking or adding fluids.

• Release the pilot system pressure before breaking a connection. Refer to RELEASE PILOT SYSTEM PRESSURE in THIS SECTION.

• 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. When exhaust leaks occur during operation, shut down the machine immediately and do not put it back to work until the necessary repairs have been completed.

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

• Clean up spills as soon as possible.

• Use clean oil and containers.

• Drain dirty oil while still warm.

• Have a fire extinguisher at hand.

• Do not exceed recommended fluid levels.

• Lower the boom assembly to the wagon frame or ground when leaving the cab, leaving the machine unattended or when performing servicing procedures.

• Service all hydraulic filters after the failure of a pump, motor, cylinder or valve. Failures of this nature could contaminate the entire hydraulic system.

• Install door safety struts when working on the machine.

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

• Clean up oil spills in engine enclosure immediately.

• Before welding on machine, disconnect all electrical connections and follow all servicing safety precautions as outlined in the WELDING, PRIOR TO in SECTION 1.

* Oil Lost from leakage Lost Oil (Litres) Leakage Rate

Lost Oil (US Gallons)

Per Day

Per Month

Per Year

Per Day

Per Month

Per Year

One drop In TEN Seconds

0.424

12.72

152.0

0.112

3.36

40.0

One drop In FIVE Seconds

0.852

25.6

306.6

0.225

6.75

81.0

One drop per second

4.26

127.76

1533.1

1.125

33.75

405.0

Three Drops per Second

14.2

425.86

5110.31

3.75

112.5

1350.0

Drops Break Into Stream

90.83

2725.5

32706.0

24.0

720.0

8640.0

3.8

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

CHECK EMERGENCY EXITS MONTHLY SLIDING WINDOWS B A

234T-031

A Sliding Window Handle B Screen Hand Knob

1. Push the sliding window handle and slide window fully open.

2. Close window firmly to verify the latch seats correctly.

WINDOW SCREEN HAND KNOBS B

234T-031

A

2000199

A Window Screen Hand Knob – Outside Cab B Window Screen Hand Knob – Inside Cab

1. Turn the inside and outside window screen hand knobs counterclockwise to verify they can be opened by hand.

2. Turn knobs clockwise to tighten.

IMPORTANT! Retighten window screen knobs HAND-TIGHT ONLY to ensure quick exit in case of emergency.

3.9

Lubrication and Maintenance FIRE PREVENTION

Tigercat 2160 Loader Forwarder FIRE EXTINGUISHER

Proper maintenance of your machine will greatly extend its life and reduce your operating costs.

Fire can result in a machine loss which can be financially devastating.

CAUTION

A

After transporting (trucking) a machine from one job sight 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 during the journey.

1. When allowed to accumulate, forest debris and fine organic material (twigs, pine needles, branches, bark, leaves, sawdust, small wood chips, etc.) and any other combustible materials form a fuel source that is extremely difficult to extinguish when ignited. 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.

2. Pay close attention to wiring and plumbing routes during maintenance. All wiring harnesses and hydraulic hoses must be properly restrained and clamped to prevent damage from chaffing.

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

4. In case of fire, lower the grapple to the ground and turn OFF the engine before discharging the fire suppression system.

2000016

A Charge Gauge

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.

Maintain a charged fire extinguisher on the machine at all times and know how to use it.

Refer to the manufacturer's use and information manual for proper usage, additional information and recommended inspection and maintenance intervals.

Refer to FIRE PREVENTION in SECTION 1 for additional information.

3.10

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

SCHEDULED MAINTENANCE

WARNING

For service and replacement intervals refer to SERVICE AND LUBRICATION POINTS in THIS SECTION.

FREQUENTLY • Check for water in fuel filter/water separator.

• Visual engine check.

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

• Check the engine cooling air intake screens for possible restriction.

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

• Check for debris, snow and ice buildup on emergency exits and remove accumulation immediately.

• 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)!

3.11

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

EVERY 8 HOURS

• Centre joint oscillation bearing: 1 fitting – 1 shot.

PERFORM

• Centre joint oscillation lock cylinder ends: 4 fittings – purge.

• FREQUENTLY Maintenance.

• Drain fuel filter/water separator.

• Conduct an overall visual inspection.

CHECK • Engine coolant level.

• Engine oil level.

• Steering cylinder ends: 4 fittings – 1 shot.

• Driveshaft hanger bearing – wagon frame: 1 fitting – 1 shot.

• Driveshaft flange bearings – pedestal and wagon frames: 2 fittings– 1 shot.

• Grapple yoke pins: 2 fittings – purge.

• Air intake precleaner.

• Grapple rotate pinion: 1 fitting – 4 shots, rotate 90° after each shot.

• Air intake filter restriction indicator.

• Grapple arm pins: 6 fittings – purge.

• Replace primary filter if indicator is in red zone.

• Grapple cylinder pins: 4 fittings – purge.

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

• Boom joint: 2 fittings – purge.**

• Air cleaner unloader valve.

• 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.

• Boom knuckle: 2 fittings – purge.** • Cylinders: boom, stick & hoist: 4 fittings total – purge.** **Lubricating cylinder pins and boom joints: 1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

• Hydraulic oil level.

• Swing gearbox upper gearing oil level. Fill bottle to halfway mark.

• Pump drive gearbox oil level at dipstick.

• Transmission oil level at dipstick.

• For leakage around hydraulic components and flexible hoses.

2000009

• For loose nuts, bolts and fittings.

2. Fully extend the stick boom.

• Condition and tension of belts.

3. Lower the main boom and rest the grapple firmly on the wagon bed.

• Exhaust system for leaks.

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

CLEAN • Debris between oil cooler, engine radiator, A/C condenser and charge air cooler.

• Air intake precleaner compartment.

• Remove potentially damaging limbs or sticks and all debris.

LUBRICATE • Swing bearing: 1 fitting – 4 shots while swinging.

• Swing pinion: 1 fitting – 10 shots while swinging.

• Axle input yoke bearings: 2 fittings – 1 shot.

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

IMPORTANT: Care must be taken to protect the boom hoses from snagging, kinking or bending when putting the machine in the service position. Replace any hose that has been kinked, bent, cut or is otherwise damaged.

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL and ATTACHMENT MANUFACTURER'S DOCUMENTATION for additional required maintenance at this scheduled time period.

• Centre joint articulation bearings: 2 fittings – 1 shot.

3.12

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

EVERY 48 HOURS

EVERY 125 HOURS

PERFORM

PERFORM

• 8 HOURS Maintenance.

• FREQUENTLY Maintenance.

CHECK

• 8 HOURS Maintenance.

• Centre joint for looseness.

CHECK • Hydraulic oil return filters restriction indicator on filter heads with engine running at HIGH with oil flow.

Refer to CENTRE JOINT– ARTICULATION MAINTENANCE AND INSPECTION in THIS SECTION for instructions. If a problem is found corrective action should be taken immediately.

• Fluid level in batteries unless maintenance free.

• Engine speed.

Refer to CENTRE JOINT in SECTION 11 of the SERVICE MANUAL for more detailed checking and adjustment procedures.

• All hydraulic pressures.

• Hydraulic pumps and motor securing bolts.

• Torque tightening points as per new machine maintenance.

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL and ATTACHMENT MANUFACTURER'S DOCUMENTATION for additional required maintenance at this scheduled time period.

• Main and stick booms and cylinders.

• Swing bearing area.

• Centre joint area.

• Bunk area.

• Grapple.

CLEAN/REPLACE • Recirculating air filter – A/C heater unit. * • Fresh air filter – cab. *

VISUALLY INSPECT FOR DAMAGE TO • Boom.

• Wagon and pedestal frames.

• Centre joint area.

• Grapple.

Complete repairs immediately.

VISUALLY INSPECT FOR • Frayed electrical wiring and hydraulic hoses.

NOTE: Neglecting the proper maintenance of these items can result in fire.

• Wear in any other components.

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL and ATTACHMENT MANUFACTURER'S DOCUMENTATION for additional required maintenance at this scheduled time period.

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

3.13

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

EVERY 250 HOURS

EVERY 500 HOURS

PERFORM

PERFORM

• FREQUENTLY Maintenance.

• FREQUENTLY maintenance.

• 8 HOURS Maintenance.

• 8 HOURS Maintenance.

• 125 HOURS Maintenance.

• 125 HOURS Maintenance.

CHECK

• 250 HOURS Maintenance.

• Condition and tension of serpentine belt.

• Oil level in bogie axle housings: 4 places.

• Fire extinguisher and turn it to mix contents.

• All hydraulic pressure specifications.

• Visually for oil leaks in Flexxaire® variable-pitch cooling fan.

DRAIN AND REFILL • Oil in transmission.

• Oil in pump drive gearbox.

REPLACE • Engine oil and filter. * • Engine fuel filter. * • Fuel filter/water separator filter. * • DEF dosing module filter * (Tier 4f machines only).

LUBRICATE • Rotary manifold seal: 1 fitting – 2 shots. Do not use a power grease gun. Refer to LUBRICATION POINTS– ROTARY MANIFOLD SEAL in THIS SECTION. Refer to ENGINE OPERATION AND MAINTENANCE MANUAL and ATTACHMENT MANUFACTURER'S DOCUMENTATION for additional required maintenance at this scheduled time period.

CHECK • Torque on swing bearing and swing gearbox retaining bolts.

• Torque on centre joint pin securing bolts.

• Torque on transmission securing bolts.

• Torque on bogie axle mounting bolts.

• Torque on wheel retaining bolts.

• DEF fill strainer for cleanliness. Remove and clean if required.

DRAIN AND REFILL • Oil in swing gearbox – fill bottle to halfway mark.

REPLACE • Hydraulic oil return filters. * • Drive charge filter. * • Swing charge filter. * • Scrubber filter. * • Recirculating air filter – A/C heater unit. * • Fresh air filter – cab. * • Engine crankcase ventilation filter. * (Tier 4f machines only.)

Refer to the ENGINE MANUFACTURER'S DOCUMENTATION for replacement instructions.

LUBRICATE • Pedestal frame centre driveshaft: 1 fitting – purge.

• Pedestal frame axle input driveshaft: 1 fitting – purge.

• Door, door screen and access cover hinges.

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL and ATTACHMENT MANUFACTURER'S DOCUMENTATION for additional required maintenance at this scheduled time period.

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

3.14

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

EVERY 1000 HOURS PERFORM • FREQUENTLY Maintenance.

• 8 HOURS Maintenance.

• 125 HOURS Maintenance.

• 250 HOURS Maintenance.

• 500 HOURS Maintenance.

CHECK • Intank fuel strainer.

• Engine serpentine belt.

• Oil level in Flexxaire® variable-pitch cooling fan.

Check rear seal for signs of leakage. Inspect fan blades for any physical damage.

Refer to FAN MANUFACTURER'S OPERATION AND MAINTENANCE MANUAL for details.

• Centre joint for looseness.

Refer to CENTRE JOINT– ARTICULATION MAINTENANCE AND INSPECTION in THIS SECTION for instructions. If a problem is found take corrective action immediately.

Refer to CENTRE JOINT in SECTION 11 of the SERVICE MANUAL for more detailed checking and adjustment procedures.

DRAIN AND REFILL • Oil in bogie axle differentials and housings. Refer to AXLES, BOGIE– DRAINING AND REFILLING in THIS SECTION and SECTION 8 of the SERVICE MANUAL for bogie axle draining and refilling procedure.

Fill bogie axle housings with both level/fill plugs in line with level ground.

REPLACE • Air cleaner unloader valve.

LUBRICATE • Bogie axle slew bearings: 8 fittings – 1 shot. Refer to AXLES, BOGIE– SLEW BEARING LUBRICATION in THIS SECTION. Refer to ENGINE OPERATION AND MAINTENANCE MANUAL and ATTACHMENT MANUFACTURER'S DOCUMENTATION for additional required maintenance at this scheduled time period.

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

3.15

Lubrication and Maintenance EVERY 2000 HOURS PERFORM • FREQUENTLY Maintenance.

Tigercat 2160 Loader Forwarder REPLACE • All air intake rubber components such as elbows and connectors – High temperatures in this area can cause the rubber to harden.

• 8 HOURS Maintenance.

NOTE: High-temperature silicone connectors do not need to be replaced unless they are damaged.

• 125 HOURS Maintenance.

NOTE: Refer to AIR INTAKE SYSTEM in THIS SECTION.

• 250 HOURS Maintenance.

• 500 HOURS Maintenance.

• 1000 HOURS maintenance.

CHECK • All hydraulic system components especially cooling fan for proper operation after hydraulic oil has been replaced.

• Hydraulic oil tank breather.

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL and ATTACHMENT MANUFACTURER'S DOCUMENTATION for additional required maintenance at this scheduled time period.

• Air intake precleaner.

DRAIN AND REFILL • Hydraulic oil tank with recommended hydraulic oil.

Refer to APPROVED HYDRAULIC OILS in THIS SECTION. It is strongly recommended that a program of regular oil testing be used. Oil change intervals can be established from oil test results.

Make sure the hydraulic oil type selected on the computer display matches the oil type being used.

Adjust oil type if needed. Refer to COMPUTER CONTROL SYSTEM – ADJUSTMENT MENU – HYDRAULIC OIL GRADE SELECTION in SECTION 2 or SECTION 6 of the SERVICE MANUAL, for selecting hydraulic oil type setting procedure.

NOTE: When refilling the hydraulic system, vent pumps, motors and valves of air by opening a plug or hose fitting located near or on top of the pumps, motors and valves until oil free of air is seen flowing out of the plug or hose fitting. Failure to vent air from the hydraulic system could cause serious damage to hydraulic components. Tighten plugs or fittings and clean up any spilled oil when completed.

NOTE: Changing diffuser/strainers, filters and replacing the hydraulic oil tends to aerate the oil.

For maximum pump life, do not operate the machine for one hour after servicing to allow entrained air to escape from the oil prior to applying working pressures to the pumps.

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

3.16

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

EVERY 2 YEARS

SEASONAL

REPLACE

REPLACE

• Engine coolant. Antifreeze must comply with international specifications ASTM D-6210.

• Drain and refill hydraulic oil tank with recommended hydraulic oil if required to meet operating temperature range.

• Oil in Flexxaire® variable-pitch cooling fan.

Refer to APPROVED HYDRAULIC OILS in THIS SECTION.

Refer to FAN MANUFACTURER'S OPERATION AND MAINTENANCE MANUAL for details.

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL and ATTACHMENT MANUFACTURER'S DOCUMENTATION for additional required maintenance at this scheduled time period.

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

3.17

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

82703BENG

3.18

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance Tigercat Model 2160

SERVICE AND LUBRICATION POINTS

REFER TO Tigercat OPERATOR'S MANUAL FOR FURTHER INFORMATION CAPACITY

ENGINE OIL/FILTER

•

•

35

9.2

•

•

REP •

DESCRIPTION QTY

2000 

1000 

500 

REP

CHK

USG

2

CHANGE COOLANT EVERY 2 YEARS

CHK

LITERS

COOLING SYSTEM

250 

8

1

125 

SERVICE POINT NO.

SERVICE EVERY ITEM

SEE ENGINE OPERATION AND MAINTENANCE MANUAL FOR REQUIRED ANTIFREEZE SOLUTION AND MIXTURE.

• SEE ENGINE OPERATION AND MAINTENANCE MANUAL FOR PROCEDURES, CAPACITIES AND REPLACEMENT INTERVALS.

3

CRANKCASE VENTILATION FILTER - T4F ONLY

4

FUEL FILTER (ENGINE)

5

FUEL FILTER/WATER SEPARATOR

6

DEF DOSING MODULE FILTER - T4F ONLY

7

INTANK FUEL STRAINER

8

AIR INTAKE PRECLEANER

CHK

AIR INTAKE PRIMARY ELEMENT

CHK

1

AIR INTAKE SAFETY ELEMENT

CHK

1

CHECK FILTER RESTRICTION INDICATOR. REFER TO 8 HOUR SCHEDULED MAINTENANCE IN SECTION 3 OF THE MANUAL FOR DETAILS.

10

AIR CLEANER UNLOADER VALVE

CHK

1

REFER TO SECTION 3 OF MANUAL.

11

AIR INTAKE CONNECTIONS

CHK

REP

1

CHECK FOR LOOSE CLAMPS AND DAMAGED RUBBER COMPONENTS. REPLACE RUBBER COMPONENTS.

12

HYDRAULIC OIL TANK (LEVEL INDICATOR ON TANK)

CHK

D/R

13

HYDRAULIC OIL TANK BREATHER

14

HYDRAULIC OIL RETURN FILTERS (4 ELEMENTS) 3 STANDARD FILTERS 1 WATER ABSORBING FILTER

15

DRIVE CHARGE FILTER

9

16

1

REP DRN

•

1

REP

1

REP

1 CHK CHK

1

REP

REP

1 4

†

REP

1

†

REP

17

SCRUBBER FILTER

18

A/C RECIRCULATION FILTER/CAB FRESH AIR FILTER

19

SWING GEARBOX

CHK

20

TRANSMISSION

CHK

21

PUMP DRIVE GEARBOX

CHK

22

BOGIE AXLE HOUSINGS

23

BOGIE AXLE SLEW BEARINGS

1

†

REP

CHK

†

D/R

2

CLEAN OR REPLACE AS NECESSARY. ** HALF FILL RESERVOIR WITH SAE 75W-90 OR SAE 80W-140 SYNTHETIC GEAR OIL.

**

**

1

D/R

6

1.6

1

D/R

7.7

2.0

1

226

59.7

4

CHK

CHECK FILTER RESTRICTION INDICATOR ON FILTER HEADS WITH ENGINE RUNNING AT HIGH IDLE AND WITH OIL FLOW.

1

†

REP

SWING CHARGE FILTER

CLEAN AS REQUIRED. INSPECT IMPELLER FOR WEAR OR DAMAGE. REPLACE AS NECESSARY.

DRAIN AND REFILL AS REQUIRED BY SEASONAL OIL CHANGE. SEE APPROVED HYDRAULIC OILS IN SECTION 3 OF THE MANUAL.

REP

CHK

REFER TO SECTION 3 OF THE MANUAL FOR DETAILS.

1

D/R LUB

PURGE

FILL WITH MIL-L-2105C OR API-GL-5 LUBRICANT GRADE/WEATHER TEMPERATURE: BELOW -10°F(-23°C) USE 75W-90 UP TO 100°F(38°C) USE 80W-90 ABOVE 100°F(38°C) USE 85W-140

8

LITHIUM BASE EP2 GREASE

24

SWING BEARING

LUB

4 SHOTS

1

GREASE WHILE SWINGING. LITHIUM BASE EP2 GREASE 

25

SWING PINION

LUB

10 SHOTS

1

GREASE WHILE SWINGING. LITHIUM BASE EP2 GREASE 

26

AXLE INPUT YOKE BEARINGS

LUB

PURGE

2

LITHIUM BASE EP2 GREASE 

CENTRE JOINT ARTICULATION BEARINGS

LUB

PURGE

2

CENTRE JOINT OSCILLATION BEARING

LUB

PURGE

1

CENTRE JOINT OSCILLATION LOCK CYLINDER ENDS

LUB

PURGE

4

CENTRE JOINT BEARING PRELOAD

CHK 48 

28

STEERING CYLINDER ENDS

LUB

PURGE

4

LITHIUM BASE EP2 GREASE 

29

DRIVESHAFT HANGER AND FLANGE BEARINGS

LUB

PURGE

3

LITHIUM BASE EP2 GREASE 

30

MAIN AND STICK BOOM JOINTS

LUB

PURGE

4

LITHIUM BASE EP2 GREASE 

31

HOIST AND STICK CYLINDER ENDS

LUB

PURGE

4

LITHIUM BASE EP2 GREASE 

27

32 33

CHK

REFER TO SECTION 3 OF THE MANUAL FOR DETAILS.

