Tigercat 220D Loader OPERATOR'S MANUAL - PDF DOWNLOAD

OPERATOR'S MANUAL Tigercat 220D Loader TABLE OF CONTENTS

ISSUE 1.1, MARCH, 2009

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

220D-OM00

220D Available Literature Operator's Manual (this manual) ....................... Part No. 33587A Service Manual .................................................. Part No. 33588A Parts Catalog ..................................................... Part No. 33589A

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

®

ii

Tigercat 220D Loader

INTRODUCTION An Operator's manual, Service manual and a Parts catalog are provided by Tigercat to assist the dealer, customer and operator in becoming familiar with the features of the Tigercat 220D Loader, serial number 2200601 and up.

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

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

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

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

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

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

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

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

Tigercat Industries Inc.

iii

Tigercat 220D Loader

Introduction

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

IT IS Tigercat POLICY THAT NO CHANGES ARE TO BE MADE TO ITS PRODUCTS INCLUDING DELETIONS OR ADDITIONS OTHER THAN A Tigercat APPROVED OPTION FITTED IN THE FACTORY APPROVED MANNER. Official approval to make changes or install options is only as follows: i)

The relevant options for that product must be shown or listed on current Tigercat documentation or literature such as a printed specification sheet, price list, parts manual, or product literature issued by Tigercat.

ii)

Approved options or product changes authorized in writing by the Tigercat Engineering Manager.

Authorization by any other person is unacceptable.

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

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

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

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

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

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

Tigercat Industries Inc.

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Tigercat 220D Loader

SECTION 1 - SAFETY MARCH, 2009

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

Read and understand all manuals for any attachments or accessories.

CONTENTS - SECTION 1 BATTERY DISCONNECT SWITCH .......................................................... 1.6, 1.8 COOLING SYSTEM .......................................................................................... 1.8 EXHAUST FUMES ............................................................................................ 1.9 FIRE PREVENTION ........................................................................................ 1.15 DRY CHEMICAL CLEANUP PROCEDURES .............................................. 1.19 FIRE PREVENTION GUIDELINES .............................................................. 1.15 WHAT TO DO AFTER A MACHINE FIRE HAS OCCURRED ...................... 1.18 WHAT TO DO TO PREPARE FOR A MACHINE FIRE ................................. 1.16 WHAT TO DO WHEN A MACHINE FIRE OCCURS ..................................... 1.17 FIRST AID ......................................................................................................... 1.4 FLUID INJECTION INJURY ............................................................................ 1.10 FLUID LEAKS ................................................................................................... 1.8 GREASE INJECTION INJURY ........................................................................ 1.11 LIGHTNING SAFETY AWARENESS LIGHTNING SAFETY ............................................................... 1.12, 1.13, 1.14 WHAT IS A LIGHTNING STRIKE ................................................................. 1.12 LOOSE CLOTHING HAZARD ........................................................................... 1.9 PROTECTIVE CLOTHING ................................................................................ 1.3 SAFE REMOVAL OF COUNTERBALANCE AND CHECK CARTRIDGE .......... 1.9 SAFETY LABELS ..................................................... 1.20, 1.21, 1.22, 1.23, 1.24 SAFETY PRECAUTIONS, OPERATING ........................................................... 1.5 SAFETY PRECAUTIONS, SERVICING ............................................................ 1.7 SAFETY SYMBOLS .......................................................................................... 1.2 SIGNAL WORDS............................................................................................... 1.2

Tigercat 220D Loader

Safety

SAFETY SYMBOLS

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

Follow the instructions in the safety message.

Understanding Signal Words

DANGER DANGER 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.

1.2

Tigercat 220D Loader

Safety and adhere to. More specific measures are illustrated with pictograms which may also be attached to the machine in locations pertinent to their respective message. Keep safety labels in good condition.

Repair or replace damaged labels.

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

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

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

Follow all instructions from safety inspector and supervisors.

KEEP CLEAR When approaching an operating machine on foot, stay at least 300 feet (90M) away from the machine and all related attachments including the grapple, delimber, topping saw and ground saws until the operator recognizes your presence. Make sure that all equipment is shut down with grapple resting securely on stable ground before advancing to the machine.

Always avoid the discharge path of all saws.

Operators of this equipment must be fully trained by a qualified person in safety and operating procedures.

The operator must be fully aware of the capabilities and limitations of the equipment and must at no time exceed them. The machine is to be used only for its intended purpose. Learn the most efficient operating techniques.

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

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

Do not let an untrained person operate the machine.

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

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

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

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

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

Tigercat 220D Loader

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

GENERAL SAFETY PRECAUTIONS continued

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

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

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

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

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

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

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

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

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

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

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

Do not operate the equipment with anyone in the cab, on platforms, or anywhere else within 300 feet the machine or related equipment. The machine is provided and approved with seating for the operator only.

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

Inspect the machine daily for signs of damage, unusual wear, fluid leaks, or faulty operation. Repair or replace malfunctioning parts and systems immediately.

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

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

1.4

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.

WARNING Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

Tigercat 220D Loader

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

OPERATING SAFETY PRECAUTIONS

Ensure that the windshield guard is installed and properly secured.

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

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

During refuelling do not leave the filler nozzle unattended.

Avoid over filling and immediately clean up spilled fuel.

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

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

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

Make sure that all of the controls are positioned as specified in the starting instructions in the operator's manual.

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

Sound the machine horn before starting the machine.

WARNING

For engine starting and stopping procedures refer to STARTING ENGINE and STOPPING ENGINE in SECTION 2 of the THIS MANUAL. For correct engine speeds, refer to THROTTLE CONTROL in SECTION 2 of the THIS MANUAL.

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

1.5

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

Use only prearranged and approved signalling practices.

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

Tigercat 220D Loader

Safety

OPERATING SAFETY PRECAUTIONS continued

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

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

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

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

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

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

DANGER

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

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

DANGER

24V

32524AUNI

R0

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

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

ECM

220D-002

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

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

Serious injury or death or property damage may result.

IMPORTANT

24 VOLT ELECTRICAL SYSTEM Before transporting the machine: • Secure the grapple to the trailer and raise the stabilizers.

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

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

1.6

Tigercat 220D Loader

Safety SAFETY INTERLOCK SWITCH ON LEFT ARMREST:

SERVICING SAFETY PRECAUTIONS

The left arm rest is equipped with a safety interlock switch (1) to prevent the machine from being operated while the armrest is in the raised position (pilot system is shut off).

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

ARMREST

Conduct maintenance inspections at least as frequently as recommended in section 3 of the operator's manual.