DRIVESHAFT, PEDESTAL FRAME CENTRE

LUB

PURGE

1

DRIVESHAFT, PEDESTAL FRAME AXLE INPUT

LUB

PURGE

1

REFER TO SECTION 3 OF THE MANUAL.

GRAPPLE, Tigercat FIRE EXTINGUISHER

35

DOOR, DOOR SCREEN AND ACCESS COVER HINGES

36

ROTARY MANIFOLD SEAL

LITHIUM BASE EP2 GREASE 

SEE MANUFACTURER'S MAINTENANCE SCHEDULE.

GRAPPLE, OTHER MANUFACTURER

34

LITHIUM BASE EP2 GREASE 

CHK PURGE

LUB LUB

82703BENG

3.19

1

TURN TO MIX CONTENTS.

20

LITHIUM BASE EP2 GREASE 

1

DO NOT USE POWER GREASER. REFER TO SECTION 3 OF THE MANUAL FOR DETAILS. LITHIUM BASE EP2 GREASE 

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

APPROVED HYDRAULIC OILS In addition to providing the vehicle with its normal operational functions, hydraulic oil is also used to apply the brakes and operate the differential locks.

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

3.20

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

ARTICULATION LOCK BAR WARNING To prevent movement of the machine and possible injury, install the articulation lock bar before performing any work in the centre joint area.

Install the articulation lock bar when performing all servicing and maintenance procedures or when transporting the machine.

The articulation lock bar is stored on the left side of the pedestal frame next to the access steps.

2000178

To install the articulation lock bar:

Articulation Lock Bar in Stored Position

1. Park the machine on level ground with the wagon frame and pedestal frame in a straight position.

Refer to PARKING THE MACHINE in SECTION 1.

A

D

B

2. Remove both retaining bolts from the articulation lock bar in the stored position.

3. Relocate the articulation lock bar between the wagon and pedestal frames. Line up the holes at each end of the articulation lock bar with the holes in the frames.

4. Secure the articulation lock bar in place with both retaining bolts.

5. After work or transport is completed, remove the articulation lock bar and return to the storage location on the pedestal frame. Secure in place with both retaining bolts.

D

C

2000175

A B C D

3.21

Articulation Lock Bar in Locked Position

Wagon Frame Pedestal Frame Articulation Lock Bar Retaining Bolts

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

SERVICE AND MAINTENANCE ACCESS DOORS AND COVERS A

B

C

E

D

F G

L K

J

I

H

2000036

A B C D E F G H I J K L

Left Side Door Surge Tank Cover Engine Compartment Front Access Door Pump Compartment Access Door Cab Riser Left Access Door Swing Drive Gearbox Cover DEF Tank Fill Cover Hydraulic Oil Fill Cover Left Pedestal Frame Cover Right Pedestal Frame Cover Transmission Cover Windshield Washer Bottle Cover

Provides Access to: Cab Engine Coolant Fill Fuel Filter/Water Separator, Engine ECU, Fuse and Relay Panel, Engine Oil Dipstick Hydraulic System Filters, Hydraulic System Pumps Fuel Tank Intank Fuel Strainer, Cab Tilt Pump Swing Drive Gearbox Bottle DEF Tank Fill Cap Hydraulic Oil Fill Pump and Switch Oscillation Lock Control Valve Parking Brake Release Hand Pump Transmission, Drive Motors Windshield Washer Bottle

3.22

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

C

A

D

B

2000037

A B C D

Engine Compartment Rear Access Door Cooler Package Access Door Cab Riser Right Access Door Cab Window and Screen – Right Side

Provides Access to: Engine Oil Filter, Aftertreatment System Components, Engine Belts, Batteries Cooler Package Fuel Tank Intank Fuel Strainer, Cab Tilt Pump Emergency Exit

3.23

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

HINGED ACCESS DOORS The pump compartment, rear engine compartment and cooler package access doors are hinged and latched for ease of maintenance.

ENGINE COMPARTMENT FRONT ACCESS DOOR

A

A

B

A

2000172

A Engine Compartment Front Access Door B Door Latch

2000171

A Door Latch

To open these doors, lift the latch handle outwards, turn 90 degrees and pull the handle to swing the door open.

The engine compartment front access door is removable. To open, lift both latch handles outwards, turn 90 degrees and using both handles lift the door up and out of the opening. Store the door against the railing when performing service.

ACCESS DOOR LATCHES

A 2000204

A

2000152

A Door Safety Stop in Locked Position

B 2000205

A Latched Position B Lift Outwards from Latched Position C Turn 90 Degrees to Unlatch, Pull to Open

These doors are equipped with a door safety stop. To brace the door open, lift the door safety stop out of its storage position in the door and place the safety stop bolt in the hole provided in the door ledge. Store the safety stop back in the door before closing.

CAUTION Install the Door Safety Stop when opening the doors to perform service in the engine compartment, pump compartment and on the cooler package. If not used, the doors could close unexpectedly causing personal injury or component damage.

3.24

C 2000206

Tigercat 2160 Loader Forwarder

RELEASE PILOT SYSTEM PRESSURE WARNING The accumulators maintain pressure in the hydraulic circuits when the machine if off. To prevent injury from fluid injection, release pilot system pressure before performing any work on any hydraulic circuit.

Release pressure from the accumulators prior to working on any hydraulic circuit.

Lubrication and Maintenance

TOWING INSTRUCTIONS NOTE: For instructions on transporting the machine, refer to VEHICLE MOVING INSTRUCTIONS found in the operator's manual case in the cab.

Make repairs at the point where the machine is parked if possible.

Towing is only recommended over short distances.

Prior to towing the machine perform the following operations: 1. Disabling the oscillation lock.

2. Disconnecting the transmission.

3. Preparing the steering cylinders.

B

4. Releasing the parking brakes.

5. Towing the machine.

Prepare the machine as described in PREPARING THE MACHINE FOR MAINTENANCE in SECTION 1.

DISABLING THE OSCILLATION LOCK A

A

2000193

A G1 Accumulator Test Port B Accumulator Section

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

2. Remove the riser step and deck plate in front of the cab door to gain access to the hydraulic manifold.

3. Connect a 0-345 bar (0-5000 psi) gauge to the G1 (accumulator) test port.

2000180

4. Turn ON the battery disconnect switch.

5. Turn the ignition key switch to the RUN position. Do not turn ON the engine.

6. Lower the left armrest and press the PILOT INTERLOCK RESET SWITCH. 7. Fully press the brake foot pedal and release it repeatedly until the pressure gauge reads 0 bar (0 psi). This may require pressing the brake foot pedal 60 times or more.

Pressure may remain in the system after completing all of the above steps. Use caution when loosening hydraulic connections.

A Oscillation Control Valve Manual Override Control

The oscillation lock can be turned OFF mechanically using the manual override control on the oscillation control valve.

The control valve is located under the left pedestal frame cover. Refer to ACCESS DOORS AND COVERS in THIS SECTION. To turn OFF the oscillation lock, turn the manual override control counterclockwise and allow the stem to extend.

To turn ON the oscillation lock for normal operation, push the stem in and turn it clockwise.

For additional information, refer to SECTION 5 of the SERVICE MANUAL. 3.25

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

DISCONNECTING THE TRANSMISSION

PREPARING THE STEERING CYLINDERS

IMPORTANT! Before towing, place the transmission in NEUTRAL. Do not tow a machine in gear. The extremely high forces created will cause significant damage to the components of the hydrostatic drive system and the transmission.

IMPORTANT! Disconnect the transmission from the drive wheels prior to towing the machine. Towing the machine with the transmission connected will cause significant damage to the transmission and hydrostatic drive system.

SM47

A

A

B

A Normal Hose Connection B Hoses on One Cylinder Cross Connected for Towing

To allow the machine to steer while towing and prevent damage to the steering cylinders, cross connect the hydraulic hoses on one of the steering cylinders. This will allow trapped oil to flow freely between the two steering cylinders, providing ease of turning with some dampening effect.

2000149

A Transmission Disconnect Lever – Shown in Engaged Position

The transmission is equipped with a lever that disconnects the transmission from the drive wheels.

Insert a short bar into the hole of the transmission disconnect lever and pull the lever up.

The transmission is accessed is by lifting the hinged pedestal frame deck plate. Refer to ACCESS DOORS AND COVERS in THIS SECTION.

3.26

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

RELEASING THE PARKING BRAKES

TOWING THE MACHINE

WARNING Adequate steps must taken to prevent the machine from moving prior to releasing the brakes. This may include chocking the wheels or securing it to a second vehicle.

A

2000198

A Camera 1 – Wagon Frame B

A

Tow the machine from the wagon frame, using the pintle hitch.

C

Use a vehicle of adequate power and size for towing.

WARNING All braking has been disabled. Use an additional vehicle of adequate size as a hold-back and braking vehicle.

IMPORTANT! Do not tow the machine over 3 km/h (2 mph).

2000179

A Parking Brake Release Hand Pump B Pressure Release Valve C Handle

When towing is complete: 1. Chock the wheels.

The parking brake release hand pump is located under the right pedestal frame cover. Refer to ACCESS DOORS AND COVERS in THIS SECTION.

2. Re-apply the brake. Turn the hand pump pressure release valve counterclockwise. Turn the brake release valve to its normal position.

1. Turn the pressure release valve on the parking brake release hand pump clockwise until snug.

3. Reconnect the steering cylinder hoses in the correct orientation.

2. Install the handle and pump by hand to release the brakes. With the ignition key turned ON, the parking brake icon on the computer display will turn OFF when the brakes are released.

A

A pressure of 40 bar (580 psi) is required to release the parking brakes.

NOTE: The pressure will gradually reduce causing the brakes to reapply after several hours.

2000149

A Transmission Disconnect Lever – Shown in Engaged Position

4. Reconnect the transmission. Return the transmission disconnect lever to the engaged position.

5. Turn ON the oscillation lock.

3.27

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

SWING DRIVE LUBRICATION

PEDESTAL FRAME LUBRICATION

SWING GEARBOX

To access the pedestal frame lubrication points, remove the lynch pin and raise the bulkhead cover located on the pedestal frame above the centre joint.

A

D E

2000158

A Half Fill Bottle with Recommended Gear Oil.

The swing gearbox upper gearing is filled with gear oil.

Check oil level in the bottle every 8 hours. The oil bottle is located under the swing drive gearbox cover located on the left side of the upper structure. Oil level in the bottle must be kept at the half full mark at all times.

Drain and replace swing gearbox upper gearing gear oil every 500 hours. Use SAE 75W-90 or 80W-140 synthetic gear oil.

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

SWING BEARING AND SWING PINION

A

C

B

2000166

A B C D E

Rotary Manifold Seal Grease Fitting Centre Joint Oscillation Bearing Grease Fitting Axle Input Yoke Bearing Grease Fitting Bulkhead Cover Lynch Pin

ROTARY MANIFOLD SEAL Apply two shots of grease every 250 hours.

A

NOTE: During cold weather applications the swing and machine functions must operate for several hours to achieve operating temperature. Warm the lubricating grease to 22°C (72 F) before lubricating the rotary manifold seal. Do not over grease!

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

B 2000059

A Swing Bearing Grease Fitting B Swing Pinion Grease Fitting

To lubricate the swing bearing, apply 4 shots of grease while swinging every 8 hours to the upper grease fitting located between the foot pedals in the operator's cab.

CENTRE JOINT OSCILLATION BEARING Apply one shot of grease every 8 hours.

AXLE INPUT YOKE BEARING Apply one shot of grease every 8 hours.

To lubricate the swing pinion (or teeth), apply 10 shots of grease while swinging every 8 hours to the lower grease fitting located between the foot pedals in the operator's cab.

3.28

Tigercat 2160 Loader Forwarder DRIVESHAFT FLANGE BEARING – PEDESTAL FRAME

Lubrication and Maintenance

WAGON FRAME LUBRICATION A

B

C

A

D

E

2000197

A Driveshaft Flange Bearing Grease Fitting – Pedestal Frame

The grease fitting for the pedestal frame centre driveshaft flange bearing is located on the right side of the centre joint.

2000051

A B C D E

Apply one shot of grease every 8 hours.

STEERING CYLINDER ENDS – CENTRE JOINT

Axle Input Yoke Bearing Grease Fitting Steering Cylinder End Grease Fitting Driveshaft Flange Bearing Grease Fitting Driveshaft Hanger Bearing Grease Fitting Steering Cylinder End Grease Fitting

The lubrication bulkhead for the wagon frame lubrication points is located on the left side of the frame near the centre joint.

AXLE INPUT YOKE BEARING A

Apply one shot of grease every 8 hours.

STEERING CYLINDER ENDS Apply one shot of grease every 8 hours.

DRIVESHAFT FLANGE BEARING Apply one shot of grease every 8 hours.

DRIVESHAFT HANGER BEARING 2000197

A Steering Cylinder Ends Grease Fitting

Apply one shot of grease every 8 hours.

The grease fittings for the steering cylinder ends are located on both sides of the centre joint.

Apply one shot of grease every 8 hours.

3.29

Lubrication and Maintenance

CENTRE JOINT ARTICULATION BEARINGS LUBRICATION

Tigercat 2160 Loader Forwarder OSCILLATION LOCK CYLINDER ENDS LUBRICATION

A

A

2000169

A 2000200

A Oscillation Lock Cylinder Ends Grease Fittings B

The fittings for the outer cylinder ends are accessed through a slot in the top of the pedestal frame.

Apply one shot of grease every 8 hours.

2000170

A Upper Articulation Bearing Grease Fitting B Lower Articulation Bearing Grease Fitting

Apply one shot of grease every 8 hours. This purges the articulation pivot bearings of debris and water.

3.30

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

ARTICULATION MAINTENANCE AND INSPECTION

OSCILLATION BEARING MAINTENANCE AND INSPECTION

Prepare the machine as described in PREPARING THE MACHINE FOR MAINTENANCE in SECTION 1 before servicing the centre joint.

Prepare the machine as described in PREPARING THE MACHINE FOR MAINTENANCE in SECTION 1 before servicing the oscillation bearing.

Visually inspect the centre joint oscillation bearing for looseness every 1000 hours.

With an observer on the ground, keeping well clear of the centre joint area, perform the following test to check for looseness of centre joint oscillation: 1. Rest the boom or grapple firmly on the wagon frame.

Drive the machine in forward and reverse rapidly several times.

2. Check for motion between the centre joint and pedestal frame. Also check for a “clunking” sound at the oscillation joint.

A

B

D

C

2000167

A B C D

Pedestal Frame Centre Joint Wagon Frame Check for Movement in this Joint Area

3. Movement between centre joint and pedestal frame or clunking indicates a loose oscillation joint and oscillation joint preload must be checked. Refer to OSCILLATION– PRELOAD – CHECKING in SECTION 11 of the SERVICE MANUAL. Take immediate action to correct problems if any symptoms described above are observed.

Visually inspect the centre joint articulation for looseness every 1000 hours.

With an observer on the ground, keeping well clear of the centre joint area, perform the following test to check for looseness of centre joint articulation.

1. Swing the boom 90 degrees to one side of the machine. Fold the stick boom down, and rapidly raise and lower the main boom several times to “bounce” machine (it may be necessary to adjust the boom up and boom down parameters using the computer display).

2. As the machine bounces, check for motion between the wagon frame and centre joint lugs. Also check for a “clunking” sound at the centre joint area.

3. Movement between wagon frame and centre joint lugs or clunking of the pivot indicates a loose articulation joint and articulation preload must be checked. Refer to ARTICULATION– PRELOAD – CHECKING in SECTION 11 of the SERVICE MANUAL. Take immediate action to correct problems if any symptoms described above are observed.

NOTE: A more precise method using a dial indicator will provide an accurate assessment of the condition of the centre joint. Refer to SECTION 11 of the SERVICE MANUAL for details.

3.31

Lubrication and Maintenance

DRIVESHAFTS When operating in extremely wet or dusty conditions or when the regular service schedule has been neglected, insufficient lubrication to the spline area of the pedestal frame driveshafts will result in premature wear. In addition old grease often forms into a semi-solid, rubberlike plug preventing the purging of contaminants (water, dirt, sand, etc.) through the slip spline seal.

Tigercat 2160 Loader Forwarder PEDESTAL FRAME AXLE INPUT DRIVESHAFT SLIP SPLINE LUBRICATION

The most common cause of joint and slip spline failure is lack of proper lubrication.

B

A

Lubricate the driveshaft splines every 500 hours.

PEDESTAL FRAME CENTRE DRIVESHAFT SLIP SPLINE LUBRICATION

2000005

B

A

C

A Grease Fitting B Relief Hole in End of Driveshaft C Axle End of Driveshaft

4. Apply grease to grease nipple until new, clean grease appears at the relief hole at yoke end of slip spline.

5. Plug or cover relief hole and continue to apply pressure to grease nipple until new, clean grease appears at slip spline seal.

C 2000004

A Grease Fitting B Relief Fitting in End of Driveshaft C Centre Joint End of Driveshaft

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

6. If grease does not appear at slip spline seal and continues to exit from the covered relief hole, remove the driveshaft and inspect for hardened grease build up, rust or other contaminants within the driveshaft. Repair or replace the driveshaft.

Refer to SECTION 8 of the SERVICE MANUAL for complete details regarding driveshaft installation.

2. Block the wheels and allow machine to cool.

3. Apply grease to the grease nipple until new, clean grease exits from the relief fitting.

Check to see if grease is exiting from the relief fitting. If grease does not exit from the relief fitting, remove the relief fitting and apply grease at the grease nipple. If grease flows out of relief fitting hole replace the relief fitting.

If grease does not exit from the relief fitting hole, remove the driveshaft and inspect for hardened grease build up, rust or other contaminants within the driveshaft. Repair or replace driveshaft.

3.32

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

DRIVESHAFT INSTALLATION

Torque driveshaft U-joint fasteners to 150 – 163 N-m (110 – 120 lbf-ft) – lubricated.

A

G

D

I J K

B

H

C

F

E

F

2000003

A B C D E F

Wagon Frame Axle Input Driveshaft Wagon Frame Centre Driveshaft Pedestal Frame Centre Driveshaft Pedestal Frame Axle Input Driveshaft Centre Coupler Centre U-Joints

G H I J K

3.33

Wagon Frame Bogie Axle Pedestal Frame Bogie Axle Hanger Bearing – Wagon Frame Centre Driveshaft Flange Bearing – Wagon Frame Centre Driveshaft Flange Bearing – Pedestal Frame Centre Driveshaft

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

BOGIE AXLES

DRAINING AND REFILLING BOGIE AXLE

The bogie axle oil reservoirs (differential, bogie housings and planetary drives) are interconnected and can be accessed at two locations per bogie to check and set the correct oil level in the bogie axles.

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

Drain and replace the oil in the bogie axles every 1000 hours.

2. Allow bogie axles to sit for at least 30 minutes before draining the oil from the bogie housings to allow particulate to settle in the oil pan.

CHECKING BOGIE AXLE OIL LEVEL 1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

NOTE: The machine and the bogie axles must be level when checking the oil level.

3. Clean around all fill/level and drain plugs.

4. Remove the bogie housing fill/level plugs (one per housing).

NOTE: Do not remove the drain plugs until the fill/ level plugs have been removed.

5. Remove the bogie housing drain plugs (two per housing) and drain the oil into a suitable container for disposal.

B

B

NOTE: The machine and bogie axles must be level and the oil must be warm when draining and refilling.

A

2000001

A Fill/Level Plug – 2 Places per Axle (5/8 in female hex) B Drain Plug – 4 Places per Axle (1-1/2 in male hex head)

2. Clean around the fill/level plug. Either bogie housing can be checked.

3. Remove the fill/level plug.

4. Wearing oil-resistant protective gloves, insert a finger into the fill/level plug hole to determine the oil level. The correct oil level is at the bottom of the fill/ level plug holes.

5. If bogie axle oil level is low, remove the fill/level plug on the opposite bogie housing.

6. Place drain pans under the level/fill holes. Pump new oil into one of the levels/fill holes until oil starts weeping out the hole. Do not overfill.