When servicing or repairing equipment, shut the engine down. Turn Master Disconnect switch OFF. Install a “DO NOT START ENGINE” sign on the operator’s cab door when making repairs to the machine.

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

1 LIMIT SWITCH ACTUATING LEVER ON SEAT BASE

•

• 247-25

PILOT SYSTEM SHUT OFF

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

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

WARNING, HOT FLUIDS AND HOT MACHINE SURFACES CAN CAUSE SERIOUS BURNS! Before servicing the machine, allow the engine cooling system, fuel system, exhaust system, hydraulic system and machine surfaces to cool down.

•

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

•

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

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

The left arm rest safety interlock switch (pilot system shut off limit switch) and the pilot reset switch are a safety feature and their function must not be defeated in any way.

WARNING

•

With the engine running and the left arm rest DOWN, push the pilot reset switch.

1.7

Tigercat 220D Loader

Safety

SERVICING SAFETY PRECAUTIONS continued

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

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

24V

32524AUNI

R0

ECM

220D-002

Never use your bare hand to check for fluid leaks.

Fluid leaks under pressure may not be visible.

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

Turn the battery disconnect switch off and disconnect the battery negative terminal. Also, disconnect the engine ground connection from the frame.

•

• •• ••

DISCONNECT THE TWO MULTI-PIN PLUGS FROM THE ENGINE CPU

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

DISCONNECT THE TWO MULTI-PIN PLUGS FROM THE PLUS 1 CONTROLLER 220D-

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

250B-

Disconnect the engine CPU (Central Processing Unit) by unplugging the two multi-pin connectors from the left side of the engine. Also disconnect the two multi pin connectors on the optional Plus 1 controller (if equipped).

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

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

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

IMPORTANT

24 VOLT ELECTRICAL SYSTEM

1.8

Tigercat 220D Loader

Safety

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

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

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.

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

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

VERTICAL CENTERLINE

LOWER FRAME

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

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

•

COUNTERBALANCE VALVE

•

STABILIZER UP IN VERTICAL POSITION

• • •

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

CYLINDER

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

STABILIZER COUNTERBALANCE/CHECK VALVE CARTRIDGE REMOVAL

230-06A

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

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

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

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

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

1.9

Tigercat 220D Loader

Safety

SERVICING SAFETY PRECAUTIONS continued

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

FLUID INJECTION INJURY 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.

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

• Seek professional medical attention immediately.

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

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

Always wear thick protective gloves.

• Be sure to wear safety goggles for eye protection.

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

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

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

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

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

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

•

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

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

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

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

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

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

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

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

1.10

Tigercat 220D Loader

Safety

SERVICING SAFETY PRECAUTIONS continued 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.

ALWAYS 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: •

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

•

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

•

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

•

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

•

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

•

Remove dirt and grease from grease fittings prior to greasing.

•

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

•

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

1.11

Tigercat 220D Loader

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.

1.

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.

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

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

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.

Designate a member of your crew to

•

Monitor daily weather forecasts

•

Observe local weather conditions

•

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

2.

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

3.

Anticipate a high-risk situation and take action early by moving to a low-risk location.

Do not hesitate. If there is lightning, you are in danger.

4.

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

5.

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

6.

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.

1.12

Tigercat 220D Loader

Safety WHAT TO DO IF YOU ARE OUTSIDE AND SEE LIGHTNING OR HEAR THUNDER.

LIGHTNING SAFETY CONT'D Unfortunately loggers do not often work close to buildings and therefore other alternatives need to be considered.

If you can, get inside.

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.

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.

1.

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

2.

If inside a building: •

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

•

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

3.

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

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

•

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

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.

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

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

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

1.13

Tigercat 220D Loader

Safety

LIGHTNING SAFETY CONT'D If you are caught outside and have no where else to go.

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

1.

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

1.

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

2.

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

2.

3.

Get away from open water such as ponds or streams.

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.

4.

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

3.

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

5.

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

6.

Avoid entering any small enclosures or shelters.

7.

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

8.

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

9.

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

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

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

11. Do not use the telephone except for emergencies.

1.

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

2.

Call your local emergency response telephone number immediately.

3.

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

Use a portable defibrillator if one is available.

4.

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

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

1.14

Tigercat 220D Loader

Safety 4.

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

5.

Inspect the machine regularly for any signs of diesel fuel or hydraulic system leakage. Check for worn or eroded fuel or hydraulic lines before starting up any equipment.

6.

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

7.

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

8.

Use only nonflammable solutions for cleaning the machine and components.

9.

Inspect the exhaust system daily for any signs of leakage. Check for worn, cracked, broken or damaged pipes or muffler. Also check for missing or damaged bolts or clamps. Should any exhaust leaks or defective parts be found, repairs must be made immediately. Engine exhaust leaks can cause fires. Do not operate the machine until the exhaust leak is repaired.

FIRE PREVENTION

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

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

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

1.

2.

3.

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

1.15

10. During daily operation of the machine, the occurrence of exhaust leaks are usually accompanied by a change or increase in engine exhaust noise levels. These audible warnings cannot be ignored.

Should any exhaust leaks occur during operation, the machine must be shut down immediately and not put back to work until the necessary repairs have been completed.

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

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

Tigercat 220D Loader

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

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

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

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

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

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

EQUIPMENT FIRES ADVERSELY EFFECT YOUR ABILITY TO LOG, MAY INCREASE YOUR INSURANCE PREMIUMS DRAMATICALLY OR PREVENT YOU FROM OBTAINING INSURANCE COVERAGE AT ALL.

WHAT TO DO TO PREPARE FOR A MACHINE FIRE

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

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

1.16

•

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

•

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

•

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

•

Ensure that you have the proper fire extinguishers on site. Most fires involving mobile forestry equipment will be Class A or B. Dry chemical extinguishers should be rated ABC and pressurized water extinguishers should be rated A. Class A fires involve ordinary combustibles such as wood, cloth, paper, rubber and many plastics, Class B fires occur with flammable liquids such as diesel fuel, oil and grease and Class C fires apply to energized electrical equipment.

Tigercat 220D Loader FIRE PREVENTION continued •

•

•

•

•

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

Safety fire emergency is recorded and readily available at all times.

WHAT TO DO WHEN A MACHINE FIRE OCCURS •

1. Lower all working attachments to the ground.

2. Shut the engine off.

3. Activate the fire suppression system**.

Ensure that your fire detection system* is in working order. Refer to FIRE DETECTION SYSTEM in SECTION 2 of the OPERATOR’S MANUAL.

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

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

Ensure that your fire suppression system** is charged and in working order. Refer to FIRE SUPPRESSION SYSTEM in SECTION 2 of the OPERATOR’S MANUAL.

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

Ensure that you are familiar with the recommended procedures for fire contained in the emergency action plan of your company.

Ensure that you follow all national, state / provincial and local regulations dealing with fire fighting in effect in your specific geographic region. Regulations will vary from region to region but most will usually require that:

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

•

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

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

•

Ensure that after you have received the training as outlined above, that you know how to use the fire extinguisher, the pressurized water system (if applicable) and the fire suppression system** on your machine. There is not enough time available to read instructions during a fire emergency.

•

Ensure that all information necessary for you to immediately contact all sources of help (local fire department, etc) in the event of a 1.17

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

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

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

1. Workers assigned to fire fighting duties must be physically capable of performing them safely and effectively.

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

If operating the machine when a fire occurs:

•

Be aware that engine coolant , diesel fuel or hydraulic hoses could fail during a fire. If this happens, hot coolant, fuel or oil could possibly be ignited by the fire.

•

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

•

If possible a dry chemical fire extinguisher or fire suppression system** should be used first to fight a machine fire. Then immediately afterwards use the pressurized water hose supplied with the machine (if applicable) or a pressurized water extinguisher (if available). A fire suppressed by dry chemical may re-ignite from the heat retained by any debris in the area. The water will cool the area, reducing the chances of re-ignition.

Tigercat 220D Loader

Safety •

FIRE PREVENTION continued •

WHAT TO DO AFTER A MACHINE FIRE HAS OCCURRED •

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

•

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

Break the plastic seal as the pin is pulled.

•

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

Release the hose before taking aim.

•

Squeeze the handle 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

Remain with the machine until help arrives.

Before returning the machine to work.

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

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

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

•

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

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

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

20229A

•

•

•

•

TYPICAL FIRE EXTINGUISHER ACCESS HOLE

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

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

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

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

1.18

Tigercat 220D Loader

Safety

DRY CHEMICAL CLEANUP PROCEDURES

3.

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

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

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

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

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

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

1.

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

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

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

2.

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

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

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

Wash the area with a mild soap and water solution. Rinse thoroughly with water. Blowdry to remove all residual water.

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

1.19

Tigercat 220D Loader

Safety

SAFETY LABELS SAFETY LABELS CAB LABELS The following safety labels are installed in the cab.

These labels are located inside the cab in full view of the operator. All labels must be periodically cleaned and inspected to ensure legibility is maintained. Replace any label that becomes illegible, damaged or removed.

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

NO RIDERS

READ OPERATOR'S MANUAL Always read the operator’s manual before operating the machine. Pay close attention to WARNINGS and HAZARD identifications.

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

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

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

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.

1.20

Tigercat 220D Loader

Safety CRUSH HAZARD

SAFETY LABELS CRUSH HAZARD

This label is located on the delimber, it warns of the CRUSH HAZARD caused by the delimber knives and that approaching personnel are subject to crush injurys by delimber knives WHICH COULD RESULT IN DEATH OR SERIOUS INJURY. Do Not Operate the machine until all personnel are a safe distance away from the machine.

This label is located in four places on the lower frame near each of the cylinder and lock valves. It warns of the CRUSH HAZARD caused by a tipping or falling machine.

The delimber knives will close automatically when the engine is shut down. Do Not approach the delimber arms until the engine is shut down and the delimber arms are closed.

Do not service the stabilizer cylinder or lock valve while the machine is supported by the stabilizers! Servicing the stabilizer cylinder or lock valve while the machine is supported by the stabilizers could cause the machine to tip or fall WHICH COULD RESULT IN DEATH OR SERIOUS INJURY.

Do not operate the machine when any personnel approach! If any person attempts to approach the machine during operation, STOP THE MACHINE IMMEDIATELY.

Never loosen or remove bolts, hoses or valves from the stabilizer cylinder or lock valve while the machine is supported by the stabilizers.

ALWAYS be aware of the location of other personnel who are working in the area and be prepared to stop operations if they enter your working area without warning. Be prepared for this potential and take appropriate action if required!

Before servicing the stabilizer cylinder or lock valve, lower the machine to the ground or trailer, so that the lower frame is resting completely on the ground or trailer frame ensuring the machine can not tip or fall; Raise the stabilizer until it is in the "overcenter" position and stop the engine. In this position, the weight of the stabilizer will not influence pressures in either end of the cylinder.

1.21

Tigercat 220D Loader

Safety SLIPPERY SURFACE WHEN WET

SAFETY LABELS CRUSH HAZARD

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

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

This label is located on the access area of the upper platform it warns of a slippery surface when wet. Avoid mounting or dismounting the machine in areas with slippery surfaces. If this is not possible clean up or cover slippery surfaces with a non-slip material.

1.22

Tigercat 220D Loader

Safety ENTANGLEMENT HAZARD

SAFETY LABELS ELECTROCUTION HAZARD!

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

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

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

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

1.23

Tigercat 220D Loader

Safety CHECK DAILY

SAFETY LABELS FIRE PREVENTION!

CHECK DAILY FOR DEBRIS LEAKS DAMAGED WIRES/HOSES WORKING FIRE FIGHTING DEVICES Presented by T.E.A.M. Working Group

21907A R1

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

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

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

FIRE EXTINGUISHER ACCESS HOLE

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

This label indicates the location of each FIRE EXTINGUISHER ACCESS HOLE. The label is installed on each fire extinguisher hole on the engine hood.

Maintain a CHARGED fire extinguisher on the machine at all times, know where it is and KNOW HOW TO USE IT! 1.24

Tigercat 220D Loader

SECTION 2 - CONTROLS & OPERATION MARCH, 2009

Read and understand the entire manual including Safety section prior to operating any equipment.

Read and understand all manuals for any attachments or accessories used with the Loader.