7. Wait 5 minutes and check the level in the opposite housing. Continue until the oil levels are correct in both bogie housings.

8. When the oil stops weeping from the level/fill holes install both level/fill plugs.

A 2000002

A Differential Drain Plug (13 mm female square)

6. Remove the differential drain plug and drain the oil into a suitable container for disposal.

7. The drain plugs are magnetic. Clean off any filings collected on all 5 magnetic drain plugs.

8. Install and tighten the differential drain plug and the bogie housing drain plugs.

9. Place drain pans under the level/fill holes. Pump new oil into one of the levels/fill holes until oil starts weeping out the hole. Do not overfill.

Refer to SERVICE AND LUBRICATION POINTS in THIS SECTION for oil capacity and recommended gear oils.

10. Install the bogie axle housing fill/level plugs and check for leaks.

11. Run bogie axles for at least 10 minutes to remove trapped air in confined spaces.

12. Remove the fill/level plugs, recheck oil level and top up the oil levels if required.

3.34

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

BOGIE AXLE SLEW BEARING LUBRICATION

BOGIE AXLE SLEW BEARING INSPECTION Inspect the bogie axle slew bearings for leaks and for wear.

The bogie axle slew bearings are lifetime lubricated bearings and do not require servicing.

To protect the bearings, replace soiled grease in the prechambers (buffer chambers) every 1000 hours.

1. While on flat and level ground, drive the machine straight (not articulated) back and forth a few times to settle the slew bearings.

Refer to the SERVICE AND LUBRICATION POINTS CHART in THIS SECTION for correct grade of grease.

2. Prepare the machine as described in PREPARING THE MACHINE FOR MAINTENANCE in SECTION 1.

B

3. Inspect the area around the slew bearings for oil leaks and for contact between the slew ring and frame. If oil leaks or contact is observed, the slew bearing must be replaced immediately.

A

A

B

2000150

A Grease Nipple – 2 Places per Axle B Grease Outlet Port– 2 Places per Axle

To replace the grease in the pre-chamber: 1. Clean the area around the grease nipples (one upper and one lower) and the outlet ports (one upper and one lower.

1085B-035

A Top of Bogie B Feeler Gauge

The outlet ports are sealed with an M14 hex head plug. Plastic caps may cover the grease nipples and outlet ports.

NOTE: There are multiple access locations along the circumference of the slew bearing. The grease nipple and outlet ports are those located closest to the centre of the machine.

A

2. Remove the hex head plug from the upper outlet port.

3. Inject grease into one of the grease fittings until new grease appears at the open outlet port.

4. Inject grease into the other grease fitting until new grease appears at the open outlet port.

5. Replace and tighten the upper outlet port plug.

6. Remove the hex head plug from the lower outlet port.

7. Inject grease into one of the grease fittings until new grease appears at the open outlet port.

1085B-027

A Feeler Gauge

4. Use a feeler gauge to measure the gap between the top of the slew bearing and the frame. Measure as close to the top as possible.

5. Use a feeler gauge to measure the gap between to bottom of the slew bearing and the frame.

6. Replace the slew bearing as soon as possible if:

8. Inject grease into the other grease fitting until new grease appears at the open outlet port.

a. The top or bottom measurement is less than 0.5 mm (0.02 in), or

9. Replace and tighten the lower outlet port plug.

b. The difference between the 2 measurements is greater than 1.25 mm (0.05 in).

10. Reinstall the protective caps if applicable.

If the machine is put back into service before a new bearing is installed, measure the gap regularly to detect any rapid decrease of the remaining gap.

11. Perform this process for all four bogie axle slew bearings.

3.35

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

TRANSMISSION The transmission is mounted in the pedestal frame. It has one oil reservoir that requires draining and refilling.

A

Check the transmission oil level every 8 hours.

Drain and replace the transmission oil every 250 hours.

B

CHECKING TRANSMISSION OIL LEVEL 1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

C

NOTE: The machine must be level when checking transmission oil level.

2000040

A 2000164

B 2000166

A Transmission Dipstick B Transmission Fill Cap

2. Remove the lynch pin and raise the bulkhead cover on the pedestal frame.

C

3. Clean around the transmission dipstick and fill cap.

4. Remove the dipstick and read the level. The fluid level should fall between the ADD and FULL marks on the dipstick. Wait at least 5 minutes after stopping the engine before taking the reading.

2000038

A Transmission Drain Plug B Magnetic Plug C Bottom Cover Plate – Pedestal Frame

5. If transmission oil level is low, remove the fill cap and carefully add transmission oil checking the level regularly with the dipstick. Do not overfill.

4. Remove the bottom cover plate closest to the centre joint on the pedestal frame.

6. Replace and tighten the fill cap.

5. Remove the transmission drain plug on the hydraulic motor side of the transmission.

Refer to SERVICE AND LUBRICATION POINTS in THIS SECTION for transmission oil capacity and recommended transmission oils.

6. Drain the transmission fluid into a suitable container.

NOTE: Dispose of the waste transmission fluid according to local regulations.

7. Replace the dipstick.

DRAINING AND REFILLING TRANSMISSION 1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

NOTE: The machine must be level when draining and refilling the transmission.

2. Clean around the dipstick and fill cap.

7. Remove the magnetic plug and clean off any filings that have collected.

8. Install the transmission drain plug and magnetic plug.

9. Fill the transmission with the correct quantity of transmission fluid.

Refer to SERVICE AND LUBRICATION POINTS in THIS SECTION for transmission oil capacity and recommended transmission oils.

3. Remove the transmission fill cap.

10. Install and tighten the fill cap.

3.36

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

PUMP DRIVE GEARBOX

DRAINING AND REFILLING PUMP DRIVE GEARBOX

The pump drive gearbox is located through the engine compartment front access door. It has one gear oil reservoir that requires draining and filling.

NOTE: Drain the pump drive gearbox when the oil is cold. This will allow particulate that has settled to the bottom of the pump drive gearbox to be removed when the gear oil is drained.

Check the pump drive gearbox oil level every 8 hours.

Drain and replace the pump drive gearbox gear oil every 250 hours.

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

CHECKING PUMP DRIVE GEARBOX OIL LEVEL

NOTE: The machine must be level when draining and refilling the pump drive gearbox.

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

2. Clean around the dipstick and fill plug.

3. Remove the gearbox fill plug.

NOTE: The machine must be level when checking pump drive gearbox oil level.

NOTE: Do not remove the drain plug until the fill plug has been removed.

B

A

2000148

C

A Pump Drive Gearbox Dipstick B Pump Drive Gearbox Fill Plug

A

2. Clean around the dipstick.

3. Remove the dipstick and read the level. The fluid level should fall between the ADD and FULL marks on the dipstick. Wait at least 5 minutes after stopping the engine before taking the reading.

4. If gearbox oil level is low, remove the fill plug and carefully add oil checking the level regularly with the dipstick. Do not overfill.

Refer to SERVICE AND LUBRICATION POINTS in THIS SECTION for gearbox oil capacity and recommended gear oils.

5. Replace and tighten the fill plug.

6. Replace the dipstick.

B

2000196

A Pump Drive Gearbox Magnetic Plug B Pump Drive Gearbox Drain Hose B Pump Drive Gearbox Drain Plug

4. Locate the gearbox drain hose and remove the drain plug.

5. Drain the gear oil into a suitable container.

NOTE: Dispose of the waste gear oil according to local regulations.

6. Remove the magnetic plug from the bottom of the gearbox and clean off any filings that have collected.

7. Install the gearbox drain plug in the drain hose and the magnetic plug in the bottom of the gearbox.

8. Fill the gearbox with the correct quantity of gear oil.

Refer to SERVICE AND LUBRICATION POINTS in THIS SECTION for gearbox oil capacity and recommended gear oils.

9. Install and tighten the fill plug.

3.37

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

ADDING ENGINE COOLANT

DRAINING ENGINE COOLANT B

Refer to SCHEDULED MAINTENANCE or SERVICE AND LUBRICATION SCHEDULE in THIS SECTION for maintenance and service intervals.

To drain the engine coolant from the system:

A

1. Open the coolant shut-off valve, if not already open.

Refer to ENGINE– COOLANT SHUT-OFF VALVE in SECTION 2.

C

2. Open the engine coolant surge tank cover.

3. Slowly loosen the engine coolant fill cap to the first stop to relieve pressure before removing completely.

2000057

A Engine Coolant Surge Tank B Engine Coolant Fill Cap C Engine Coolant Level Sight Glass

A

C

B

Engine coolant is added to the system through the coolant surge tank. The tank is located under the surge tank cover located on top of the engine compartment.

The coolant level sight glass is located on the side of the tank.

NOTE: A proper solution of coolant antifreeze must be used when filling the surge tank.

WARNING

A

B

2000419

A Coolant Drain Shut-off Valve B Coolant Drain Hose C Coolant Drain Hose Plug

Do not remove the coolant fill cap when the engine is hot, release of pressurized coolant can cause serious burns.

Turn OFF the engine. Only remove the coolant fill cap when it is cool enough to touch with bare hands.

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

4. Locate the coolant drain hose and remove the plug in the end of the hose.

5. Place the end of the drain hose into a suitably sized container.

6. Open the coolant drain shut-off valve.

7. Drain the engine coolant.

8. Close the coolant drain shut-off valve. Replace the plug in the hose and tighten the hose clamp.

9. Fill the cooling system. Refer to ENGINE COOLANT – ADDING in THIS SECTION. 10. Close the engine coolant shut-off valve if required.

Refer to ENGINE– COOLANT SHUT-OFF VALVE in SECTION 2.

11. Replace the engine coolant fill cap.

12. Close the engine coolant surge tank cover.

3.38

Tigercat 2160 Loader Forwarder

CAB TILT

Lubrication and Maintenance DEXRON III ATF hydraulic oil is used as the oil for the cab tilt hydraulic system. Remove the fill cap on top of the tank to add oil. System capacity is 3.75 L (1 US gal) – tank capacity is 0.9 L (30 oz).

After filling the tank, place a drain pan under the tank and operate the cab tilt DOWN and UP with the fill cap off to verify the system is not overfilled. Wipe up any spilled oil and install the fill cap.

A

TILTING PROCEDURE 1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

2. Remove all loose items from the cab.

3. Close the cab door.

2000159

A

A Tilt Pump Key Switch

Cab tilt is operated hydraulically by the cab tilt pump located in the compartment below the cab. An electric pump and motor and self contained tank provide hydraulic power for the cab tilt hydraulic cylinders.

Refer to CAB TILT – TILTING PROCEDURE in THIS SECTION.

CAB TILT PUMP A B 201037

C

B

A Locking Bolts B Bolt Locker

4. Remove the locking bolts at the rear of cab riser frame. Doors on the riser frame provide access to the bolts.

201038

Left Side of Riser– Cover Plate Hidden for Clarity

A Manual Override B Fill Cap C Pump Tank

3.39

Lubrication and Maintenance 5. Insert key in cab tilt pump key switch on electrical box in engine compartment.

Tigercat 2160 Loader Forwarder 7. Using the cab tilt pump key switch, turn the key counterclockwise to tilt the cab forward (DOWN) until the tilt cylinder stops.

NOTE: Do not leave the cab partially tilted. The cab should be either fully forward or fully upright.

8. Using the cab tilt pump key switch, turn the key clockwise to tilt the cab (UP) back to its upright operating position.

9. Install the locking bolts at the rear of the cab riser frame.

WARNING Failure to install the cab locking bolts will render the machine unsafe.

6. Check there are no obstacles in front of the cab that would prevent the cab from tilting.

WARNING Check that no personnel are in front of the cab before tilting.

3.40

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

CAB LOCKING BOLT STORAGE B

A bolt locker is provided in the cab riser to store the cab riser mounting bolts while the cab is tilted. Prior to tilting the cab for maintenance or transporting, remove the cab riser mounting bolts and store in the bolt locker.

A

C

C

B

A 200185

200179

A Bolt Locker B Bolt Locker Gate C Cab Locking Bolts

A Bolt Locker B Bolt Locker Gate C Cab Locking Bolts B

2. Close the bolt locker gate.

A

C

B 880D-049

A Bolt Locker Gate B Cable Tie

A

200178

3. When transporting the machine, secure the bolt locker gate with a cable tie.

A Bolt Locker B Bolt Locker Gate C Cab Locking Bolts

1. Lift the bolt locker gate and place the locking bolts upside down in the bolt locker.

3.41

Lubrication and Maintenance

HYDRAULIC SYSTEM NOTICE

Tigercat 2160 Loader Forwarder IMPORTANT! Before servicing the hydraulic system, park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

HYDRAULIC SYSTEM COMPONENTS A

B

C

D

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 system components.

The cleanliness of hydraulic oil cannot be guaranteed unless it is pre-filtered before use.

E

F

G

Use of filters other than genuine Tigercat replacement filters is not recommended. Replace filters at the recommended time intervals.

Refer to SCHEDULED MAINTENANCE in THIS SECTION.

H

I

2000018

WARNING

A B C D E F G H I J

WARNING: HOT HYDRAULIC OIL AND HOT MACHINE SURFACES CAN CAUSE SERIOUS BURNS! • Before servicing the machine, allow the engine cooling system, fuel system, exhaust system, hydraulic system and machine surfaces to cool down.

• Use a thermometer to check surface and system temperatures to verify 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).

3.42

J

Hydraulic Oil Tank Hydraulic Oil Tank Vacuum Pump Filter Head (Qty 2) Water Absorbent Filter (Qty 1) Hydraulic Oil Return Filters (Qty 3) Hydraulic Oil Level Sight Gauge and Low Level Sending Unit Clean Out Cover Hydraulic Oil Temperature Sending Unit Hydraulic Oil Return Diffuser/Strainers (Qty 2) Hydraulic Oil Heater (Optional)

Tigercat 2160 Loader Forwarder HYDRAULIC OIL TANK

Lubrication and Maintenance HYDRAULIC OIL LOW LEVEL SENDING UNIT A low level sending unit is installed in the tank. A message is sent to the computer display when the hydraulic oil tank level is low. The alarm light will flash and the alarm will also sound.

Refer to COMPUTER CONTROL SYSTEM– MESSAGES– CRITICAL – HYDRAULIC OIL LEVEL LOW in SECTION 2.

A

B

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 tank.

HYDRAULIC OIL TEMPERATURE SENDING UNIT

2000147

A Hydraulic Oil Level Sight Gauge B Hydraulic Oil Low Level Sending Unit

Located at the left rear of the upper structure, the hydraulic oil tank has a capacity of 182 L (48 US gal).

HYDRAULIC OIL LEVEL SIGHT GAUGE An oil level sight gauge, viewable through the front engine compartment indicates the HIGH and LOW levels of the hydraulic oil.

Maintain the hydraulic oil between the HIGH and LOW level marks on the gauge label. Check oil level with all cylinders fully retracted to obtain an accurate level reading. Overfilling the tank may cause excess oil to discharge from the breather vent.

A temperature sending unit activates the hydraulic oil temperature gauge on the computer display main screen. A message is sent to the computer display when the hydraulic oil temperature exceeds the recommended operating range for the type of hydraulic oil in use. The alarm light will flash and the alarm will also sound.

Refer to COMPUTER CONTROL SYSTEM– MESSAGES– CRITICAL – HYDRAULIC OIL TEMPERATURE HIGH in SECTION 2.

HYDRAULIC OIL HEATER (OPTIONAL) An optional 120V, 2000W immersion heater with one outlet plug can be provided in the bottom of the hydraulic oil tank. The tank must be drained before the heater can be removed. Refer to HYDRAULIC OIL TANK – DRAINING in THIS SECTION.

CAUTION Do not leave the hydraulic oil heater plugged in for a prolonged period of time without the hydraulic oil circulating. Localized high temperatures next to the heating rods can damage the hydraulic oil

3.43

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

HYDRAULIC OIL TANK VACUUM

VACUUM SWITCH IN CAB – LEFT ARMREST B

A

B A 2000134

2000161

A Vacuum Switch OFF Position B Vacuum Switch ON Position

Push the top of the switch to put it in the ON position to activate the vacuum pump.

NOTE: This switch will not function with the battery disconnect switch is in the OFF position.

VACUUM SWITCH IN ENGINE COMPARTMENT 2000160

A B C D E F

E

D

C

F

Vacuum Pump Air Vent Check Valve Vacuum Sensing Switch Solenoid Valve Air Vent Breather Hydraulic Oil Tank

The purpose of the vacuum pump system is to hold the hydraulic oil in the tank when servicing pumps and other hydraulic components, minimizing any oil spill. When activated, a solenoid valve closes off the hydraulic oil tank breather air supply. The pump removes tank air to create a vacuum, which then holds the oil in the tank.

This system eliminates the need to drain the hydraulic oil tank before servicing the system.

NOTE: When the ignition key switch is in the RUN position, the vacuum pump system will not start. When the vacuum pump is on, the engine cannot be started.

IMPORTANT! Do not use the vacuum pump when changing hydraulic filters. Using the vacuum pump system while changing filters creates the risk of introducing much more air into the hydraulic system.

The vacuum system can be used when changing the case drain strainer.

A

2000159

A Vacuum Switch – Engine Compartment

This switch is located in the front engine compartment and WILL function with the battery disconnect switch in the OFF position. Push the right side of the switch to put it in the ON position to activate the vacuum pump.

Activating the pump will create a vacuum condition (9 in. Hg) in the hydraulic oil tank. The vacuum pump will automatically start and stop as necessary to maintain the tank vacuum. The vacuum switch will also lock out the start solenoid to prevent the engine from being started.

Relieve the vacuum in the tank by placing the vacuum switch in the OFF position.

NOTE: The engine will not start until the tank vacuum has been relieved.

Do not attempt to start the machine or turn the ignition key switch to the RUN position.

Do not leave machine unattended or overnight with the vacuum pump ON. 3.44

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

HYDRAULIC OIL TANK – DRAINING

CLEAN OUT COVER

To drain the hydraulic oil tank:

The clean out cover is located on the side of the hydraulic oil tank and is accessed through the pump compartment (left side) door. Refer to ACCESS DOORS AND COVERS in THIS SECTION.

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

2. Turn OFF the engine.

Removing the clean out cover provides access into the hydraulic oil tank for cleaning, inspection and mounting of components.

NOTE: The swing brake is automatically applied when the engine is turned OFF.

IMPORTANT! Remove the clean out cover only when the hydraulic oil tank has been completely drained of hydraulic oil.

Refer to HYDRAULIC OIL TANK – DRAINING in THIS SECTION.

3. Remove the ignition key.

4. Turn OFF the battery disconnect switch.

To remove the clean out cover: B

A A B

2000019

C

A Environmental Drain Plug B Drain Hose

5. Remove the dust cap from the environmental drain plug on the bottom of the tank.

2000020

A Clean Out Cover B O-ring C Fastener (Qty 10)

6. Thread the drain hose onto the environmental drain plug.

NOTE: Once the drain hose seats itself, the valve will open and hydraulic oil will begin to drain through the hose.

1. Remove the clean out cover fasteners.

2. Remove the clean out cover.

3. Remove the O-ring.

CAUTION

NOTE: Install a new O-ring when reinstalling the clean out cover.

Drain the hydraulic oil tank when the hydraulic oil temperature is below 38°C (100°F), but warm enough to be less viscous.

7. Drain the hydraulic oil into a suitable container.

NOTE: Dispose of the waste hydraulic oil according to local regulations.

8. Remove and store the drain hose.

9. Install the environmental drain plug dust cap.

3.45

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

HYDRAULIC OIL TANK – ADDING OIL Prior to adding hydraulic oil to the tank, determine and repair the source of the oil loss.

A

A

B

C 2000184

D

5. Connect the hose end of the fill wand to the quickconnect fitting.

2000181

A B C D

A Quick-Connect Fitting

6. Insert the fill wand into the hydraulic oil container.

Hydraulic Oil Fill Pump Cover Hydraulic Oil Fill Pump Switch Hydraulic Oil Fill Quick-Connect Connection Hand Knob

The electric hydraulic oil fill pump, located inside the front left of the upper structure, is used to add oil to the hydraulic oil tank. Hydraulic oil is pumped into the hydraulic oil tank through the return filter manifold.

This ensures any hydraulic oil added is filtered prior to entering the hydraulic oil tank. Refer to APPROVED HYDRAULIC OILS in THIS SECTION.

NOTE: The hydraulic oil container should be anchored to prevent tipping in both the full and empty conditions.

7. Turn ON the hydraulic oil fill pump. Press and hold the hydraulic oil fill pump switch located under the cover on the upper structure.

With the engine compartment front access door open, observe the hydraulic oil level sight gauge on hydraulic oil tank to determine when to release the switch. The hydraulic oil level should be within 5 cm (2 in) of the HIGH mark on the sight gauge with all cylinders fully retracted.

1. Remove the fill wand from the storage compartment in the wagon frame.

2. Loosen the hand knob and swing open the hydraulic oil fill pump cover on the front left of the upper structure.

3. Remove the protective cap from the quick-connect fitting and thoroughly clean the outside surface of the connection.

A

B

8. Release the hydraulic oil fill pump switch.

9. Remove the hose end of the fill wand from the quickconnect fitting and replace the protective cap.

10. Replace the plug on the fill wand.

11. Wipe clean and return the fill wand to the storage compartment.

12. Close the oil fill pump cover and tighten the hand knob.

IMPORTANT! Failure to keep the fill wand and quick-connect fitting clean will significantly reduce the life of the filter elements.

CAUTION 2000183

A Fill Wand B Hexagon Socket

4. Remove the plug from the fill wand.

Direct contact with oil implies a risk of skin complaints. Wash off oil on skin immediately with soap and water. Refer to WORKING WITH OIL in SECTION 1.

NOTE: A hexagon socket located inside the upper structure can be used to remove the plug.

3.46

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

REFILLING THE HYDRAULIC SYSTEM When filters are replaced, there is a nominal amount of oil loss through leakage and oil contained in the filters.

This requires a hydraulic system top-up or refill.

Before refilling, check the computer to verify which oil type is selected. Use the same type and grade of oil to refill the system. This will allow the program to optimize the cooling and warning functions to best suit the oil type. Refer to COMPUTER CONTROL SYSTEM – ADJUSTMENT MENU – HYDRAULIC OIL GRADE SELECTION in SECTION 2 for selecting hydraulic oil type setting procedure.

It is strongly recommended that a program of regular oil testing be used. Oil change intervals can be established from oil test results.

Refer to HYDRAULIC OIL TANK – ADDING OIL in THIS SECTION. NOTE: Changing strainers, filters and replacing the hydraulic oil tends to aerate the oil. For maximum pump life, the machine should sit for one hour after servicing to allow entrained air to escape from the oil prior to applying working pressures to the pumps.

When refilling the hydraulic system, vent pumps, motors and valves of air by opening a plug or hose fitting located near or on top of the pumps, motors and valves until oil free of air is seen flowing out of the plug or hose fitting.

Failure to vent air from the hydraulic system could cause serious damage to hydraulic components. Tighten plugs or fittings and clean up any spilled oil when completed.

Check all hydraulic system components especially the cooling fan for proper operation after hydraulic oil has been replaced.

3.47

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

HYDRAULIC OIL RETURN FILTERS

FILTER RESTRICTION PRESSURE SWITCH A

A

B

2000060

A Hydraulic Oil Return Filters (White) – QTY 3 B Water Absorbing Return Filter (Blue) – QTY 1

The return oil entering the hydraulic oil tank passes through four spin-on hydraulic oil return filters mounted on two filter heads in the pump compartment. One of the filters is a water absorbing (blue) filter which is in place to assist with the removal of unwanted moisture from the hydraulic oil.

For service and replacement intervals refer to SCHEDULED MAINTENANCE in THIS SECTION. There is a bypass valve, preset at 1.7 bar (25 psi), built into each filter head, which will open when the filters become restricted. Before the valve is activated, a filter restriction pressure switch will cause the Hydraulic Oil Filter Restricted icon on the computer display to illuminate RED. Refer to HYDRAULIC SYSTEM – FILTER RESTRICTION PRESSURE SWITCH in THIS SECTION. If the Hydraulic Oil Filter Restricted icon illuminates RED between scheduled maintenance intervals, stop the machine and change the return filters immediately.

NOTE: The Hydraulic Oil Filter Restricted icon will illuminate YELLOW when the hydraulic oil temperature is low and the filter restriction switch is activated. Allow the hydraulic oil to warm to operating temperature and the icon should change to GREY. Refer to MACHINE PREPARATION in SECTION 2.

2000061

A Filter Restriction Pressure Switch

A filter restriction pressure switch is installed on one of the filter heads. When an oil pressure differential in excess of 1.4 bar (20 psi) is encountered at the return filters, this pressure switch closes and the Hydraulic Oil Filter Restricted icon illuminates RED on the computer display. A message is sent to the computer display, the alarm will sound and the alarm light will flash continuously.

Refer to COMPUTER CONTROL SYSTEM– MESSAGES– ALERT– HYDRAULIC OIL FILTER RESTRICTED in SECTION 2.

FILTER/DIFFUSERS SERVICE NOTE: The return filters should be checked/changed when the Hydraulic Oil Filter Restricted icon displays RED on the computer display. If the icon continues to display RED after the filters have been changed, the diffuser/strainers attached to the base of the return tubes in the hydraulic tank should be examined for possible obstruction.

Refer to HYDRAULIC OIL TANK – RETURN DIFFUSER/ STRAINERS in THIS SECTION. IMPORTANT! Do not use these warnings as a substitute for changing the hydraulic oil return filters at regular intervals as per SCHEDULED MAINTENANCE in THIS SECTION. This information is assuming that operating conditions and running temperatures are normal.

3.48

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

RETURN FILTER RESTRICTION INDICATOR

B

A

2000146

A Return Manifold B Return Filter Restriction Indicator

The IN side of the return filter heads are connected to a return manifold. A filter restriction indicator is mounted on the manifold.

With the hydraulic oil at normal operating temperature, the engine speed at HIGH and with no machine functions operating, the return filter restriction indicator should be in the GREEN zone. If the pointer is in the RED zone, replace all four return filters.

3.49

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

FILTER CHANGE PROCEDURE – RETURN FILTERS

 'O' RING GASKET A

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

2. Open the pump compartment access door to access the return filters.

3. Wipe clean the area around the filters and filter head.

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

5. Wearing eye and face protection (in case of an oil spray), unscrew the old filter.

B C FILTR_SEALS 2

A Filter Head B Gasket C Filter Element

a. Remove the used gasket and clean the gasket seat in the head.

6. Dispose of old filter and any oil properly.

7. The new Tigercat filter is supplied with two gaskets enclosed. Examine the filter head closely to determine which gasket to use and follow the instructions for proper installation.

b. Apply clean oil to the new gasket surfaces. c.

 SQUARE SECTION GASKET

d. Screw on the new filter until the gasket makes contact.

A

e. Tighten the filter until the top edge makes metal to metal contact with the filter head (approximately 11⁄2 additional turns after gasket contact).

B C FILTR_SEALS 2

A Filter Head B Gasket C Filter Element

Install the new gasket on the inside lip of the filter.

8. Use the fill pump to raise the hydraulic oil level up to the FULL line, replacing oil lost during filter change.

Refer to HYDRAULIC OIL TANK– ADDING OIL in THIS SECTION. 9. Clean up any spilled oil.

a. Remove the used gasket and clean the groove in the head.

10. Start the engine and check for leaks. Refer to STARTING ENGINE in SECTION 2.

b. Apply clean oil to new gasket surfaces.

11. Run engine at LOW for at least five minutes to purge any remaining air from the filter system. Then turn OFF the engine for 15 minutes to allow air bubbles in the hydraulic oil tank to rise.

c.

Install the new gasket into the groove in the filter head.

d. Screw on the new filter until the gasket makes contact.

12. Re-check hydraulic oil level and top-up as needed.

e. Tighten the filter an additional 3⁄4 turn.

3.50

Tigercat 2160 Loader Forwarder DRIVE CHARGE FILTER

Lubrication and Maintenance BYPASS PRESSURE SWITCH – CHARGE FILTERS

A

A

2000060 T250D-114

A Drive Charge Filter

The drive charge filter is located in the pump compartment on the front of the hydraulic oil tank.

Hydraulic oil from the drive pump charge passes through this filter before being used in the drive hydraulic circuit.

For service and replacement intervals refer to SCHEDULED MAINTENANCE in THIS SECTION.

SWING CHARGE FILTER

A Bypass Pressure Switch – Charge Filters

A bypass switch in the drive charge and swing charge filter heads sends a message to the computer display when an oil flow restriction in excess of 3.5 bar (50 psi) is encountered at the charge filters. This pressure build up opens the bypass valve in the filter head allowing oil to bypass the filter element and return to the hydraulic oil tank.

Refer to COMPUTER CONTROL SYSTEM– MESSAGES– ALERT– DRIVE CHARGE FILTER BYPASSED and COMPUTER CONTROL SYSTEM– MESSAGES– ALERT– SWING CHARGE FILTER BYPASSED in SECTION 2.

A

2000060

A Swing Charge Filter

The swing charge filter is located in the pump compartment on the front of the hydraulic oil tank.

Hydraulic oil from the swing pump charge passes through this filter before being used in the swing hydraulic circuit.

For service and replacement intervals refer to SCHEDULED MAINTENANCE in THIS SECTION.

3.51

Lubrication and Maintenance SCRUBBER FILTER

Tigercat 2160 Loader Forwarder BYPASS PRESSURE SWITCH – SCRUBBER FILTER

A

A

2000062

A Bypass Pressure Switch – Scrubber Filter

2000060

A Scrubber Filter

The scrubber filter is located in the pump compartment on the left side. The scrubber filter is used to filter all hydraulic oil from the cooling pump.

For service and replacement intervals refer to SCHEDULED MAINTENANCE in THIS SECTION.

A bypass switch in the scrubber filter head sends a message to the computer display when an oil flow restriction in excess of 3.5 bar (50 psi) is encountered at the scrubber filter. This pressure build up also opens the bypass valve in the filter head allowing oil to bypass the filter element.

Refer to COMPUTER CONTROL SYSTEM– MESSAGES– ALERT– SCRUBBER FILTER BYPASSED in SECTION 2.

FILTER CHANGE PROCEDURE – CHARGE FILTERS AND SCRUBBER FILTER 1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

2. Open the pump compartment access door to access the filters.

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

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

5. Wearing eye and face protection (in case of an oil spray), unscrew the old filter.

6. Dispose of old filter and any oil properly.

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

8. The new filter has an attached gasket. Apply clean oil to the gasket surface.

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

10. Hand tighten filter an additional ½ turn only.

11. Start the engine and check for leaks. Refer to STARTING ENGINE in SECTION 2.

3.52

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

CASE DRAIN STRAINER

A

2000060

A Case Drain Strainer

The case drain strainer is located in the pump compartment on the left side. The case drain strainer is used to filter all case drain oil from the pumps and motors before it returns to the hydraulic oil tank.

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

IMPORTANT! The case drain strainer element is not a filter element.

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

3.53

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

HYDRAULIC OIL RETURN DIFFUSER/ STRAINERS

CHANGING OR CLEANING THE DIFFUSER/ STRAINERS This procedure should only be performed in the event of a pump or motor catastrophic failure or hydraulic oil contamination.

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

2. Install a DO NOT START ENGINE sign on the operator's cab door and in the engine compartment.

3. Drain the hydraulic tank. Refer to HYDRAULIC OIL TANK – DRAINING in THIS SECTION. Remove the hose once the tank is drained.

4. Remove the clean out cover and O-ring. Refer to HYDRAULIC OIL TANK – CLEAN OUT COVER in THIS SECTION. 5. Before removing the diffuser/strainers, clean any debris from the bottom of the tank and wipe it clean.

6. Remove the diffuser/strainers.

A

2000021

A Diffuser/Strainers in Hydraulic Oil Tank

There are two reusable diffuser/strainers fitted to the return tubes inside the hydraulic oil tank. Inspecting, changing or cleaning the diffuser/strainers is only to be performed in the event of a catastrophic pump or motor failure or hydraulic oil contamination.

7. Carefully clean the diffuser/strainers (they are easily damaged by rough handling).

8. Check for a buildup of foreign materials where the diffusers screw onto the pipes and cover plate.

9. Re-install the diffuser/strainers.

NOTE: Repair any burrs created when removing the diffuser/strainers before reinstalling.

10. Reinstall the clean out cover with a new O-ring.

11. Refill the hydraulic tank and check for leaks.

Refer to HYDRAULIC OIL TANK – ADDING OIL and HYDRAULIC SYSTEM – REFILLING in THIS SECTION.

3.54

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

AIR CONDITIONING SYSTEM

COMPONENTS

All service work must be performed by a certified A/C technician. Charge the system with R134a refrigerant only. Polyalkylene Glycol (PAG) oil should be present in the system and must be used on O-rings and fittings during assembly.

COMPRESSOR

A

A/C SYSTEM TOTAL CAPACITIES R134a Refrigerant

1.8 kg (4 lb)

PAG Oil Compressor shipping quantity (Shipping oil from vendor)

200 ml (6.76 oz)

Tigercat factory added oil

+

44 ml (1.48 oz)

Total

=

244 ml (8.25 oz)

When replacing air conditioning system components, it is important to replace PAG oil that has been lost when parts are changed. The total amount of PAG oil added to compensate for replacement components should not exceed the total capacity.

When recharging the system, only add the quantity of oil reclaimed during the recovery process.

Low PAG oil levels can starve the compressor for oil and lead to compressor failure. Too much PAG oil can hurt the cooling performance.

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. This will circulate PAG oil to all components of the A/C system.

NOTICE Before disconnecting any lines or removing the PAG oil plug, make sure the refrigerant has been removed from the A/C system by recovering it with the appropriate recovery equipment.

2000168

A A/C Compressor

The compressor draws in the low-pressure refrigerant vapour from the A/C system.

The compressor is powered by a separate drive belt connected to the engine crankshaft. When the A/C system is turned on, the compressor clutch engages and the compressor pumps refrigerant vapour under high pressure to the condenser.

The compressor and charge ports are accessed through the front engine compartment door.

CONDENSER The condenser is part of the cooler package.

Refer to CLEANING COOLER PACKAGE in THIS SECTION for the location of the condenser.

Refrigerant flows through the condenser tubing from top to bottom. The high internal pressure coupled with the large volume of air cooling the condenser as it passes over the condenser core produces a condition in which vapour refrigerant converts to liquid refrigerant (condensation). This change usually takes place in the bottom third portion of the condenser.

3.55

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

RECEIVER-DRIER B

C

A

2000190

A Sight Glass (Indicates Condition of Charge) B High-Pressure Switch C Moisture Indicator

The receiver-drier is located in the rear engine compartment behind the cooler package. It is accessible through the engine compartment rear access door.

EXPANSION VALVE The high pressure liquid refrigerant flows into the expansion valve and then passes through a variable orifice. The orifice limits the speed and therefore the flow of refrigerant causing the pressure of the refrigerant to drop. The refrigerant exits the expansion valve as a low pressure liquid.

Refer to AIR CONDITIONING SYSTEM– EVAPORATOR, HEATER CORE AND BLOWERS in THIS SECTION for the location of the expansion valve.

3.56

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

EVAPORATOR, HEATER CORE AND BLOWERS

B

Liquid refrigerant flows into the evaporator coil. As the blowers pull the warm cab air across the evaporator coil, heat is absorbed by the refrigerant. This results in cooling of the air as it passes across the evaporator coil.

When enough heat is absorbed by the refrigerant, the refrigerant changes to a low pressure vapour.

A

A 2000026

A A/C Heater Unit Access Cover B Thumb Screws

4. Remove the A/C heater unit access cover thumb screws and remove the access cover.

2000027

A

B

A

B

234-093

A A/C Heater Unit Cover Panel B A/C Heater Unit

The evaporator core, heater core and blowers are a part of the A/C heater unit located in the cab behind the A/C heater unit cover panel behind the operator's seat.

2000022

A B C D

To inspect the evaporator and blowers do the following: 1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

2. Slide the operator's seat as far forward as possible and adjust the seat backrest as far forward as possible.

D

C

Blower Heater Core Evaporator Core Expansion Valve

5. Inspect the evaporator core, heater core and blowers for dirt and debris. Remove if required.

6. Install the A/C heater unit access cover and fasteners.

3. Remove the six socket head capscrews fastening the A/C heater unit cover panel and remove the panel.

3.57

Lubrication and Maintenance CAB AIR FILTERS

Tigercat 2160 Loader Forwarder FRESH AIR FILTER – CAB

Inspect and clean the cab air filters every 125 hours.

Replace the filters regardless of condition every 500 hours.

A

B A

B

2000029

B

A

234-093

A Recirculating Air Filter B Fresh Air Filter – Cab

RECIRCULATING AIR FILTER – A/C HEATER UNIT B

2000030

C

A Fresh Air Filter – Cab B Filter Securing Plate C Wing Nut A 2000028

A Recirculating Air Filter B Thumb Screws

The filter is located at the base of the A/C heater unit.

Remove the two thumb screws on the filter box cover to access the filter.

To inspect, clean or replace the A/C recirculation filter: 1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

2. Remove the two thumb screws on the A/C heater unit access panel.

3. Remove the filter and housing.

4. Inspect, clean or replace the filter.

This filter is located adjacent to the AC heater unit, behind the left side door.

To inspect, clean or replace the cab fresh air filter: 1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

2. Remove the wing nut and washer at the bottom of the filter securing plate.

3. Lower the filter securing plate to clear the retaining tabs from the holder.

4. Slide the filter out.

5. Inspect, clean or replace the filter.

6. Hold the filter in position and install the filter securing plate.

IMPORTANT! Install the filter with the air flow arrows facing into the cab.

5. Install the filter and housing on the A/C heater unit access panel.

6. Install the thumb screws and tighten.

7. Install the wing nut and washer and tighten.

3.58

Tigercat 2160 Loader Forwarder INSPECTION Perform the following inspection along with the 125 HOURS inspection outlined in SCHEDULED MAINTENANCE in THIS SECTION.

Lubrication and Maintenance 11. Check the color in the moisture indicator: BLUE is OK; PINK indicates desiccant material in drier is saturated with moisture.

In the latter situation: a. Replace the receiver-drier.

1. Check A/C recirculating and cab fresh air filters in the operator cab. Refer to CAB AIR FILTERS in THIS SECTION.

b. Evacuate the system. c.

2. Check the condenser core for dirt and debris.

Clean as required. Refer to CLEANING COOLER PACKAGE in THIS SECTION.

CAUTION If using pressurized water or compressed air for cleaning, use at 2 bar (30 psi) or less.

Use personal protective equipment (safety glasses) to guard against flying debris.

3. Check the evaporator core, located inside the A/C heater unit, for dirt and debris. Also check the inside of the A/C heater unit. Clean as required.

4. With the engine stopped, check the air conditioner compressor belt tension and condition.

Recharge the system with both refrigerant and PAG oil *.

*Indicates these repairs must only be carried out by a certified A/C technician.

For additional SERVICE information refer to Tigercat A/C SERVICE MANUAL part number 18795A, available from the Tigercat parts department.

IMPORTANT! It is recommended that when the A/C system is not in use (during cold weather), that it be run for a period of five minutes every two weeks. This will circulate oil to all components of the A/C system.

The air conditioner circuit uses a binary switch (located on the top of the receiver-drier) on the high pressure side. The switch has two settings: • The high pressure protection activates at 27 bar (391 psig) for rising pressure and 21 bar (304 psig) for falling pressure.