CONTENTS - SECTION 2 A/C ON/OFF SWITCH ..............................................................................................................2.11 AIR CLEANER ..........................................................................................................................2.26 AIR CLEANER UNLOADER VALVE .........................................................................................2.26 AIR CONDITIONER/HEATER ..................................................................................................2.11 AM/FM STEREO RADIO/CD ....................................................................................................2.17 AUXILIARY POWER OUTLET ..................................................................................................2.10 BATTERY DISCONNECT - SWITCH .......................................................................................2.22 BULB TEST SWITCH ...............................................................................................................2.12 CAB CONTROLS ....................................................................................................................... 2.5 CARE OF THE MACHINE .........................................................................................................2.36 CARE OF POLYCARBONATE WINDOWS ........................................................................... 2.36 CAUTIONS ........................................................................................................................2.38 CLEANING INSTRUCTIONS .............................................................................................2.38 CONCEALING HAIRLINE SCRATCHES ...........................................................................2.38 FIRE PRECAUTIONS ........................................................................................................2.39 GRAFFITI REMOVAL ........................................................................................................2.39 INSPECTION AND MAINTENANCE ..................................................................................2.37 RESISTANCE TO CHEMICALS .........................................................................................2.37 RESISTANCE TO WATER .................................................................................................2.37 CHECK ENGINE OIL LEVEL ....................................................................................................2.29 CLEANING A/C CONDENSER AND COOLER PACKAGE .......................................................................................................2.30 CONTROL PANEL ..................................................................................................................... 2.6 CONTROL VALVES HOIST CONTROL VALVE ..................................................................................................... 2.25 STICK CONTROL VALVE ..................................................................................................... 2.25 DISPLAY MODULE COMPONENT DESCRIPTION .............................................................................................. 2.14 FAULTS AND WARNINGS .................................................................................................... 2.15 KEYPAD FUNCTIONS .......................................................................................................... 2.15 START-UP OPERATION ....................................................................................................... 2.14 ENGINE COMPARTMENT .......................................................................................................2.22 ENGINE OIL LEVEL ..................................................................................................................2.29 ENGINE SPEED - SWITCH ....................................................................................................... 2.8 FAN SPEED - OFF/LOW/MED/HIGH .......................................................................................2.11 FILTER AIR CLEANER ....................................................................................................................... 2.26 HYDRAULIC RETURN .......................................................................................................... 2.24 PILOT .................................................................................................................................... 2.24 FILTER RESTRICTION INDICATOR ........................................................................................2.26 FILTERS ...................................................................................................................................2.13 FIRE EXTINGUISHER ..............................................................................................................2.17 FOOT PEDAL - SWING ............................................................................................................. 2.6 FUEL TANK AND FILLER .........................................................................................................2.27 FUSE AND RELAY PANEL - CAB ............................................................................................2.18 FUSES AND RELAYS - ELECTRICAL BOX .............................................................................2.19

Tigercat 220D Loader Controls and operation SECTION 2 - CONTROLS & OPERATION Tigercat 220D Loader

HAND FILL PUMP .....................................................................................................................2.23 HEAT - VARIABLE ....................................................................................................................2.11 HORN - SWITCH ....................................................................................................................... 2.7 HOT WATER SHUT OFF VALVE .............................................................................................2.12 HYDRAULIC OIL LEVEL .................................................................................................................................... 2.12 RESERVOIR .......................................................................................................................... 2.23 TEMP. - GAUGE .................................................................................................................... 2.12 TEMPERATURE .................................................................................................................... 2.12 HYDRAULIC RETURN FILTERS ..............................................................................................2.24 ICONS, PICTOGRAM DESCRIPTIONS ............................................................................. 2.3, 2.4 JOYSTICK LEVERS ................................................................................................................... 2.5 KEY SWITCH ............................................................................................................................. 2.9 LIGHT - DOME ..........................................................................................................................2.17 LIGHTER ...................................................................................................................................2.10 LIMIT SWITCH ........................................................................................................................... 2.9 LOADER MOUNTING/INSTALLATION ....................................................................................2.35 LOW COOLANT - RED LIGHT .................................................................................................2.16 LOW FUEL LEVEL ....................................................................................................................2.12 MACHINE OPERATION ...........................................................................................................2.28 MACHINE PREPARATION .......................................................................................................2.33 OPERATOR’S SEAT ADJUSTMENTS .................................................................................................................... 2.20 HEIGHT ADJUSTMENT ........................................................................................................ 2.20 LUMBAR ................................................................................................................................ 2.20 RIDE ADJUSTMENT ............................................................................................................. 2.20 PICTOGRAM DESCRIPTIONS .......................................................................................... 2.3, 2.4 PILOT MANIFOLD ....................................................................................................................2.25 PILOT RESET - SWITCH .......................................................................................................... 2.9 PILOT SYSTEM SHUT OFF ...................................................................................................... 2.9 PRE-START CHECKS ..............................................................................................................2.28 RADIO - 2 WAY ........................................................................................................................2.17 SERVICE LIGHTS ....................................................................................................................2.10 SETTING THE MACHINE .........................................................................................................2.32 STABILIZER OPERATION ........................................................................................................ 2.7 STARTING THE ENGINE .........................................................................................................2.31 STOPPING THE ENGINE .........................................................................................................2.34 SWING - FOOT PEDAL ............................................................................................................. 2.6 TAPE DECK/RADIO .................................................................................................................2.17 THROTTLE CONTROL ............................................................................................................. 2.8 TRAILER MOUNTING ..............................................................................................................2.34 TRANSPORTING THE LOADER ..............................................................................................2.36 UNLOADER VALVE ..................................................................................................................2.26 WAIT TO START - YELLOW LIGHT ........................................................................................2.16 WATER IN FUEL - YELLOW LIGHT ........................................................................................2.16 WINDOWS ................................................................................................................................2.17 WINDSHIELD WASHER FLUID ...............................................................................................2.17 WINDSHIELD WIPER/WASHER ..............................................................................................2.17 WORK LIGHTS .........................................................................................................................2.10 2.2

Tigercat 220D Loader

Controls and operation

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

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

or FAST =

and the rabbit

that are often used to describe

.

The pictograms used on this machine are as follows:

= Battery Disconnect

= Hydraulic Oil Temperature High

= Engine STOP = Hydraulic Oil Level Low = Engine WAIT TO START = Hydraulic Oil Level

= Engine WARNING

= Control Lever Multiple Direction = Hydraulic Oil Level High = Control Lever One Direction = Control Lever Two Direction = Hydraulic Oil Level Low = Fuel - Diesel

= Speed FAST or Hi

= Fuel Level Low

= Speed SLOW or LOW = Horn = Switch ON = Pilot Reset

= Switch OFF = Hydraulic Oil Temperature

2.3

Tigercat 220D Loader

Controls and operation

PICTOGRAM DESCRIPTIONS CONTINUED

= SWING CLOCKWISE

= Delimber CLOSE

= Delimber OPEN

= SWING COUNTERCLOCKWISE

= Slasher Saw CUT = Hoist Boom DOWN

= Slasher Saw RETRACT = Hoist Boom UP = Stabilizer DOWN = Stick Boom IN = Stabilizer UP = Stick Boom OUT = Grapple Saw CUT = Grapple CLOSE = Instrument Bulb Test

= Grapple OPEN

= Grapple ROTATE CLOCKWISE

= Grapple ROTATE COUNTERCLOCKWISE

2.4

Tigercat 220D Loader

Controls and operation IMPORTANT

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

CAB CONTROLS NOTE All joystick and Foot Pedal controls require pilot pressure. Refer to PILOT RESET in THIS SECTION.