Refer to ENGINE BELTS in THIS SECTION. 5. Check all A/C hoses for kinks.

• The low pressure protection activates at 1.9 bar (29 psig) for falling pressure and 2 bar (30 psig) for rising pressure.

6. Run the air conditioning system for three to five minutes.

7. Use a thermometer to check the air temperature exiting vents in the cab.

8. Listen to the compressor and blower motor for abnormal noises.

9. Verify the compressor clutch engages.

10. Inspect the sight glass on the receiver-drier with the A/C ON. A constant stream of bubbles indicates the system is low on refrigerant and requires charging *.

Refer to AIR CONDITIONING SYSTEM– COMPONENTS – RECEIVER-DRIER in THIS SECTION.

3.59

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

ENGINE BELTS

BELT REMOVAL AND REPLACEMENT

Check belt condition and tension every 1000 hours. The engine belts are accessible through either the engine compartment front and rear access doors.

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

A

B C A

D 2000063

A Cooling Fan Guard

2. Remove the cooling fan guard from the cooler package.

3. Remove the cooling fan from the front of the engine.

2000025

A B C D

A/C Compressor Adjusting Bolts A/C Compressor Pivot Bolts A/C Compressor Belt Serpentine Fan Belt

4. Loosen the A/C compressor adjusting bolts and swing the compressor towards the engine.

5. Remove the A/C compressor belt.

6. Remove and replace the serpentine belt.

The cooling fan (not shown) is driven by the serpentine belt. Belt tension is automatically tightened by a spring loaded tensioner.

The A/C compressor is driven by a separate belt. Belt tension is tightened by loosening the pivot bolts below the compressor and the adjusting bolts above to enable the compressor to swing.

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for inspection and replacement information for the serpentine belt.

7. Install a new A/C compressor belt and swing the compressor away from the engine and tighten the A/C compressor adjusting bolts.

NOTE: Belt tension specification is 55 ± 2 kgf (121 ± 5 lbf).

8. Install the cooling fan on the engine.

9. Install the cooling fan guard on the cooler package.

3.60

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

FUSES AND RELAYS Each circuit of the machine is protected against current overload by fuses. 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.

FUSE AND RELAY PANEL – CAB The cab fuse and relay panel is located on the right side of the cab below the main console behind a removable cover.

2000195

81261BENG

3.61

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

FUSE AND RELAY PANEL – ENGINE COMPARTMENT The main fuse and relay electrical box is located in the front engine compartment.

2000194

85471BENG

3.62

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

ENGINE DIAGNOSTICS CONNECTION

A

234B-012

A Engine Diagnostics Connection

The engine diagnostics connection is located in the cab on the right side, under the main console.

Plug a remote electronic diagnostic device into this connection such as a laptop computer with appropriate engine manufacturer’s programming to perform engine performance analysis and tuning.

IMPORTANT! This operation can only be performed by a trained service technician.

3.63

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

BATTERY CARE Tigercat uses two types of batteries dependant on the machine application, model and design.

• Absorbed Glass Mat (AGM) • Flooded Lead Acid (FLA).

NOTICE Before charging the battery, it is important to identify which type of battery you have.

Read and follow the battery and charger manufacturer's instructions prior to connecting or charging a battery.

All batteries are sensitive to overcharging. Charging or maintaining AGM batteries requires the use of a smart charger with an AGM setting. The peak charging voltage for AGM batteries varies slightly between battery manufacturer's. Exceeding this voltage can cause permanent battery damage. Refer to the BATTERY MANUFACTURER'S charging instructions for more information.

Refer to BATTERY MANUFACTURER'S instructions for charging or maintaining FLA batteries.

3.64

Tigercat 2160 Loader Forwarder

ENGINE FILTERS – REMOVE AND REPLACE IMPORTANT! Failure to service and replace engine filters at the proper intervals specified in the ENGINE OPERATION AND MAINTENANCE MANUAL could cause damage to the machine and result in the product warranty becoming null and void. Check the Tigercat parts catalog for replacement filters.

Lubrication and Maintenance FUEL FILTERS These engines use filters with a very fine micron rating.

If the fuel supply is dirty, the fuel filter must be replaced more frequently than recommended in SCHEDULED MAINTENANCE in THIS SECTION. Operating the machine with a clogged fuel filter will result in low engine power. It is also recommended to drain the fuel filter/ water separator bowl daily.

NOTICE

Refer to the appropriate ENGINE OPERATION AND MAINTENANCE MANUAL for the oil and fuel filter replacement procedure. Read and understand the SAFETY section in each of THESE MANUALS.

ENGINE OIL FILTER

Tigercat does not recommend the pre-filling of spin-on filters due to the risk of damage to the fuel system caused by unfiltered fuel. Unfiltered fuel used to pre-fill filters enters directly into the fuel circuit. Contaminants in unfiltered fuel can cause significant and costly damage to fuel system components. The cleanliness of fuel cannot be guaranteed unless it is pre-filtered before use.

A

Use of filters other than genuine Tigercat replacement filters is not recommended. Replace filters at the recommended time intervals.

Refer to SCHEDULED MAINTENANCE in THIS SECTION.

2000155

A Engine Oil Filter

The engine oil filter is located on the rear of the engine.

It is accessed through the engine compartment rear access door.

When installing a new oil filter, do not pre-fill with engine oil as this may result in engine damage. This type of failure is not warrantable by the engine manufacturer.

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

For service and replacement intervals refer to SERVICE AND LUBRICATION POINTS in THIS SECTION. Refer also to ENGINE OPERATION AND MAINTENANCE MANUAL for more detailed information.

3.65

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder 1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

2. Allow machine to cool.

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

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

WARNING

A

B 2000163

A Engine Fuel Filter B Fuel Filter Pressure Switch

The engine fuel filter is located on the front of the engine.

The engine fuel filter is equipped with a pressure switch with sends a message to the computer when a clog is detected. Refer to COMPUTER CONTROL SYSTEM– MESSAGES– CRITICAL – MAIN FUEL FILTER CLOGGED– ENGINE DERATE and COMPUTER CONTROL SYSTEM– MESSAGES– ALERT– MAIN FUEL FILTER CLOGGED in THIS SECTION.

WARNING The fuel pump high-pressure fuel lines and fuel rail contain very high pressure fuel. Do not loosen any fittings while the engine is running.

Personal injury and property damage can result.

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

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

6. Check the seating area for the O-ring on the filter head and wipe clean.

7. Lubricate the O-ring on top of the new filter with clean engine oil. Do not pre-fill the new filter.

8. Screw the new filter onto the filter head as specified by the filter manufacturer. Note: Mechanical over tightening can damage the filter element.

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

Loosen the plug on the top of the remote fuel filter/ water separator. Pump the hand primer until fuel begins to seep out around the loosened plug.

Continue to pump until no air bubbles are visible (approximately 30 pumps). Tighten the plug. Pump the hand primer 30 more times.

10. Start the engine and check for leaks. Refer to STARTING ENGINE in SECTION 2.

3.66

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

FUEL FILTER/WATER SEPARATOR

DRAINING FUEL FILTER/WATER SEPARATOR A

A

B

C

B

I

E C

H

D

F G

822D-025

A B C D E F G H I

D

2000168

A

O-Ring Hand Primer Pump Vent Plug Filter Head Fuel Filter Harness (Heater Element not shown) Sensor, Water in Fuel Heater Drain Valve with Hose Barb Separator Bowl

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

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

B

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

4. Loosen the metal vent plug on the filter head.

5. Turn the drain valve open on the separator bowl to allow the fuel to drain completely from the separator bowl into a suitable container.

NOTE: A drain hose can be attached to the drain valve if required.

6. Close the drain valve.

C D

800824

A B C D

Hand Primer Vent Plug Fuel Separator Bowl Drain Tap

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, refer to SERVICE AND LUBRICATION POINTS in THIS SECTION.

The fuel filter/water separator is accessed through the engine compartment front access door.

3.67

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

CHANGING FUEL FILTER/WATER SEPARATOR

15. Close the vent plug.

Refer to SCHEDULED MAINTENANCE and SERVICE AND LUBRICATION POINTS in THIS SECTION for filter replacement intervals.

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

16. Start the engine and check for leaks. Refer to STARTING ENGINE in SECTION 2.

WARNING To lower the risk of causing accidental fires, Do not leave fuel or oil soaked rags laying around.

2. Drain the fuel from the filter/water separator as described previously in this section.

3. Disconnect the fuel heater and the 'water-in-fuel' sensor from the wiring harness.

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

A

FUEL HEATER 801168 802236

A Filter Removal Tool (BH859)

4. Remove the water separator bowl from the filter head.

NOTE: A bowl wrench is supplied with the machine (Tigercat Part Number: BH859).

5. Dispose of any fuel properly.

A

6. Remove and discard the O-ring from the top of the separator bowl.

7. Clean the separator bowl.

B

8. Remove the filter cartridge from the filter head (pressure fit) and discard properly.

9. Place the new filter into position on the filter head.

10. Lubricate the O-ring with clean engine oil and install at the top of the separator bowl.

11. Install (screw) separator bowl onto the filter head, hand tighten, then turn an additional 3⁄4 turn only.

12. Reconnect the fuel heater and the 'water-in-fuel' to their respective wiring harness.

13. Turn the ignition key switch to the ON position to energize the fuel supply shut-off solenoid valve.

14. Prime the fuel system using the hand primer until fuel spills out the metal vent plug.

2000168

A Fuel Filter/Water Separator B Fuel Heater (Bottom of Clear Bowl)

The fuel heater is incorporated into the fuel filter/water separator and is controlled electronically by the engine ECU.

3.68

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

FUEL TANK COMPONENTS FUEL FILL CAP

A

A

B

B 200183

A Inner Fuel Fill Tube B Air Vent Passage

2000185

Fuel Fill Tube

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

A Fuel Fill Cap B Fuel Fill Tube

The fuel tank is located on the front of the upper structure below the cab. The fuel tank has a usable capacity of 457 L (121 US gal).

The fuel fill cap is located on the top of the fuel tank in front of the cab.

The fuel level sender is located on the top of the fuel tank under the cab, accessible through the cab riser. The fuel level sender sends a signal to the computer which displays an on-screen fuel level gauge.

3.69

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

FUEL TANK STRAINER

A

200184

A 2000048

A

A Intank Fuel Strainer

A stainless steel 150 micron fuel strainer is screwed onto the end of the fuel supply pipe located inside the fuel tank. The strainer is accessible through the cab riser and is part of the fuel level sender on the top of the fuel tank.

Check the fuel tank strainer every 1000 hours.

CHANGING/CLEANING THE INTANK FUEL STRAINER A

NOTE: Changing the intank fuel strainer is only required if excessive quantities of foreign material have built up inside the fuel tank.

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

A 2000049

A Fuel Sending Unit

3. Remove the six fuel sending unit bolts and remove the fuel sending unit from the fuel tank. The intank fuel strainer is part of the fuel sending unit.

4. Carefully clean the intank fuel strainer.

NOTE: Use caution when cleaning the intank fuel strainer or damage may occur.

2000037

A Cab Riser Right Access Door

5. Check for buildup of foreign material where the strainer screws to the sending unit.

2. Open the cab riser right access door to gain access to the top of the fuel tank.

WARNING To lower the risk of causing accidental fires, do not leave fuel or oil soaked rags laying around.

6. Reinstall the fuel sending unit.

3.70

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

REFUELLING PROCEDURE WARNING

Do not refuel while smoking or while near an open flame or sparks.

S≤15 mg/kg ULTRA LOW SULFUR FUEL ONLY 36686AUNI R0

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

2. Allow machine to cool.

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

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

5. Clear any debris from around the fuel fill cap.

6. Remove fuel fill cap slowly to allow pressure to escape from tank.

7. Inspect fuel fill cap gasket.

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

9. Fill the fuel tank until fuel level reaches the bottom of the fuel strainer. Do not leave the fuel nozzle unattended or spillage may occur.

10. When refuelling is complete, remove the fuel nozzle and ground strap (if applicable).

11. Install fuel fill cap hand-tight.

NOTE: Before restarting the machine, Refer to STARTING ENGINE in SECTION 2.

3.71

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

AIR INTAKE SYSTEM

HOW IT WORKS

ENGINE AIR PRECLEANER

1. Dirty air (A) enters the precleaner, which is clamped onto the engine air intake.

A

2. Specially-designed vanes (B), curved and angled to precisely direct air flow, move the dirty air toward the stainless steel impeller (C).

3. The dynamically balanced, one piece impeller (C) (only moving part) creates a tornado inside the housing.

4. The centrifugal force of the tornado expels the heavier than air dirt particles (D), chaff, dust, snow, rain, etc., out the discharge louvre.

2000055

A Engine Air Precleaner – Top of Engine Compartment

The engine air precleaner cleans engine air before it reaches the air cleaner filter elements. It removes contaminants such as dust, powder, insects, rain and snow. This precleaner is self powered and self cleaning requiring virtually no maintenance.

5. Cleaned air (E) enters the engine air cleaner intake pipe, and the filter element has only the very light particles to remove.

AIR INTAKE TUBING AND JOINTS D

A B

IMPORTANT! Check the precleaner every 8 hours for foreign materials that may have plugged the intake area or the discharge louvre area. Clean as required.

C E

A plugged precleaner will create a restriction to airflow, resulting in reduced engine performance and increased fuel consumption.

If the machine is operated with a plugged precleaner, excessive air intake restriction will damage the rubber air intake tube which will lead to ingestion of dirt into the engine resulting in engine failure. The air intake filter restriction indicator may not function properly if the air intake tube is damaged.

C

C D

B A E

480-017

A B C D E

Dirty Air Specially-designed Vanes Stainless Steel One Piece Impeller Foreign Particles Cleaned Air

2000023

A B C D E

Engine Air Precleaner Air Cleaner Air Intake Tube Air Intake Connector Hose Air Intake Rubber Elbow

Check all air intake system components, rubber elbows, connector hoses, tubes and clamps every 8 hours 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.

NOTE: High-temperature silicone connectors do not need to be replaced unless they are damaged.

3.72

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

AIR CLEANER B

In addition to the SCHEDULED MAINTENANCE in THIS SECTION, the following instructions should also be noted.

A

NOTE: Replace secondary (safety) filter every third primary filter change.

C

D

2000024

A B C D

Air Cleaner Air Filter Restriction Indicator Air Filter Restriction Sensor Air Cleaner Unloader Valve

The most common and most damaging air intake servicing problems are over servicing and improper servicing.

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

IMPROPER SERVICING

B

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

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

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

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

NOTE: Do not clean and reuse filter elements.

Cleaning causes dust to bypass the filter and be deposited on the inner surface of the filter media.

The dust is then drawn directly into the engine.

A 726D-006

A Primary Element B Secondary (Safety) Element

The air cleaner on this machine uses two filter elements, a primary element and a secondary (safety) element.

It is accessible through the engine compartment front access door.

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

4. Clean the inside of the housing.

5. Clean the sealing surface before inserting a new filter element.

6. Inspect the new filter for damage.

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

8. Check connections hoses and tubes for an air tight fit. All clamps, bolts and connections must be tight.

Check rubber elbows for splits or wear points. Leaks in these locations send dust directly to the engine.

3.73

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

AIR FILTER RESTRICTION INDICATOR

A

AIR CLEANER UNLOADER VALVE

B

A 2000153

2000162

A Air Filter Restriction Indicator B Hose to Air Filter Restriction Sensor

An air filter restriction indicator is connected to the outlet side of the air filter. Service to the air filter is required when the restriction indicator shows RED. This indicator provides a continuous reading whether the engine is running or is shut down. After servicing the filter, reset the indicator by pressing the reset button.

AIR FILTER RESTRICTION SENSOR

A 2000125

A Engine Air Intake Filter Restriction Icon

The machine is also equipped with an engine air filter restriction sensor on the outlet of the air cleaner which sends a signal to the computer in the event of filter restriction. The engine air intake pressure icon turns YELLOW when service to the filter is required and turns RED, along with a CRITICAL message, when service to the air filter has reached a critical state.

A Air Cleaner Unloader Valve

Check the rubber air cleaner unloader valve on the air cleaner housing every 8 hours. If this valve is missing, damaged or has become hard, it will cause the air cleaner to become ineffective.

Replace the unloader valve every 1000 hours.

Remove the unloader valve from the tube of the air cleaner housing. A good valve should be soft and flexible. Check and clean the valve. If it is plugged, check the filter elements as they may also need to be replaced. Reattach the valve to the tube. The valve should suck closed at about one-third of HIGH engine speed. When operating in high dust conditions this valve should be checked and squeezed every two hours to release dust buildup.

Refer to AIR INTAKE SYSTEM– AIR CLEANER UNLOADER VALVE in THIS SECTION and SERVICE AND LUBRICATION POINTS in THIS SECTION.

Refer to AIR INTAKE SYSTEM– AIR CLEANER – OVER SERVICING and IMPROPER SERVICING in THIS SECTION. Refer to COMPUTER CONTROL SYSTEM– MESSAGES– ALERT– ENGINE AIR FILTER RESTRICTED in SECTION 2.

3.74

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

THE AFTERTREATMENT SYSTEM AND ITS RELATED COMPONENTS ARE APPLICABLE TO TIER 4F MACHINES ONLY.

AFTERTREATMENT SYSTEM Tier 4f machines are equipped with a combination Diesel Oxidation Catalyst (DOC) and high-efficiency Selective Catalytic Reduction (SCR) aftertreatment system to limit the nitrogen oxide exhaust gas values (NOX) to meet Tier 4f emission standard requirements with low fuel consumption. This process is electronically controlled by the DENOX 2.2 system.

The DOC uses oxidation at high temperatures to convert carbon monoxide (CO), hydrocarbons (HC) and the soluble organic fraction (SOF) of diesel particulates into inert compounds, carbon dioxide (CO2) and water vapour (H2O). In addition, the DOC converts nitrogen oxide (NO) into nitrogen dioxide (NO2). Increased NO2 levels enhance the performance of the SCR catalyst at low temperatures and increase the effectiveness of the DOC/SCR aftertreatment system as a whole.

The high-efficiency SCR process is based on a series of chemical reactions which involve the reaction of ammonia with the oxygen in the exhaust gas to reduce nitrogen oxides (NOX) in the exhaust gas by transforming it into inert compounds: free nitrogen (N2) and water vapour (H2O). In addition, the high-efficiency catalytic converter includes a clean up catalyst (CUC) which reduces any excess ammonia (NH3), which may result from the SCR process.

IMPORTANT! Do not idle the engine longer than one hour. Damage to the emission control system will result. When this machine idles for an extended period, excess hydrocarbon buildup is created in the DOC/SCR aftertreatment system. Burn off of excess hydrocarbon, at full load, immediately after a long idle period, generates excess heat which causes damage to emission control system components.

IMPORTANT! When cleaning the machine with pressurized water it is important to avoid getting water directly or indirectly into the exhaust tube. Water in the exhaust tube will damage sensors and SCR system components and affect the proper operation of the aftertreatment system and the engine.