1

2

•

••

220C-002

220C-002

1. LEFT HAND JOYSTICK LEVER Hoist Boom

2. RIGHT HAND JOYSTICK LEVER Stick (Jib) Boom Push the joystick lever forward to move the Stick in.

Push the joystick lever forward to lower the Hoist Boom.

Pull the joystick lever back to move the Stick out.

Pull the joystick lever back to raise the Hoist Boom.

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

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

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

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

2.5

Tigercat 220D Loader SWING LEFT

3

Controls and operation SWING RIGHT

4

•• 5

•

•• •

156-8A

FOOT PEDAL

••

5

6

•

3. FOOT PEDAL - SWING Depress the Left side of the foot pedal to swing left.

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

8

7

•

The foot pedal will automatically return to the center position once released. The swing will slow to a stop.

• ••

11

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

• • • • • • • • • • • • • • • • •

10

•

•

9

13

Stabilizer Operation UP/Down Switch (6)

12

•

14

Optional Accessory Switches (5) & (18)

••

•

Right Front StabilizerSwitch (7) Left Front Stabilizer Switch (8) Right Rear Stabilizer Switch (9)

16

Left Rear Stabilizer Switch (10) Stabilizer All Switch (11)

••

15

Not used (12)

•

Not Used (13) 19

Horn Switch (14)

••

17

Engine Speed Switch (15)

••

Pilot Reset Switch (16)

20

Ignition Key Switch (17) 18

Auxillary Power (24V) Outlet (19)

•

Auxillary Power (12V) Outlet (20)

21

Service lights Switch (21)

•

Work Lights Switch (22)

••

22

••

Procede to the next pages of this section for more details of these switch functions.

5. OPTIONAL SWITCH LOCATION

220D-001.AI

2.6

Tigercat 220D Loader

Controls and operation

6. STABILIZER OPERATION

4

The 4 stabilizers are controlled using the buttons located on the instrument panel to the right of the seat.

•

•

•• 5

First select a direction (up or down) using the Stabilizer Direction selector switch (6).

The center position on the switch turns off all stabilizers. This switch should be left in the center position whenever stabilizers are not being moved. This will prevent accidental operation of the stabilizers.

Next use buttons (7), (8), (9) or (10) to control each stabilizer separately or use the ALL button (11) to move all stabilizers at once. The All button should be used to ensure that each stabilizer is applying equal pressure to the ground prior to operating the loader or lifting any loads.

•• • 5

6

• 8

7

•

• ••

11

Also see SETTING THE MACHINE in THIS SECTION. 10

12. NOT USED

••

•

•

9

13

13. OPTIONAL SWITCH LOCATION

12

•

14

••

•

14. HORN - SWITCH Depressing the Horn rocker switch (10) will sound the horn.

16

••

15

• 19

••

17

••

20

18

• 21

•

••

22

•• 220D-001.AI

2.7

Tigercat 220D Loader

Controls and operation

15. THROTTLE CONTROL

4

This is a three position "momentary" switch connected into the engine CPU circuit to adjust the engine RPM. between the (IDLE) and

•• 5

••

(FULL) throttle set points.

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

•

••

5

6

•

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

8

7

•

•

WARNING

••

11

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

10

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

NOTE: All operations should be performed at FULL throttle.

Maintaining Correct Engine RPM. It is most important that the IDLE and FULL RPMs. of the engine be correct at all times: IDLE 900 RPM (No Load) FULL 2230 to 2300 RPM max (No Load) RATED WORKING 2200 RPM NOTE: At start-up the engine will always default to IDLE.

•

•

9

13 12

•

14

••

•

16

••

15

• 19

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

••

17

••

20

18

AUTO IDLE DOWN - OPTIONAL If the engine is set to run a full throttle and no functions are activated for a few minutes, the engine will idle down. The engine will return to the set idle speed as soon as a function is activated.

• 21

•

••

22

•• 220D-001.AI

2.8

Tigercat 220D Loader

Controls and operation

16. PILOT RESET - SWITCH

4

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

•• 5

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

•• •

••

5

6

•

ARMREST

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

8

•

16A

LIMIT SWITCH ACTUATING LEVER ON SEAT BASE

• ••

11

•• 10

•• 247-25

7

•

•

9

13

PILOT SYSTEM SHUT OFF

12

•

14

16A.PILOT SYSTEM SHUT OFF - LIMIT SWITCH

••

•

When the L.H. arm rest is placed in the UP position, a limit switch shuts OFF the pilot system DEACTIVATING all operating functions and throttles the engine speed down to LOW Idle. When the L.H. arm rest is placed in the DOWN position, the limit switch closes and turns ON the pilot system. But the operating functions are not REACTIVATED until the PILOT RESET switch (item 16) is pressed.

16

••

15

• 19

17. KEY SWITCH

••

17

This is a three position switch.

OFF Position - All electrical power through the Key switch is turned OFF.

••

Electrical power is still available for the horn, lighter, radio/CD player, 2 way radio, cab dome light, defroster fan, work lights, auxillary power and service light.

20

18

• 21

•

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

••

22

••

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

220D-001.AI

2.9

Tigercat 220D Loader

Controls and operation

18. OPTIONAL ACCESSORY SWITCH

4

This switch location is used for various optional functions.

•• 5

19. LIGHTER - 24 VOLT OUTLET Depress lighter fully into socket and wait until it pops back up. Pull lighter out of socket and use coil to light cigar(ette). CAUTION: Lighter coil reaches high temperature which can cause burns to skin and can start fire. Handle with care. DO NOT use in presence of explosive or flammable liquids or vapor. Serious injury, death and/or property damage may result.

20. AUXILIARY POWER OUTLET, 12 VOLTS

•• •

••

5

6

• 8

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

7

•

• ••

11

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

10

•

•

13 12

•

14

22. WORK LIGHTS

9

••

•

This switch controls the work lights located on the front of the cab and on the stick boom. The circuit draws current directly from the battery and is protected by a fuse located in the fuse panel.