3.75

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

AFTERTREATMENT SYSTEM COMPONENTS V

R

U

P

Q

M

N

K

G

L

O

T E S W B H

D

A

2000006

3.76

X

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

O

L

Q

P

U

W M B

V G

J

F

C

A

T

S

N

D

H

X

2000008

2000007

A B C D E F G H I J K L

DEF Tank Sending Unit (Includes Level Sensor) DEF Quality Sensor (In Bottom of DEF Tank) Heater Valve ECU – Engine (Denox 2.2 Dosing System) Exhaust Flap Diesel Oxidation Catalyst (DOC) DEF Supply Module DEF Dosing Module Filter (in Supply Module) Dosing Module (DEF Injector) Mixer Tube Catalytic Converter (includes SCR and CUC)

M N O P Q R S T U V W X

3.77

Humidity and Temperature Sensor DOC Inlet Temperature Sensor Catalytic Converter Inlet Temperature Sensor Catalytic Converter Outlet Temperature Sensor NH3 Sensor ECU – NH3 Sensor Inlet NOx Sensor ECU – Inlet NOx Sensor Outlet NOx Sensor ECU – Outlet NOx Sensor Air Filter Engine

R

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder M

W

T E

F

HC

S

V

R

U

Q

NOx I

CO

N

HC – Hydrocarbons NOx– Nitrogen Oxides CO – Carbon Monoxide NH3 – Ammonia N2 – Free Nitrogen H2O – Water CO2 – Carbon Dioxide

H

B X

P

L

O

C

G

D H2O

N2

NH3

CO2

K 630E-276

A B C D E F G H I J K L

EXHAUST GAS FLOW DIRECTION

A

COOLANT LINE

DEF Tank Sending Unit (includes Level Sensor) DEF Quality Sensor Heater Valve ECU – Engine (Denox 2.2 Dosing System) Exhaust Flap Diesel Oxidation Catalyst (DOC) DEF Supply Module DEF Dosing Module Filter (in Supply Module) Dosing Module (DEF Injector) Mixer Tube Catalytic Converter (includes SCR and CUC)

The DOC/SCR aftertreatment system is electronically managed by the DENOX 2.2 system incorporated into the engine ECU. The ECU calculates and adjusts the flow rate of the DEF solution into the system based on current engine speed, torque delivered, exhaust temperature, amount of nitrogen oxides and ammonia present.

The exhaust passes through the diesel DOC which uses oxidation at high temperatures to convert carbon monoxide (CO), hydrocarbons (HC) and the soluble organic fraction (SOF) of diesel particulates into inert compounds, carbon dioxide (CO2) and water vapour (H2O). It also converts nitrogen oxide (NO) into nitrogen dioxide (NO2) which enhances the performance of the SCR catalyst.

The supply module pump picks up the DEF solution from the tank and sends it under pressure through the dosing module filter to the dosing module (DEF injector) to be injected into the exhaust at the outlet of the DOC and

M N O P Q R S T U V W X

J DEF LINE

Humidity and Temperature Sensor DOC Inlet Temperature Sensor Catalytic Converter Inlet Temperature Sensor Catalytic Converter Outlet Temperature Sensor NH3 Sensor ECU – NH3 Sensor Inlet NOx Sensor ECU – Inlet NOx Sensor Outlet NOx Sensor ECU – Outlet NOx Sensor Air Filter Engine

pass through the mixer tube upstream of the catalytic converter.

The first phase of the SCR process takes place in the first part of the catalytic converter: high temperature exhaust gas evaporates the DEF solution instantly and, by hydrolysis, converts it into ammonia (2NH3) and carbon dioxide (CO2). Evaporation of the solution lowers exhaust gas temperature, bringing it closer to the optimum temperature required by the process.

The exhaust fumes and ammonia at the proper reaction temperature, are introduced into the catalytic converter, where the second phase of the process takes place: by reacting with the oxygen in the exhaust gases the ammonia is converted into free nitrogen (N2) and water vapour (H2O).

Finally the high efficiency catalytic converter incorporates a clean up catalyst (CUC) which reduces any excess ammonia (NH3) which may result from the SCR process.

3.78

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

DIESEL EXHAUST FLUID (DEF) TANK

C

B

B

A

41581AUNI R0

724G-017

A

D

2000043 724G-018

A DEF Tank Fill Cap B DEF Tank Fill Cover

The DEF tank is located in the front left of the upper structure under the hinged DEF tank fill cover. The DEF tank fill point is equipped with a strainer to prevent contaminants from entering the tank. Do not remove this strainer when filling the DEF tank.

DEF tank capacity is 43L (11.4 US gal). Do not overfill tank. The tank is equipped with an expansion capacity of 7% required to allow for the expansion of DEF in cold temperature conditions. DEF freezes at −11°C (12°F).

A DEF Tank B Fill Cap/Strainer C Sending Unit D DEF Quality Sensor

The DEF tank includes a fill cap/strainer, a sending unit and DEF quality sensor.

SENDING UNIT

A DEF level indicator is shown on the computer display main screen, below the fuel gauge.

DEF QUALITY SENSOR

A B

D C 620E-082

The DEF quality sensor is located on the bottom of the DEF tank. It must be removed to drain the tank.

A B C D

Coolant Heater Coil Level Sensor Strainer Temperature Sensor

The sending unit incorporates a heater coil, vent port, level sensor, strainer, temperature sensor, heating system inlet/outlet connections, DEF inlet/outlet connections and an electrical connector.

3.79

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

DRAINING AND CLEANING THE DEF TANK Drain and clean the DEF tank when: • A DEF-related alarm occurs and the problem may be due to a blocked DEF line or a pressurization problem.

• Any situation where a contaminated DEF supply is suspected.

6. Disconnect and carefully remove the DEF quality sensor from the tank.

7. Drain the remaining DEF in the tank into a suitable container.

NOTE: DEF is corrosive to most metals. Protect the electrical connections once the DEF quality sensor has been disconnected.

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

8. Clean the inside of the tank with clean DEF, distilled water or demineralized water. Thoroughly drain the tank after cleaning.

2. Read the DEF level indicator on the computer display main screen to estimate the container capacity required to properly drain the DEF.

9. Reinstall the quality sensor into the DEF tank.

Tighten and then torque the M6 bolts to 2.5 – 3.5 N-m (1.8 – 3.5 lbf-ft).

3. Open the DEF tank fill cover at the front left of the upper structure and remove the DEF tank fill cap.

10. Replace the left front underguard cover on the bottom of the upper structure.

4. Using the appropriate equipment, syphon as much DEF as possible from the tank into a suitable container to enable removal.

Do not reuse the DEF that has been drained from the tank. Use a licensed waste disposal contractor or as otherwise required by local laws to dispose of DEF. If any DEF has spilled, rinse well with water.

A

B 2000044

A DEF Quality Sensor B Underguard Cover – Left Front of Upper Frame

5. Remove the left front underguard cover from the bottom of the upper structure to expose the DEF quality sensor in the bottom of the DEF tank.

3.80

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

REMOVING THE DEF TANK AND SENDING UNIT 1. Drain and clean the DEF tank. Refer to DIESEL EXHAUST FLUID TANK – DRAINING AND CLEANING in THIS SECTION.

A A

B

2000046

A DEF Tank Retaining Bracket

4. Remove the four bolts from the DEF tank retaining bracket and remove the bracket.

2000045

A DEF Tank Compartment Cover B Front Deck Plate – Platform

2. Remove the DEF tank compartment cover and the front deck plate from the upper structure.

C

B

D

B A

A

F

E

1000004

A B C D E F

Electrical Connector Coolant Inlet DEF Supply Vent Port DEF Return Coolant Outlet

2000047

Sending Unit

A DEF Tank B Sending Unit

5. Carefully slide or tip the DEF tank towards the centre of the upper structure, just enough to provide access to the sending unit.

3. Disconnect the hoses and electrical connector from the DEF sending unit at the top of the tank. Make note of the connection locations. Press the white and green tabs to release the connector locks.

6. Use a large oil filter wrench to turn the sending unit counterclockwise approximately 10 degrees.

7. Slowly lift the sending unit straight up and out of the tank.

3.81

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder CLEANING THE DEF FILL STRAINER Remove and clean particles and debris from the DEF fill strainer every 500 hours.

A

1. Clean the area around the outside of the fill cap to prevent DEF contamination.

A

T250D-122

A Sending Unit Inlet Strainer

8. Inspect the inlet strainer at the bottom of the sending unit.

B 802174

A Fill Cap B Fill Neck A

B

2. Remove the fill cap.

3. Clean the area under the fill cap to prevent DEF contamination.

EARLIER DESIGN A

1000007

A Clip B Sending Unit Inlet Strainer

9. Remove the clip that secures the strainer and remove the strainer from the sending unit.

10. Clean the strainer with clean DEF, distilled water or demineralized water.

11. Reinstall the strainer in the sending unit.

12. Remove and clean the DEF fill strainer. Refer to DIESEL EXHAUST FLUID TANK – STRAINER, CLEANING in THIS SECTION. 13. Reinstall the sending unit and the DEF fill strainer.

14. Slide the DEF tank back into position and install the DEF tank retaining bracket.

15. Reconnect the DEF lines and electrical connector to the sending unit.

16. Replace the DEF tank retaining bracket.

17. Reinstall the DEF tank compartment cover and the front deck plate.

1000002

A Fill Strainer

1. Rotate the fill strainer counterclockwise and pull it straight out.

2. Hold the flap open, invert the strainer and lightly tap against a clean, hard surface to dislodge and remove any particles.

3. Rinse the fill strainer with clean DEF, distilled water or demineralized water 4. Install the clean fill strainer into the fill neck. Turn clockwise to tighten.

5. Install the fill cap.

3.82

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance FILLING THE DEF TANK

LATER DESIGN

1. Park the machine as described in PARKING THE MACHINE in SECTION 1.

2. Clean the area around the top of the fill cap to prevent DEF contamination.

A

B 802174

A Fill Cap B Fill Neck

802169

1. Pull the fill strainer straight out.

3. Remove the fill cap.

A

4. Clean the area under the fill cap to prevent DEF contamination.

NOTICE Do not remove the DEF fill strainer when filling the tank. Contamination of the DEF can occur.

802170

A Fill Strainer

2. Invert the strainer and lightly tap it against a clean, hard surface to dislodge and remove any particles.

3. Rinse the fill strainer with clean DEF, distilled water or demineralized water.

4. Install the clean fill strainer into the fill neck.

5. Install the fill cap.

IMPORTANT! Avoid contamination of DEF when performing maintenance on the system as this may cause costly damage to SCR system components and will affect the proper operation of the aftertreatment system and the engine.

5. Insert the filling container spout into the flap on the top of the fill strainer and fill the tank. Do not remove the fill strainer to fill the tank.

NOTE: To avoid contamination, do not re-use DEF. Fill the tank with new DEF only. Refer to DIESEL EXHAUST FLUID (DEF) in THIS SECTION for DEF specifications.

NOTE: A section of the DEF tank remains empty when the DEF level reaches the strainer to accommodate DEF expansion when it freezes.

6. Install the fill cap.

3.83

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

DIESEL EXHAUST FLUID (DEF) DEF is used by the DOC/SCR aftertreatment system to lower the concentration of nitrogen oxides from the diesel engine exhaust.

DEF is an aqueous urea solution with 32.5% high purity urea and 67.5% deionized water.

NOTE: DEF may also be referred to as AUS32 or AdBlue. All DEF must be American Petroleum Institute (API) Certified DEF or meet ISO 22241 specifications.

IMPORTANT! Store DEF between −5°C (23°F) and 30°C (86°F) and out of direct sunlight to maximize shelf life and to avoid DEF quality problems caused by improper storage.

IMPORTANT! Avoid contamination of DEF when performing maintenance on the system as this may cause costly damage to SCR system components and will affect the proper operation of the aftertreatment system and the engine.

NOTE: Extremely low levels of DEF or DEF quality problems will generate computer messages and these conditions may affect engine performance and damage to the DOC/SCR aftertreatment system components.

Take action to correct DEF quality problems immediately.

NOTE: DEF quality problems may result in derating of engine performance to meet emission standard requirements. Take action immediately to correct DEF quality problems to avoid affecting engine performance and damage to the DOC/SCR aftertreatment system components.

WARNING Use only Diesel Exhaust Fluid (DEF) which meets ISO 22241 specifications. Do not fill the DEF tank with any other fluid.

DEF is injected into the exhaust gas stream during normal operation of the Selective Catalytic Reduction (SCR) aftertreatment system.

Use of other fluids may cause component damage, or a fire risk which could result in death or serious injury.

NOTE: When the engine is stopped, all DEF is pumped back to tank before the engine power system is turned OFF. This process takes approximately 90 seconds.

Refer to AFTERTREATMENT SYSTEM in THIS SECTION for more information regarding the use of DEF and its function in the DOC/SCR aftertreatment system.

Refer to COMPUTER CONTROL SYSTEM– MESSAGES in SECTION 2.

3.84

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

DIESEL EXHAUST FLUID (DEF) HANDLING AND STORAGE

AVOID DEF QUALITY PROBLEMS WITH PROPER HANDLING PRACTICES

DEF is an aqueous urea solution with 32.5% high purity urea and 67.5% deionized water.

Most DEF quality problems can be avoided entirely with a little care and proper handling of DEF.

NOTE: DEF may also be referred to as AUS32 or AdBlue and must meet ISO 22241 specifications. Use only DEF meeting this standard.

WHEN FILLING THE DEF TANK: • Clean the area around the fill cap and avoid introducing contaminants into the DEF tank when filling.

It is important to avoid contamination of DEF as this may cause costly damage to SCR system components and affect the proper operation of the SCR system and the engine.

When a problem with DEF quality is detected information messages are sent to the computer display.

• Use only DEF that meets ISO 22241 specifications.

The use of any other fluid will contaminate the aftertreatment system and will pose a safety hazard.

PROPER STORAGE CONTAINERS • To prevent contaminants from affecting DEF quality, handle DEF only in storage, transport and filling containers intended exclusively for that purpose.

NOTE: DEF quality problems may result in derating of engine performance to meet emission standard requirements. Take action immediately to correct DEF quality problems to avoid affecting engine performance and damage to SCR aftertreatment system components.

• Polyethylene or stainless steel containers are recommended. Refer to DEF MANUFACTURER'S DOCUMENTATION for recommendations.

• DEF is corrosive to metals other than stainless steel.

Transport in metal containers other than stainless steel will result in contamination.

Refer to COMPUTER CONTROL SYSTEM– MESSAGES in SECTION 2.

For safety information refer to DIESEL EXHAUST FLUID (DEF) in SECTION 1.

PROPER STORAGE CONDITIONS DEF quality problems can often be avoided with proper storage and handling practices to maximize shelf life.

• Store DEF between −5°C (20°F) and 30°C (86°F).

• Store DEF in areas out of direct sunlight.

• Store DEF away from heat sources.

• DEF shelf life is limited. Use DEF on a first in-first out basis, within DEF manufacturer's recommended shelf life limits. DEF beyond manufacturer's recommended shelf life limits may not meet ISO 22241 specifications.

3.85

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

HEATER VALVE

Heating is switched OFF when: • DEF tank temperature >16°C (61°F) • Supply module temperature >10°C (50°F) • Ambient air temperature >−4°C (25°F) Heating is switched ON when: • DEF tank temperature <15°C (59°F) • Supply module temperature: +8°C (46°F)

A

• Ambient air temperature: −5°C (23°F) When conditions require heating the system will thaw DEF within 30 minutes of engine start for proper operation of the aftertreatment system.

2000064

A Heater Valve A

NOTE: When the engine is stopped, all DEF is pumped back to tank before the engine power system is turned OFF. This process takes approximately 90 seconds.

HEATED DEF SUPPLY LINES B

C 630E-265

A B C D

The DEF supply lines are heated by an electrical wire element built into each hose. The electrical connector is at the Supply Module end of the line. There are three heated lines and two types. There is one 24V line and two 12V lines. The lines can be identified by the electrical connector. The 24V line has a male connector and the 12V lines have female connectors.

D A

Connector Coolant Outlet Coolant Inlet Coolant Bypass

The heater valve is mounted on the upper structure under the pump drive gearbox.

B T250D-117

24 V Heated DEF Line

The heater valve controls the flow of engine coolant through the DEF tank heater coil and the supply module when heating of the DEF is required. The heater valve also controls the constant flow of engine coolant to the dosing module for cooling purposes. This machine is equipped with electrically heated DEF supply lines.

IMPORTANT! If removing the heater valve care should be taken to reconnect the cooling hoses correctly. The heater valve is directional and if the hoses are connected incorrectly the DEF may overheat which will reduce its quality.

DEF freezes at −11°C (12°F).

Temperature sensors signals control the operation of both the electrically heated DEF supply lines and the heater valve which, depending on the temperature, opens or closes the flow of hot engine coolant to the heater coil and supply module.

A

C T250D-118

12 V Heated DEF Line

A DEF Line B Male Electrical Connector C Female Electrical Connector

The two 12V lines run from the Supply Module to the DEF Tank. These two lines are connected electrically in series, so if any one of these two lines fail the element in the other line would not function. For full description of wiring, refer to SECTION 6 of the SERVICE MANUAL.

3.86

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

DENOX 2.2 DOSING SYSTEM

EXHAUST FLAP

A A

2000058

2000071

A Engine ECU

A Exhaust Flap

DENOX 2.2 control system is incorporated into the engine ECU. The DOC/SCR aftertreatment system is electronically managed by the DENOX 2.2 control system. The engine ECU calculates and adjusts the flow rate of the DEF solution into the system based on current engine speed, torque delivered, exhaust temperature, amount of nitrogen oxides and ammonia present and the humidity levels in incoming air.

An exhaust flap is located at the exhaust outlet from the engine. The computer controls the exhaust flap to automatically regulate temperature of the exhaust entering the diesel oxidation catalyst (DOC) to optimum levels for proper operation of the aftertreatment system.

The exhaust flap is also used during engine overspeed to aid in braking.

3.87

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

DIESEL OXIDATION CATALYST (DOC)

DEF SUPPLY MODULE

A

A 2000070

A DEF Supply Module

The DEF supply module is located at the left of the rear of the engine compartment below the DOC. 2000201

A Diesel Oxidation Catalyst

The diesel oxidation catalyst (DOC) is located at the left of the rear of the engine compartment upstream of the catalytic converter (SCR/CUC) and at its outlet incorporates the mixer tube and the mounting for the dosing module.

The supply module pump picks up the DEF solution from the tank and sends it under pressure to the dosing module, mounted on the DOC. DEF is injected into the exhaust at the outlet of the diesel oxidation catalyst and upstream of the catalytic converter.

The DOC uses oxidation at high temperatures to convert carbon monoxide (CO), hydrocarbons (HC) and the soluble organic fraction (SOF) of diesel particulates into inert compounds, carbon dioxide (CO2) and water vapour (H2O).

In addition the DOC converts nitrogen oxide (NO) into nitrogen dioxide (NO2). Increased NO2 levels enhance the performance of the SCR catalyst at low temperatures and increase the effectiveness of the DOC/SCR aftertreatment system as a whole.

3.88

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

DEF DOSING MODULE FILTER

REMOVE DEF DOSING MODULE FILTER

The DEF dosing module filter should be replaced as part of scheduled maintenance every 250 hours.

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

If DEF and/or aftertreatment fault codes have occurred then Tigercat recommends performing a DEF flushing test and Urea Dosing System Test (UDST) at every DEF dosing module filter change to ensure proper operation of the DEF supply module.

NOTE: Verify that engine is at operating temperature before turning OFF the engine.

If no DEF and/or aftertreatment fault codes have occurred then only the DEF dosing module filter replacement is required.

2. Wipe clean the area around the DEF supply module and filter including the supply module ports with particular attention to the inlet port and filter cap to avoid introducing contamination into the filter housing while performing this procedure.

3. Place container below to catch the spills.

CHANGING DEF DOSING MODULE FILTER, DEF FLUSHING TEST AND UDST (UREA DOSING SYSTEM TEST) TOOLS REQUIRED • 27 mm (1 1⁄16 in) wrench • Container to catch DEF and flushing water • Clean distilled/demineralized water • 1 L (0.25 US gal) plastic water bottle with hose attached* • Laptop computer with Tigercat by FPT E.A.SY. engine diagnostic software to run UDST test*

630E-281

4. Turn the filter cover counterclockwise to remove from the supply module. Use a 27 mm (1 1⁄16 in) wrench.

• PT-Box* IMPORTANT! Do not contaminate the DEF when performing maintenance on the system as this may cause costly damage to SCR system components and affect the proper operation of the aftertreatment system and the engine. *Items required if performing a DEF flushing test and UDST. 630E-282

5. Remove the equalizing element and note the colour of the filter inside (black or grey).

3.89

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

630E-285

6. Find the filter removal tool provided with the replacement parts select the correct edge BLACK (B) for black filters or GREY (G) for grey filters.