16

••

15

• 19

••

17

••

20

18

• 21

•

••

22

•• 220D-001.AI

2.10

Tigercat 220D Loader

••

244-003

••

••

•

C

Controls and operation

• B

A

D

E

A/C HEATER CONTROL PANEL

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

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

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

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

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

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

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

2.11

Tigercat 220D Loader 26 25

••

Controls and operation

•

REAR OF ENGINE

28

27

••

••

••

SHUT-OFF VALVE

29 HOSE TO A/C HEATER UNIT

••

••

•

24

BULB TEST & WARNING LIGHTS 24. BULB TEST SWITCH 250BT-002

220D-003

29. HOT WATER SHUT OFF VALVE (ENGINE)

Hold this switch in the ON position to test the bulbs in the 3 warning lights; Items 26, 27, and 28. Replace the bulb in any light that does not come ON. If the light does not come ON after inserting a new bulb, check the fuse labelled "gauges". Bulbs should be tested at the start of each shift.

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

25. HYDRAULIC OIL TEMP. - GAUGE The gauge labelled HYDRAULIC OIL TEMPERATURE displays the hydraulic oil temperature in the hydraulic reservoir.

26. HYDRAULIC OIL TEMP - RED LIGHT This light will come on when the hydraulic oil temperature rises above 82°C (180°F) .

If the light turns on, check the following: • • • •

HOT WATER SHUT OFF VALVE

Plugged oil cooler Low hydraulic oil level Malfunction in a hydraulic circuit High loads on the hydraulic system

Do not continue to operate the machine if temperature remains above 82°C (180°F).

Operation at high hydraulic oil temperature will shorten the life of hydraulic components.

27. LOW HYDRAULIC OIL LEVEL - RED LIGHT This light will come on when the hydraulic oil level falls 49 litres (13 gallons) from the full mark.

When this light first comes on stop engine and determine cause. Repair leaks and refill the tank to FULL mark on the sight gauge. Pressurize the hydraulic tank and inspect for leaks.

28. LOW FUEL LEVEL - YELLOW LIGHT This light is used as a Low Fuel Level warning. The indicator light will come ON when the FUEL level drops below 20 gal. US (76L).

2.12

Tigercat 220D Loader

Controls and operation

FILTER

•

EXTERNAL AIR FILTER ACCESS PANEL

••

RECIRCULATION AIR FILTER

234E-009

•• LOWER RIGHT SIDE OF OPERATOR'S CAB

A/C HEATER UNIT

30. FILTERS - CAB

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

245DIG-01

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

2.13

Tigercat 220D Loader

Controls and operation

31. DISPLAY MODULE 1

••

7

••

2

••

3

•• 4 244-007

••

•

••

5

6

DISPLAY MODULE

COMPONENT DESCRIPTION 1. Amber Warning LED 244-046

2. Display

DISPLAY MODULE

3. Menu Key

The Display Module is the operator interface with the electronic engine controls and a multifunction tool that enables the operator to view various engine parameters and service codes. The display is a graphical backlit LCD screen controlled via menu selection. The display can show either a single parameter or a quadrant display showing 4 parameters simultaneously.

Diagnostic capabilities include fault codes with text translation for the most common fault conditions.

4. Left Arrow Key 5. Right Arrow Key 6. Enter Key 7. Red Shutdown LED KEYPAD FUNCTIONS MENU KEY - This key is pressed to enter or exit menu screens.

The Display Module has four buttons used to navigate the display with ease.

LEFT ARROW KEY - This key is pressed to scroll through the screen either moving the parameter selection toward the left or down.

DISPLAY PARAMETERS

RIGHT ARROW KEY- This key is pressed to scroll through the screen either moving the parameter selection toward the right or up.

The following are some of the functions displayed by the Display Module: Engine RPM Engine Hours Machine Hours System Voltage % Engine Load at the current RPM Coolant Temperature Oil Pressure Fuel Economy Throttle Position Engine Manifold Air Temperature Current Fuel Consumption Active Service Codes Stored Service Codes from the engine Set Units for display (English or Metric) Engine Configuration Parameters

ENTER KEY - This key is pressed to select the parameter that is highlighted on the screen.

Refer to manufactures Operations Manual (supplied with the machine) for detailed information.

START-UP OPERATION When power is first applied to the Display Module, the “Logo Screen” will be displayed, the “Wait to Start” message will be displayed. Once the “Wait to Start” message is no longer displayed the operator may start the engine. When the engine has started the display will show the single engine parameter display.

2.14

Tigercat 220D Loader

Controls and operation NOTE: The fault can only be cleared by correcting the cause of the fault condition.

Some of the display and warning functions are: LOW ENGINE OIL PRESSURE - RED LED This light will come ON when the engine oil pressure falls below 7 psi. If this light comes ON stop the engine and determine cause.

SINGLE PARAMETER DISPLAY MAIN MENU NAVIGATION 244-007

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

1. Starting at the single or four engine parameter display, depress the “Menu Button”.

TACHOMETER This display indicates the RPM. of the engine.

HOUR METER There are two options available for displaying hours:

244-047

TOTAL ENGINE HOURS - displays total hours the engine has run as provided by the engine computer.

2. The first seven items of the “Main Menu” will be displayed.

3. Depressing the “Arrow Buttons” will scroll through the menu selections.

MACHINE HOURS - displays the total hours the engine has run as calculated by the display module.

4. Pressing the right arrow button will scroll down to reveal the last items of “Main Menu” screen highlighting the next item down.

ENGINE OIL PRESSURE Oil pressure at low idle and high idle will display 69 psi (476 kPa). If oil pressure drops below 7 psi (48 kPa) the display will read 0 and the LOW ENGINE OIL PRESSURE - RED LED will turn ON, stop engine and determine cause. Check engine oil pressure every time the engine is started.

5. Use the arrow buttons to scroll to the desired menu item or press the “Menu Button” to exit the Main menu and return to the engine parameter display.

FAULTS AND WARNINGS During normal operation the single or four parameter screen will be displayed. When the PowerView receives a fault code from an engine control unit the single or four parameter screen will be replaced with the “Active Fault Codes” message.

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

To acknowledge and “Hide” the fault and return to the single or four parameter display press the “Enter Button”. The display will return to the single or four parameter screen.

! ! !

VOLTAGE DISPLAY Normal operating range is between 24-28 volts. A reading in excess of 30 volts indicates a possible faulty voltage regulator. A reading of less than 23 Volts indicates a possible faulty battery or alternator.