630E-287

9. Clean surfaces with distilled/demineralized water only to avoid DEF contamination.

Check the area around the filter for cracks. If cracks are found the supply module must be replaced.

10. Thoroughly clean the filter cover to avoid introducing contamination.

DEF FLUSHING TEST A 630E-284

7. Insert the tool edge completely until a click is felt or heard.

630E-286

8. Pull out the filter, using a tool in the slot on the filter removal tool if required.

630E-333

A Inlet Port

1. Disconnect the DEF hose from the inlet port of DEF supply module.

2. Fill the plastic bottle with distilled/demineralized water.

3.90

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

A

630E-331

630E-332

A Inlet Port

3. Connect the water bottle hose to the inlet port of the DEF supply module.

7. Distilled water will be drawn from the bottle and flushed through the DEF supply module. Suction may begin to collapse the bottle and water flow out the bottom of the module will increase.

630E-328

8. The results of the UDST will show a flat line for DEF pressure (red line) because the pump cannot build pressure without the filter in place.

630E-334

4. Raise the water bottle above the DEF supply module.

5. A small amount of water will flow through the supply module and out the bottom where the filter has been removed.

9. Repeat the UDST test a second time to ensure the supply module is thoroughly flushed and working correctly.

10. When the UDST flushing procedure has been performed twice successfully remove the bottle and hose.

11. Reinstall the DEF module inlet hose.

6. With the aid of an assistant run a UDST test from the laptop computer. Refer to PT Box Manual for UDST test information.

3.91

Lubrication and Maintenance REPLACE FILTER

Tigercat 2160 Loader Forwarder 4. Check that all personnel are clear of the machine before starting the engine.

5. Insert the ignition key and turn to the RUN position.

6. Sound horn to warn personnel of machine start-up.

7. Start the engine.

8. Check for leaks.

9. Turn OFF the engine.

10. Remove the ignition key.

630E-288

1. Install the new filter. Lubricate the O-rings on the filter with clean DEF solution for easy installation.

IMPORTANT! Do not contaminate the DEF when performing maintenance on the system as this may cause costly damage to SCR system components and affect the proper operation of the aftertreatment system and the engine.

WARNING Use only diesel exhaust fluid (DEF) which meets ISO 22241 specifications. Do not fill the DEF tank with any other fluid.

630E-289

2. Install the new equalizing element.

NOTE: The equalizing element must be replaced with each filter change.

DEF is injected into the exhaust gas stream during normal operation of the Selective Catalytic Reduction (SCR) aftertreatment system.

Use of other fluids may cause component damage, or a fire risk which could result in death or serious injury.

630E-290

3. Reinstall the clean filter cover, tighten to 20 N-m (15 lbf-ft). Use a 27 mm (1 1⁄16 in) wrench.

3.92

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

UDST (UREA DOSING SYSTEM TEST) 1. With the aid of an assistant run a UDST test from the laptop computer. Refer to PT Box Manual for UDST test information.

630E-327

2. If the supply module is functioning correctly the test should show a characteristic curve as shown above, DEF pressure (red line).

3. A confirmation screen will indicate System is OK if the supply module is functioning correctly.

4. Repeat the UDST test a second time to confirm results.

630E-330

5. If the UDST test passes twice the supply module is OK.

630E-329

6. If the UDST test fails twice note the error mode(s) and contact customer service.

3.93

Lubrication and Maintenance DOSING MODULE (DEF INJECTOR)

Tigercat 2160 Loader Forwarder MIXER TUBE

A

A

2000202

A Dosing Module

The dosing module is mounted on the DOC outlet upstream of the catalytic converter. The dosing module injects DEF into the exhaust pipe.

NOTE: This module must be mounted at the correct specified angle to function properly.

630E-275

A Mixer Tube

The mixer tube is incorporated into the outlet of the DOC upstream from the catalytic converter.

The high-turbulence mixer tube is used to mix the DEF solution and exhaust gases together before they enter the catalytic converter.

The dosing module is cooled by a constant flow of engine coolant supplied by the heater valve to maintain optimum temperature for the aftertreatment process.

3.94

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

CATALYTIC CONVERTER

A

2000063

A Catalytic Converter

The catalytic converter is located at the rear of the engine compartment. Chemical reactions inside the catalytic converter reduce nitrogen oxides (NOx) in the exhaust gas.

The catalytic converter is equipped with soundproofing material and replaces the exhaust silencer. It incorporates both the selective catalytic reduction (SCR) and the cleanup catalyst (CUC) components of the aftertreatment system.

The first phase of the SCR process takes part in the first part of the catalytic converter: high temperature exhaust gas evaporates the DEF solution instantly and, by hydrolysis, converts it into ammonia (2NH3) and carbon dioxide (CO2).

Evaporation of the solution lowers exhaust gas temperature, bringing it closer to the optimum temperature required by the process.

The exhaust gases and ammonia at the proper reaction temperature, are introduced into the SCR, where the second phase of the process takes place. By reacting with the oxygen in the exhaust gases the ammonia is converted into free nitrogen (N2) and water vapour (H2O).

Finally the high efficiency catalytic converter incorporates a clean up catalyst (CUC) which reduces any excess ammonia (NH3) which may result from the SCR process.

3.95

Lubrication and Maintenance HUMIDITY AND TEMPERATURE SENSOR

Tigercat 2160 Loader Forwarder The control system uses this information to calculate the amount of DEF to be injected into the system.

NOTE: All three temperature sensors are identical. Note the location for analysis purposes when replacing a temperature sensor.

200101

A

A

2000072

A DOC Inlet Temperature Sensor

2000189

The DOC inlet temperature sensor is located on the left side of the rear engine compartment.

A Humidity Sensor Location

The humidity sensor is located on the air intake just past the air cleaner.

This sensor monitors the temperature and humidity of intake air sending signals to the DENOX 2.2 control system. This information is used to calculate the amount of DEF to be injected into the system.

TEMPERATURE SENSORS

A 2000203

A Catalytic Converter Inlet Temperature Sensor

The catalytic converter inlet temperature sensor is located in the front engine compartment.

A

M00013

Temperature sensors are mounted at the inlet of the DOC, the inlet of the catalytic converter and the outlet of the catalytic converter. These three sensors send exhaust temperature signals to the DENOX 2.2 control system.

2000073

A Catalytic Converter Outlet Temperature Sensor

The catalytic converter outlet temperature sensor is located on the right side of the rear engine compartment.

3.96

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

NH3 SENSOR A

A B

2000073

A NH3 Sensor

630E-264

A Electronic Control Unit B Sensor

The NH3 sensor is located on the catalytic converter outlet on the right side of rear engine compartment.

The NH3 sensor detects and sends information about the NH3 levels in the exhaust. This information is used to calculate the amount of DEF to be injected into the system and to monitor DOC/SCR aftertreatment system operation.

A

2000068

A ECU – NH3 Sensor

The NH3 sensor ECU is mounted on a bracket on the right side of the rear engine compartment.

Refer to AFTERTREATMENT SYSTEM– APPROVED ANTI-SEIZE PASTES FOR SENSORS in THIS SECTION.

3.97

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

NOx SENSOR A

A

B

2000069

A ECU – Inlet NOx Sensor

620E-088

The inlet NOx sensor ECU is mounted in the pump compartment in front of the hydraulic oil tank.

A Electronic Control Unit B NOx Sensor

There are two NOx sensors and two NOx sensor ECU's in the aftertreatment system.

A

The NOx sensors detect and send information about the dosing of DEF solution and the efficiency of the catalytic converter to the DENOX 2.2 control system.

This information is used to calculate the amount of DEF to be injected into the system and to monitor DOC/SCR aftertreatment system operation.

Each NOx sensor consists of a ceramic sensor and an electronic control unit linked by a cable. The sensor detects the concentration of nitrogen oxides in the exhaust.

The sensor, cable and control unit are considered to be one part for service/replacement purposes.

NOTE: Cable length cannot be changed as this will affect the proper operation of the sensor.

2000073

A Outlet NOx Sensor (Far Side)

The outlet NOx sensor is mounted at the outlet of the catalytic converter.

A

A

2000068 2000072

A Inlet NOx Sensor

The inlet NOx sensor is mounted upstream of the DOC.

A ECU – Outlet NOx Sensor

The outlet NOx sensor ECU is mounted on a bracket on the right rear of the engine compartment.

3.98

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

APPROVED ANTI-SEIZE PASTES FOR EXHAUST/AFTERTREATMENT SENSORS (TIGERCAT BY FPT TIER 4F ENGINES) If replacement of these components is necessary in the field, NOx sensors and NH3 sensors are pre-coated at the factory with the required anti-seize paste. The application of anti-seize is not required.

In the event anti-seize must be re-applied, use only the following approved products: • NOx sensors – Weicon High Tech Anti-seize only • NH3 sensor – Loctite X203 Dry Film Moly Anti-Seize

3.99

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

START-UP PROCEDURE AFTER MAJOR MACHINE MAINTENANCE Follow this procedure: • After major service or a rebuild.

• Whenever the machine has been drained of hydraulic oil.

• When any major component has been removed, repaired or replaced.

• If the engine fuel supply has been disconnected or drained, refer to ENGINE – RESTARTING AFTER ENGINE RUNS OUT OF FUEL in SECTION 2 for instructions. Alternately, refer to the procedure for priming the fuel system in the ENGINE OPERATION AND MAINTENANCE MANUAL.

PRE-STARTUP AND FILLING 1. Check oil levels in the pump drive gearbox, engine, transmission, and bogie axles.

2. Check the coolant level in the radiator/surge tank.

3. Do a final inspection of all fittings and clamps to ensure they are tight and will not leak.

4. Do not start engine. Purge the air from the hydraulic system as follows: a. Ensure filters are in place and tightened. b. Fill the hydraulic oil tank if the oil level is low or the tank has been drained. c.

Fill all pumps and motors with pre-filtered hydraulic oil through the highest case drain ports or hoses connected to the case drain strainer.

d. Bleed the air from the drive pump, main pump and swing pump by loosening the case drain hose fittings at each pump connection. e. Continue filling the hydraulic oil tank. f.

Tighten the case drain hose fittings to the pumps when oil is seen coming from the pump case drain ports.

IMPORTANT! All air must be evacuated from the pumps.

NOTE: Changing strainers, filters and replacing the hydraulic oil tends to aerate the oil. For maximum pump life, the machine should sit for one hour after servicing to allow entrained air to escape from the oil prior to applying working pressures to the pumps.

5. Proceed to the MACHINE START-UP procedure in THIS SECTION.

3.100

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

MACHINE START-UP IMPORTANT! Before beginning this procedure, perform the PRESTARTUP AND FILLING procedure outlined in THIS SECTION. A A

2000081

A Hydraulic Oil Pressure Indicator

3. Turn ignition key switch to RUN position. Monitor hydraulic oil pressure indicator reading closely.

4. Crank the engine for five seconds, then wait for five seconds.

234B-013

A Emergency Stop Switch

Check hydraulic oil pressure indicator during cranking to observe pressure reading. Repeat five times to pump oil into pumps and system components.

1. Push DOWN the emergency stop switch to prevent engine from starting.

WARNING

NOTE: If hydraulic oil pressure readings do not indicate a rise in pressure, check for possible cause (air in system, leaks, loose hose fittings, pumps not turning, etc.). Repair problem. Repeat steps 2, 3 and 4 until a rise in hydraulic oil pressure readings is noticed.

Machine operator must only take directions from the person doing the set-up.

2. Turn ignition key switch to the ON position, lower the left armrest and press and release the pilot interlock reset switch. This will allow oil to circulate and refill these circuits during the following cranking procedure.

5. Turn the emergency stop switch clockwise to allow it to pop back up to turn the power back ON. 6. Turn ignition key switch to RUN position and observe the computer display. Change the information menu to display the hydraulic oil pressure indicator before starting the engine.

7. Start the engine and press and release the pilot interlock reset switch.

If the hydraulic oil pressure reading does not rise within 20 – 30 seconds, turn OFF the engine. If the hydraulic oil pressure reading is between 18 – 35 bar (260 – 500 psi), run the engine at LOW for 20 minutes. Check the engine oil pressure. Refer to COMPUTER CONTROL SYSTEM– ENGINE MENU in SECTION 2. Do not operate any functions.

3.101

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

8. With engine speed at LOW: a. Apply the parking brake and hold the foot brake down to bleed the service brake and parking brake release line in the front and rear axles.

A

b. Run each BOOM function for two minutes at LOW pressure to purge air from the circuit. c.

Slowly operate the SWING function five revolutions clockwise and then five revolutions counterclockwise to purge air from the circuit.

d. Slowly operate the drive function forward and reverse a few times.

9. Set engine speed to HIGH and run each function again for two minutes to flush circuit.

10. Set engine speed to LOW and turn OFF the engine.

B

A

C

2000147

A Hydraulic Oil Tank Sight Gauge

12. With all cylinders fully retracted, check hydraulic oil level.

13. If required, top up the hydraulic oil tank with clean hydraulic oil. Refer to HYDRAULIC OIL TANK – ADDING OIL in THIS SECTION. 14. Set engine speed to LOW and release the parking brake. Slowly steer the machine to the left and right.

It may be necessary to drive the machine either towards the wagon frame or the pedestal frame to allow it to steer fully.

15. Slowly operate the drive function forward and reverse a few times.

2000057

A Engine Coolant Surge Tank B Engine Coolant Fill Cap C Engine Coolant Level Sight Glass

16. Recheck hydraulic oil level and top up if required.

17. Refer to appropriate section of the SERVICE MANUAL to check and set operating pressures.

NOTE: If possible, allow the machine to stand for four to six hours before setting any of the operating pressures. This will allow any air bubbles in the oil to escape and is a good time to check for leaks.

11. Top up the radiator/surge tank with clean coolant.

3.102

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

CARE OF THE MACHINE • All fluid levels must be at the proper level. Refer to SCHEDULED MAINTENANCE in THIS SECTION. • Lubricate all grease points at the required intervals.

Refer to SERVICE AND LUBRICATION POINTS in THIS SECTION. • The cab emergency exits must be in working order by following the EMERGENCY EXITS in THIS SECTION. • Follow proper procedure for cleaning windows.

Refer to WINDOWS– CARE OF POLYCARBONATE WINDOWS in THIS SECTION. • Do not allow branches, twigs, leaves or pine needles to build up around radiator intake doors or anywhere else on the machine. Clean as operating conditions warrant but at least once a day all debris must be remove from the machine interior.

• Do not apply load to a cold engine.

• Never park machine with head raised off the ground. Be sure the head is resting on the ground before servicing or parking the machine. Refer to PARKING THE MACHINE in SECTION 1.

• SAFETY FIRST! Follow all safety rules and regulations as outlined in SECTION 1.

IMPORTANT! When cleaning the machine with pressurized water it is important to avoid getting water directly or indirectly into the exhaust tube. Water in the exhaust tube will damage sensors and SCR system components and affect the proper operation of the after treatment system and the engine.

3.103

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

PRESSURE WASHING

PRESSURE WASHING PROCEDURE

Pressure washing is one of the easiest and most economical ways to preserve your investment.

Accumulated mud can damage track rollers, sand will grind down pins and bearings and wood debris buildup in machine enclosures is a serious fire hazard. Pressure washing is also good practice before and after servicing equipment.

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

CAUTION To avoid slips, trips or falls, all handles, steps and platforms must be kept free of grease, oil, fuel, mud, snow, ice, and forest debris.

2. Close and latch the cab door.

3. Open all engine compartment doors. Refer to ACCESS DOORS AND COVERS in THIS SECTION. 4. Tilt the cab forward. Refer to CAB TILT in THIS SECTION. 5. Turn OFF the battery disconnect switch.

6. Pressure wash: • Drive motors and compartments • Oil cooler, cooler package and enclosure screens

CAUTION

• Engine compartment • Hydraulic pumps and compartment • Main control valve and compartment • Cab windows. Refer to WINDOWS – CARE OF POLYCARBONATE WINDOWS in THIS SECTION. Use personal protective equipment to guard against flying debris.

IMPORTANT! Use a high volume, low pressure fan nozzle or nozzle setting for all equipment cleaning. High pressure spray can damage paint, penetrate electrical connections and remove labels. Use a mild detergent and make sure pressure settings are below 83 bar (1200 psi).

A

B

IMPORTANT! Allow the engine to cool down before pressure washing the engine compartment. Pressure washing a hot engine with cold water could crack the engine block or other components.

To avoid damaging sensitive machine components, do not allow water to come in contact with electrical/ electronic components or air ducts and filters inside the vehicle.

Due to the sensitive electronics on this machine use only warm water, a mild detergent and a gentle pressure wash setting.

845C-242

A Pressure Washer Extension B Platform Ladder

To clean hard-to-reach areas, use a platform ladder or attach an extension wand to your pressure washer, extend it to the desired height and lock it in place.

3.104

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

CLEANING COOLER PACKAGE Check the cooler package every 8 hours or more often where conditions cause accumulation of twigs, leaves, pine needles and dust. Also check all engine enclosure doors.

A

B

C

D

A

201065

A Cooler Package Access Door Safety Stop

3. Engage the door safety stop to prevent the door from closing during cleaning.

4. Remove any accumulated debris.

5. Use compressed air or water for cleaning.

CAUTION

2000187

A B C D

Use compressed air for cleaning only when the machine is cold to avoid the risk of fire caused by debris being blown into contact with hot surfaces.

Radiator A/C Condenser Charge Air Cooler Hydraulic Oil Cooler

The cooler package is located on the right side of the upper structure behind the cooler package access door.

If using compressed air for cleaning, use at 2 bar (30 psi) or less.

The cooler package consists of the radiator, the A/C condenser, the charge air cooler (CAC),and the hydraulic oil cooler.

The cooling fan is located behind the cooler package 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 opposite side of the machine.

Use personal protective equipment (eye wear) to guard against flying debris.

6. When the units have been cleaned return all cooling components to their operating position.

CAUTION Avoid the risk of fire caused by debris accumulating on surfaces that may become hot during machine operation. Use care when cleaning to ensure debris removed from one area of the machine does not accumulate on other areas of the machine.

CLEANING PROCEDURE 1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

2. Open the engine compartment right access door.

3.105

Lubrication and Maintenance NOTE: The cooler package must be checked daily and may have to be thoroughly cleaned on a daily, weekly or monthly basis, depending on operating conditions.

Use personal protective equipment (eye wear) to guard against flying debris. Use compressed air for cleaning only when the machine is cold to avoid the risk of fire caused by debris contacting hot surfaces. Care must be taken not to set the pressure too high otherwise damage to the components could result.

Pay particular attention to cleaning in the corners of the cooler as these areas usually plug deeply. Reversing the fan at least once per hour will help reduce the dust accumulation in the cooler cores. Refer to SWITCHES – FAN CONTROL, ENGINE in SECTION 2 to manually reverse the fan. The auto clean cycle is adjustable through the computer control system menu. Refer also to COMPUTER CONTROL SYSTEM– MAIN MENU – ADJUST MENU – FAN AUTO CLEAN in SECTION 2.

For more information on fire prevention refer to FIRE PREVENTION in SECTION 1.

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

CARE OF POLYCARBONATE WINDOWS 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.

Tigercat 2160 Loader Forwarder INSPECTION AND MAINTENANCE Daily inspection and maintenance is essential to confirm 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.

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 WINDOWS– CARE OF POLYCARBONATE WINDOWS in THIS SECTION for detailed information regarding inspection and maintenance of polycarbonate windows.

3.106

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

RESISTANCE TO CHEMICALS

CLEANING INSTRUCTIONS

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.

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.

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

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.