- Indicates Auxiliary Gage Fault.

- Indicates Fault Warning - Indicates Derate or Shutdown Fault

Pressing the “Enter Button” will redisplay the hidden fault. Pressing the “Enter Button” once again will hide the fault and return the screen to the single or four parameter display.

Refer to manufactures Operations Manual (supplied with the machine) for detailed information.

2.15

Tigercat 220D Loader

1

••

• SPN 111 FMI 1

240C-001

Controls and operation

••

2

1

••

• WAIT TO • START

•

3

POWERVIEW DISPLAY MODULE

240C-001

2

3

POWERVIEW DISPLAY MODULE

LOW COOLANT

WAIT TO START

This light (2) and an audio alarm will turn ON and a code "SPN 111 FMI 1" will be on the display (3) when the engine coolant drops below a safe operating level. If this light turns on, immediately turn off the engine and correct the fault. The engine coolant sensor is located in the side of the radiator surge tank.

Both lights (1 & 2) will be ON during the "key ON" engine pre-heat time. Heating elements (grid heater elements) located in the engine air intake manifold are turned ON to heat the intake air when starting the engine. The engine must not be started until the lights turn OFF automatically.

FILLER CAP

1

•

•• SPN 97 FMI 16

••

2 3

•• 240C-001

220D-012

POWERVIEW DISPLAY MODULE

WATER IN FUEL

CHECK ENGINE COOLANT LEVEL

This warning light (1) comes ON and a code "SPN 97 FMI 16" will be on the display (3), and an audio alarm will turn ON indicating that the engine fuel/water separator needs to be drained.

This task must be performed as soon as possible whenever this warning light is ON.

The coolant surge tank (reservoir) can be filled through the access panel located on top of the engine compartment. Ensure that the engine has cooled down sufficiently before removing radiator cap. Prior to removing cap, relieve pressure in radiator by loosening cap slowly to first stop. Use the proper solution of coolant antifreeze when filling the surge tank.

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

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

2.16

Tigercat 220D Loader

Controls and operation 31

27

••

• ASHTRAY

CUP HOLDER

234E-010

32. 2 WAY RADIO (OPTIONAL)

•

Refer to component manufacturers manual.

28

•• PORTABLE FIRE EXTINGUISHER 36. FIRE EXTINGUISHER 234E-012

••

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.

234E-011

33. LIGHT - DOME Push the lens cover of the light forward/ rearward to turn the light ON and OFF. 34

••

35

••

244-060

34. AM/FM STEREO RADIO/CD

244-019

SLIDING WINDOWS HANDLE

37. WINDOWS

Consult the manufacturer's manual for operation instructions.

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

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

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

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

234E-013

WINDSHIELD WASHER FLUID

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

2.17

Tigercat 220D Loader

234-007

Controls and operation

FUSE AND RELAY PANEL

FUSE AND RELAY PANEL 39. FUSE AND RELAY PANEL - CAB The fuse panel is located below the control panel behind a removable cover.

IMPORTANT

24 VOLT

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

ELECTRICAL SYSTEM 2.18

Tigercat 220D Loader

220D-006

Controls and operation

MAIN FUSE AND RELAY ELECTRICAL BOX

40. FUSES AND RELAYS - ELECTRICAL BOX This Main Fuse and Relay electrical box is located in the engine compartment.

2.19

Tigercat 220D Loader

Controls and operation RIDE ADJUSTMENT After adjusting height, the ride adjustment should be made by turning the RIDE ADJUSTMENT KNOB counter-clockwise for firmer adjustment or clockwise for softer adjustment.

BACK ANGLE ADJUSTMENT KNOB

LUMBAR HORIZONTAL ADJUSTMENT

ADJUSTABLE LUMBAR To position lumbar mechanism, rotate LEVER (on R.H. side of seat).

RIDE ADJUSTMENT KNOB

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

•

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

••

• FORE/AFT SLIDE LEVER 234-004

••

•

SEAT ADJUSTMENTS

•• •• •

HEIGHT ADJUSTMENT LEVER

OPERATOR’S SEAT ADJUSTMENTS

ARMREST ADJUSTMENT

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

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

234-004

ARMREST ADJUSTMENTS

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

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

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

2.20

Tigercat 220D Loader

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

BACK ANGLE ADJUSTMENT KNOB

LUMBAR HORIZONTAL ADJUSTMENT

RIDE ADJUSTMENT KNOB

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

• ••

• FORE/AFT SLIDE LEVER 234-004

••

•

SEAT ADJUSTMENTS

HEIGHT ADJUSTMENT LEVER

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

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

2.21

Tigercat 220D Loader

Controls and operation

ENGINE COMPARTMENT

AIR CHARGE COOLER

ENGINE COMPARTMENT ACCESS

•

There are 3 hinged doors and 1 removable panel provided to allow access to the engine compartment from all four sides. The front access panel is removed by lifting the latches outwards, tuning them 90° and then lifting the panel up and out. The front panel can be stored by the hand rail if desired.

RADIATOR

•• A/C CONDENSER

•• OIL COOLER

230C-002

220D-008

•

RADIATOR COMPARTMENT RIGHT SIDE

ENGINE COMPARTMENT ACCESS FRONT

220D-007

ENGINE COMPARTMENT ACCESS REAR BATTERY DISCONNECT SWITCH

•

220D-004

ENGINE COMPARTMENT ACCESS LEFT SIDE

220D-013

BATTERY DISCONNECT SWITCH

BATTERY DISCONNECT - SWITCH

IMPORTANT

Located behind the front access panel, this switch completely disconnects all electrical circuits on the machine from the battery. Turn this switch to OFF whenever the machine is left unattended for an extended period of time (overnight etc.).

24 VOLT ELECTRICAL SYSTEM 2.22

Tigercat 220D Loader

Controls and operation

RESERVOIR

•• SIGHT GAUGE

••

••

• ••

HAND FILL PUMP

HYDRAULIC OIL FILTERS

OIL FILL SHUT-OFF VALVE

•

•

•

LOW LEVEL SENDING UNIT

HYDRAULIC PUMPS

220D-014

HYDRAULIC HAND FILL PUMP

HYDRAULIC HAND FILL PUMP

•• 220D-005

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

HYDRAULIC OIL RESERVOIR

HYDRAULIC OIL RESERVOIR

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

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

A sight gauge on the front of the reservoir is visible from the front access panel or the left hand side door. The hydraulic oil level must be kept between the HIGH and LOW limits at all times. A low level switch is incorporated into the level indicator, when the hydraulic oil reaches this level the switch turns a warning light ON in the operator's cab.