• Ammonia

Brand name soaps and detergents recommended for cleaning polycarbonate are:

• Anti-freeze

• Fantastik

• Benzene

• Formula 409

• Brake fluid

• Hexcel F.O. 554

• Carbon tetrachloride

• Joy

• Cutting oils

• Lysol

• Gasoline

• Mr. Clean

• Lacquer thinner

• Neleco-Placer

• Toluene

• Pine-Sol

• Turpentine

• Top Job

• 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 time-temperature related. This means the higher the water temperature, the shorter the time before the polycarbonate is adversely affected.

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.

Refer to WINDOWS– CARE OF POLYCARBONATE WINDOWS– RESISTANCE TO CHEMICALS in THIS SECTION for a list of chemicals which should not be permitted to come into contact with polycarbonate windows.

Exposing polycarbonate to repeated steam cleaning 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.

3.107

Lubrication and Maintenance CAUTION

Tigercat 2160 Loader Forwarder GRAFFITI REMOVAL

• Do not use abusive cleaning procedures

• 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.

• Do not use brushes, razor blades, scrapers, squeegees or other sharp tools on polycarbonate windows.

• 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.

either by hand or pressure washing 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.

Refer to WINDOWS– CARE OF POLYCARBONATE WINDOWS– 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.

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 WINDOWS– CARE OF POLYCARBONATE WINDOWS– CLEANING INSTRUCTIONS in THIS SECTION.

3.108

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

SIDE WINDOW SCREENS

IMPORTANT! Retighten window screen knobs hand-tight only to ensure quick exit in case of emergency.

B

234T-031

A

REMOVAL OF ANTI-CORROSION SPRAY (IF APPLICABLE) Some machines, particularly machines shipped outside North America, are shipped with an optional anticorrosion spray to protect the machine from corrosion during shipment.

2000199

A Window Screen Hand Knob – Outside Cab B Window Screen Hand Knob – Inside Cab

The side window screens can be opened to clean the windows. Screens must be closed immediately after cleaning is complete.

This anti-corrosion spray should be removed when the machine reaches its destination as it may cause debris to stick to the treated surfaces of the machine.

A hand knob is provided on both the inside and the outside of the cab on each window screen. Unscrew one hand knob only (not both) to allow the screen to swing out on the hinges.

The anti-corrosion spray can be removed with a pressure washer, a sponge and soap.

3.109

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

PRESSURE AND SPEED SETTINGS Pressure

Location

bar

psi

Speed

Engine High (No Load)

2100 rpm

Low (No Load, Pilot System ON)

1400 rpm

Low (No Load, Pilot System OFF)

800 rpm

Pilot System (Set with Pilot System ON) Accumulator Pressure Reducing Valve

138

2000

Pilot System ON

Brakes Pressure Reducing Valve

100

1450

Pilot System ON

Multifunction Pressure Reducing Valve

45

650

Pilot System ON

Pilot Pressure Reducing Valve

28

400

Pilot System ON

Margin Pressure (‘PX’ – ‘LS’) (Note 5)

26

375

1400+ rpm

Main Valve Load Sense Relief (‘LS’ port)

310

4500

1400+ rpm

Main Valve High Pressure Limiting Control Main Pump POR – Turn IN fully (not used)

Safety Relief – Do Not Adjust Main Valve Load Sense Pressure Set Points Stick Boom IN

N/A

6 seconds **

Stick Boom OUT

N/A

6.5 seconds **

Hoist Boom DOWN

N/A

6.9 seconds **

Hoist Boom UP

N/A

7.5 seconds **

Grapple OPEN (Note 7) *

172

2500

1.6 seconds **

Grapple CLOSE *

172

2500

1.6 seconds **

Grapple Rotate CW (Note 8) *

121 ***

1750 ***

5 rev/10s (30 rpm) **

Grapple Rotate CCW (Note 8) *

121 ***

1750 ***

5 rev/10s (30 rpm) **

Steer LEFT *

296

4300

1400+ rpm

Steer RIGHT *

296

4300

1400+ rpm

22 – 28

325 – 400

Pump POR (Note 9)

283

4100

1400+ rpm

High Pressure Relief, Swing CCW – No external setting

370

5365

1400+ rpm

High Pressure Relief, Swing CW – No external setting

370

5365

1400+ rpm

Swing Pump Charge Pressure – Non-adjustable (Note 9)

Drive Pump Charge Pressure – Non-adjustable

21 – 28

300 – 400

High Pressure Relief, Work Port 'A'– Non-adjustable

445

6450

1400+ rpm

High Pressure Relief, Work Port 'B'– Non-adjustable

445

6450

1400+ rpm

Cab Tilt Main Relief

207

3000

Cab Tilt Counterbalance Valves (Note 10)

241

3500

Cab Tilt

* Set pressure with gauge on main valve 'LS' port. ** Engine speed set at 1400 rpm (Low, no load, pilot system ON). *** These pressures apply to Tigercat grapples only.

3.110

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

NOTES: 1. Hydraulic system to be at operating temperature when setting pressures.

2. Set pressures with engine speed at LOW and pilot system turned ON unless otherwise specified.

3. All pressures measured in bar (psi). All function speeds measured in seconds.

4. Pressure and speed values are for reference purposes only. Refer to SERVICE MANUAL for setting procedure.

5. Set margin pressure with the pilot system turned ON. Do not use any functions. Adjustment screw is on main pump. Refer to SERVICE MANUAL for setting procedure.

6. Port reliefs on main valve cannot be adjusted. Each port relief has a specific setting and cannot be interchanged with other port reliefs.

7. Increase time for grapple OPEN if pressure goes over 152 bar (2200 psi) while running function.

8. For Rotobec HD (heavy duty) and Hultdins grapples, set rotate to 207 bar (3000 psi).

9. Swing Pump: a. Swing machine slowly 5 times in each direction before setting pressures. b. Do not hold pressure over relief more than 8 seconds at a time. Wait 5 seconds to avoid overheating.

10. Cab Tilt: a. Turn counterbalance valves out fully, then in 1 turn. b. Tilt valve is factory preset.

3.111

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

TORQUE CHART Location

Thread Diameter

Torque (Lubricated) N-m

lbf-ft

Cylinders Piston nut, main boom cylinder Gland bolts, main boom cylinder

M75-2 6H M16-2.0 (12.9)

7150 234

5272 173

Piston nut, stick cylinder Gland bolts, stick boom cylinder

M75-2 6H M16-2.0 (12.9)

7150 234

5272 173

Piston nut, steering cylinders

1-5/8-12 UNF

2290

1690

Piston nut, oscillation lock cylinders Gland bolts, oscillation lock cylinders

M50-2 6H M16-2.0 (12.9)

2847 234

2100 173

Boom joint and cylinder pin retaining bolts

M20-2.5 (10.9)

393

290

Main and stick boom pin retaining nut

2"-12 UNF (G8)

Until snug

Until snug

Steering cylinder expander pin bolts (Note 1)

M20-2.5 (10.9)

500

370

Cab securing bolts

7/8"-9 UNC (G8)

540 – 610

400 – 450

Swing bearing bolts Swing gearbox mounting bolts Swing motor mounting bolts

7/8"-9 UNC (G8) M20-2.5 (10.9) M14-2 (10.9)

610 540 176

450 400 130

Centre joint Retaining bolts, articulation bearing Retaining bolts, articulation pin End cap bolts, oscillation

M12-1.75 M16-2.0 (10.9) M16-2.0 (10.9)

94 – 104 234 – 257 234 – 257

70 – 77 173 – 190 173 – 190

Engine mounting Mounting brackets to engine block Mounting brackets to gearbox Mounting brackets to frame

M12-1.75 (10.9) M16-2.0 (10.9) M24-3.0 (10.9)

110 237 – 257 790 – 869

80 175 – 190 583 – 641

Engine cooling fan mounting bolts

M10-1.5 (10.9)

68

50

Driveshafts Retaining nuts, yokes Bolts, driveshaft universal joints Bolts, input universal joints

1-1/4-18 UNF 1/2-20 UNF 1/2-20 UNF

645 – 710 150 – 163 150 – 163

475 – 525 110 – 120 110 – 120

Bogie axle mounting bolts and studs

M30-3.5 (12.9)

1550

1150

7/8-14 UNF (G8)

678 – 746

500 – 550

M22-2.5 (10.9) 5/8-11 UNC (GR 9) 3/4-10 UNC (GR 8)

625 216 – 237 393 – 420

460 159 – 175 282 – 310

Pump drive Pump drive coupler to engine Pump drive gearbox to engine

M10-1.5 (12.9) M10-1.5 (12.9)

47 – 61 61 – 68

35 – 45 45 – 50

Pump mounting Drive pump to pump drive gearbox Charge pump to drive pump Main pump to pump drive gearbox Cooling pump to main pump Swing pump to pump drive gearbox

M20-2.5 (10.9) M12-1.75 (10.9) M16-2 (10.9) M16-2 (10.9) M16-2 (10.9)

460 – 510 110 237 – 257 237 – 257 237 – 257

340 – 375 80 175 – 190 175 – 190 175 – 190

Wheel bolts Transmission Mounting bracket to frame Housing to mounting bracket Drive motor mounting bolts

1.

Tighten expander pin bolts evenly to keep pin located and torque to value shown. Apply grease to the pin joint. Refer to LUBRICATION– CYLINDER STEERING ENDS – CENTRE JOINT in THIS SECTION. Steer the machine twice and re-torque the bolts to the value shown.

2.

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

3.112

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

GENERAL TORQUE SPECIFICATIONS IMPERIAL

The torque values listed below are for general use only.

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

GRADE 5 BOLTS

GRADE 8 BOLTS

IMPERIAL BOLT TORQUE SPECIFICATIONS GRADE 5 BOLTS GRADE 8 BOLTS LUBRICATED COARSE Nm lbf-ft THREAD 1/4" - 20 9-9 6-7 5/16" - 18 18 - 19 13 - 14 3/8" - 16 31 - 35 23 - 25 7/16" - 14 50 - 55 37 - 41 1/2" - 13 77 - 84 57 - 62 9/16" - 12 111 - 122 82 - 90 5/8" - 11 153 - 168 113 - 124 3/4" - 10 271 - 298 200 - 220 7/8" - 9 437 - 480 322 - 354 1" - 8 654 - 720 483 - 531 1 1/8" - 7 808 - 888 596 - 655 1 1/4" - 7 1139 - 1253 840 - 924 FINE LUBRICATED THREAD Nm lbf-ft 1/4" - 28 10 - 11 7-8 5/16" - 24 20 - 22 14 - 16 3/8" - 24 36 - 39 26 - 29 7/16" - 20 56 - 62 41 - 46 1/2" - 20 86 - 95 64 - 70 9/16" - 18 123 - 136 91 - 100 5/8" - 18 173 - 190 127 - 140 3/4" - 16 302 - 332 223 - 245 7/8" - 14 482 - 530 355 - 391 1" - 14 735 - 808 542 - 596 1 1/8" - 12 906 - 996 668 - 735 1 1/4" - 12 1262 - 1388 930 - 1023

DRY Nm lbf-ft 11 - 13 8-9 24 - 26 17 - 19 42 - 46 31 - 34 67 - 74 49 - 54 102 - 112 75 - 83 147 - 162 109 - 120 203 - 224 150 - 165 361 - 397 267 - 293 582 - 640 429 - 472 873 - 960 644 - 708 1077 - 1185 794 - 874 1519 - 1671 1121 - 1233 DRY Nm lbf-ft 13 - 14 10 - 11 26 - 29 19 - 21 47 - 52 35 - 38 75 - 82 55 - 61 115 - 127 85 - 93 164 - 181 121 - 133 230 - 253 170 - 187 403 - 443 297 - 327 642 - 706 474 - 521 979 - 1077 722 - 795 1207 - 1328 890 - 980 1682 - 1850 1241 - 1365

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" - 12 1 1/8" - 12 1 1/4" - 12

LUBRICATED DRY Nm lbf-ft Nm lbf-ft 12 - 13 9 - 10 16 - 18 12 - 13 25 - 27 18 - 20 33 - 37 25 - 27 44 - 49 33 - 36 59 - 65 44 - 48 71 - 78 52 - 58 95 - 104 70 - 77 108 - 119 80 - 88 144 - 159 106 - 117 156 - 172 115 - 127 208 - 229 154 - 169 215 - 237 159 - 175 287 - 316 212 - 233 383 - 421 282 - 310 510 - 561 376 - 414 616 - 678 455 - 500 822 - 904 606 - 667 924 - 1016 681 - 750 1232 - 1355 909 - 999 1310 - 1441 966 - 1063 1746 - 1921 1288 - 1417 1848 - 2033 1363 - 1499 2464 - 2710 1817 - 1999 LUBRICATED DRY Nm lbf-ft Nm lbf-ft 14 - 15 10 - 11 18 - 20 14 - 15 28 - 30 20 - 22 37 - 41 27 - 30 50 - 55 37 - 41 67 - 74 49 - 54 79 - 87 58 - 64 106 - 116 78 - 86 122 - 134 90 - 99 163 - 179 120 - 132 174 - 192 128 - 141 232 - 255 171 - 188 244 - 268 180 - 198 325 - 358 240 - 264 427 - 469 315 - 346 569 - 626 420 - 462 680 - 748 502 - 552 907 - 997 669 - 736 1037 - 1141 765 - 841 1383 - 1521 1020 - 1122 1468 - 1615 1083 - 1191 1958 - 2154 1444 - 1588 2046 - 2250 1509 - 1660 2728 - 3000 2012 - 2213

METRIC

METRIC BOLT TORQUE SPECIFICATIONS CLASS 8.8

SIZE PITCH LUBRICATED mm Nm lbf-ft M6 1 8-9 6-7 M8 1.25 20 - 22 15 - 16 M10 1.5 39 - 43 29 - 32 M12 1.75 68 - 75 50 - 55 M14 2 109 - 120 80 - 89 M16 2 169 - 186 125 - 137 M18 2.5 234 - 257 172 - 190 M20 2.5 330 - 364 244 - 268 M22 2.5 451 - 496 332 - 366 M24 3 571 - 628 421 - 463 M27 3 837 - 921 618 - 679 M30 3.5 1135 - 1249 837 - 921 M33 3.5 1545 - 1699 1139 - 1253 M36 4 1985 - 2183 1464 - 1610

CLASS 10.9 LUBRICATED DRY Nm lbf-ft Nm lbf-ft Nm lbf-ft 11 - 12 8-9 11 - 12 8-9 15 - 17 11 - 12 26 - 29 19 - 21 27 - 30 20 - 22 36 - 40 27 - 30 52 - 57 38 - 42 54 - 60 40 - 44 72 - 79 53 - 59 91 - 100 67 - 74 94 - 104 70 - 77 126 - 138 93 - 102 145 - 160 107 - 118 151 - 166 111 - 122 201 - 221 148 - 163 226 - 248 166 - 183 234 - 257 173 - 190 312 - 343 230 - 253 312 - 343 230 - 253 323 - 356 239 - 262 431 - 474 318 - 350 441 - 485 325 - 357 457 - 503 337 - 371 610 - 670 450 - 495 601 - 661 443 - 487 623 - 686 460 - 506 831 - 914 613 - 674 761 - 838 562 - 618 790 - 869 583 - 641 1053 - 1159 777 - 855 1116 - 1228 823 - 906 1158 - 1274 854 - 940 1544 - 1699 1139 - 1253 1514 - 1665 1116 - 1228 1570 - 1727 1158 - 1274 2094 - 2303 1544 - 1699 2060 - 2266 1519 - 1671 2137 - 2351 1576 - 1734 2849 - 3134 2102 - 2312 2646 - 2911 1952 - 2147 2745 - 3020 2025 - 2227 3661 - 4027 2700 - 2970 DRY

3.113

CLASS 12.9 LUBRICATED DRY Nm lbf-ft Nm lbf-ft 13 - 14 10 - 11 18 - 19 13 - 14 32 - 35 24 - 26 43 - 47 31 - 35 63 - 70 47 - 51 84 - 93 62 - 68 110 - 121 81 - 90 147 - 162 109 - 119 176 - 194 130 - 143 235 - 259 173 - 191 274 - 301 202 - 222 365 - 401 269 - 296 378 - 416 279 - 307 504 - 554 372 - 409 534 - 588 394 - 433 712 - 784 525 - 578 728 - 801 537 - 591 971 - 1068 716 - 788 923 - 1016 681 - 749 1231 - 1354 908 - 999 1354 - 1489 998 - 1098 1805 - 1985 1331 - 1464 1835 - 2019 1354 - 1489 2447 - 2692 1805 - 1985 2498 - 2747 1842 - 2026 3330 - 3663 2456 - 2702 3208 - 3529 2366 - 2603 4278 - 4706 3155 - 3471

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

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 onto 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.

A B C

D E F

FLANGE PORT ASSEMBLY The steps to properly assemble the flange port clamping bolts are:

FLANGE.JPG

A B C D E F

4-Bolt Split Flange Components

1. Make sure sealing surfaces are free of burrs, nicks, scratches or any foreign particles.

Washers Bolts Flange Clamp Flange Head O-Ring Tapped Holes

2. Lubricate the O-ring.

3. Position flange and clamp halves.

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

• The 4-Bolt Split Flange consists of four main components:

5. Hand tighten bolts.

• A body (flange head) • An O-ring • One captive or two split flange clamps • Four bolts and washers Dash Size

Flange Size

Inch Bolt (J518)

Torque lbf-ft

Metric Bolt (ISO 6162)

Torque Nm

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

FLANGE2.jpg

A

Flange Bolt Tightening Sequence

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

Table T6 – Code 61 Flange Recommended Bolt Torque

NOTE: Does not meet ISO 6162 specification.

Dash Size

Flange Size

Inch Bolt (J518)

Torque lbf-ft

Metric Bolt (ISO 6162)

Torque N-m

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

Table T7 – Code 62 Flange Recommended Bolt Torque

NOTE: Does not meet ISO 6162 specification.

3.114

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

Parker

ASSEMBLY TORQUE JIC 37 Degree Flare

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

Thread Size

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

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

Thread Size 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

BSPT

Tube Connection Swivel or Hose Connection FFWR FFWR 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

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

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

TRIPLE-LOK FERULOK PIPE FITTINGS lbf-ft Nm (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

3.115

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

TRIPLE-LOK FERULOK PIPE FITTINGS lbf-ft Nm (lbf-in) (60) 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

HEX HEAD

HP5ON-S

P5ON-S

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

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

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

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

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

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

ORS

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

Dash Size -03 -04 -05 -06 -08 -10 -12 -14 -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

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

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

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

3.116

Tigercat 2160 Loader Forwarder

Lubrication and Maintenance

TIRE PRESSURES Manufacturer

Inflation Pressure

Tire Size

psi

kPa

23.5-25 20PR E2, L2

35

240

Nokian

750/55-26.5 20TRS, L-2, SF

87

600

Nokian

750/55-26.5 20F, SF

87

600

Nokian

780/50-28.5 24F2, SF

87

600

Bridgestone/Firestone

COMMON CONVERSIONS To Convert...

Into...

Multiply By

To Convert...

Into...

Multiply By

bar

psi

14.5

in3

cm3

16.39

cm

in

0.06102

°F

°C

(°F − 32) / 1.8

°C

°F

(°C × 1.8) + 32

lb

kg

0.4535

kg

lb

2.205

hp

kW

0.7457

kW

hp

1.341

US Gal

L

3.785

L

US Gal

0.2642

in

mm

25.4

mm

in

0.03937

lbf•ft

N-m

1.356

N-m

lbf•ft

0.7375

lbf

N

4.4482

N

lbf

0.22481

in Hg

psi

0.4912

psi

bar

0.06896

in H2O

psi

0.03613

3

3

3.117

Lubrication and Maintenance

Tigercat 2160 Loader Forwarder

WEIGHTS OF COMMERCIAL WOOD

SPECIES

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

kg/m3 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

lb/ft3 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

SPECIES

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

NOTE: The values shown here are green weights.

3.118

kg/m3 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

lb/ft3 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