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

If the oil level drops, inspect the machine including all fittings and hydraulic components for leaks. Once the source of the oil loss is located and repaired, oil can be added to the reservoir.

2.23

Tigercat 220D Loader

•• •• WATER ABSORBING RETURN FILTER (COLOUR BLUE) 220C-004

Controls and operation

••

Each filter head has a bypass valve with a 25 psi cracking pressure so that oil can bypass the filters if they become restricted. The "in" side of the filter heads are connected by hoses to a return manifold. There is also a filter restriction indicator mounted on the side of the filter housing and an oil sampling connector mounted on the return manifold. To check the condition of the filter elements; With the hydraulic oil at normal operating temperature, place engine throttle control to FULL and with saw cut function operating, the filter restriction indicator should be in the GREEN zone. If the pointer is in the RED zone replace all three filter elements.

••

HYDRAULIC RETURN FILTERS

HYDRAULIC RETURN FILTERS

HYDRAULIC RETURN FILTERS

LOCATED LOWER LEFT SIDE OF ENGINE COMPARTMENT

The majority of return oil entering the hydraulic tank passes through 3 spin-on hydraulic oil filters.

One of the filters is a water absorbing filter (color blue) which is in place to assist with the removal of unwanted moisture from the hydraulic oil (the filters are rated 10 micron abs).

••

OIL SAMPLING CONNECTOR

230C-007

PILOT FILTER ELEMENT

HYDRAULIC PILOT FILTER

HYDRAULIC PILOT FILTER A single element filter head filters all pilot oil prior to entering the pilot system. The filter head has a built-in bypass valve with a 50 psi cracking pressure so that oil can bypass the filter if the element becomes restricted.

•

230C-012

IMPORTANT

HYDRAULIC OIL RETURN MANIFOLD

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

FILTER RESTRICTION INDICATOR

•

220C-003

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

FILTER RESTRICTION INDICATOR

2.24

Tigercat 220D Loader

Controls and operation

MAIN CONTROL VALVES

A main relief valve is installed in the inlet section of the valve to protect the hydraulic system against overload pressures.

The swing, hoist boom and stick boom are each controlled by spool sections located in three separate control valves. Each control valve consists of two pilot operated, open center spool sections, an inlet section and an outlet section.

The outlet section directs return oil back to tank.

The control valves are located in the upper frame below the floor plates inside the valve compartment.

PILOT MANIFOLD The pilot manifold is located below the floor plates in the hydraulic valve compartment.

Pilot oil enters the manifold through the inlet port.

The pilot shut off valve, which is an integral part of the pilot manifold, controls the flow of oil from the INLET port to the outlet ports and to the solenoid operated pilot valves. The pilot shut off valve is activated by pressing the pilot reset switch in cab (with the left armrest down).

CONTROL VALVE OPERATING DESCRIPTION Oil enters the inlet section and is allowed to pass through the spool sections and back to tank via the outlet section. Each of these spool sections has a self centering 3-position spool which is open centered. A spring in the spool end cap holds the spool in the center neutral position. The spool is shifted by pilot pressure being applied to either end of the spool. Shifting the spool directs oil to operate any one of the three functions (or all at the same time if required but with reduced flow to each). To protect components and hoses when the valve is closed, each work port in the valve sections have a port relief valve with an anticavitation function.

Two outlet ports ('PB') on each end of the pilot manifold, feed the Stabilizer pilot manifold, both joysticks and the swing foot pedal valve.

Solenoid operated pilot valves on the manifold, when energized, supply "on demand" pilot oil to the corresponding functions. These valves are activated by controls in the cab.

Two tank ports ('T') drain return oil to the reservoir.

2.25

Tigercat 220D Loader

Controls and operation

• SAFETY ELEMENT AIR CLEANER UNLOADER VALVE

•• •

PRIMARY ELEMENT

220D-010

AIR CLEANER UNLOADER VALVE

•

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

UNLOADER VALVE AIR CLEANER .PLT

AIR CLEANER

AIR FILTER ELEMENTS

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

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

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

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

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

INDICATOR

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

••

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

INTAKE TUBING AND JOINTS 250B-023A

FILTER RESTRICTION INDICATOR

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

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

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: Replace the safety element every third primary filter change.

2.26

Tigercat 220D Loader

Controls and operation

FUEL TANK AND FILLER The tank is located underneath the cab and has a capacity of 100 US gallons. The fuel filler is located on the front of the machine below the cab.

••

FILLER TUBE

FUEL TANK CAP

• FUEL LEVEL GAUGE

••

220D-015

FUEL TANK AND FILLER

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

AIR VENT PASSAGE

•

INNER FILL TUBE

••

220D-016

FUEL FILL TUBE

2.27

Tigercat 220D Loader

Controls and operation

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

220D-011

3. Fuel level. Low fuel level light OFF.

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

SIGHT GAUGE

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

••

Read and understand this entire manual prior to operating machine.

PRE-START CHECKS

LOW LEVEL SENDING UNIT

• 230C-004

HYDRAULIC OIL SIGHT GAUGE/SENDER 4. Check that the hydraulic oil level is between the HIGH and LOW marks on the level gauge.

• 1

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

KEY SWITCH - OFF

220D-017

CONNECTING HOSE TO GEARBOX

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

206-16A

31

••

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

• ASHTRAY

•

CUP HOLDER

• •• PORTABLE FIRE EXTINGUISHER 2. Check fire extinguisher is sufficiently charged.

234E-012

2.28

Tigercat 220D Loader

Controls and operation

FILLER CAP

220D-009

••

••

ENGINE OIL LEVEL DIPSTICK

CHECK ENGINE OIL LEVEL

220D-012 CHECK ENGINE COOLANT LEVEL 9. Check engine coolant level.

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

AIR CHARGE COOLER

••

INDICATOR

••

RADIATOR

• A/C CONDENSER

• FILTER RESTRICTION INDICATOR 7. Check air filter restriction indicator.

250B-023A

OIL COOLER

••

SERPENTINE FAN BELT 230C-002

CLEAN COOLER PACKAGE

10. Clean cooler package and all screens and doors.

••

11. Ensure all doors and access panels are closed and/or securely fastened.

RESERVOIR

••

234E-013

A/C COMPRESSOR BELT 220C-037

•

CHECK WINDSHIELD WASHER LEVEL

12. Check windshield washer fluid level.

CHECK ENGINE BELTS

8. Check tension and condition of all engine belts.

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

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

2.29

Tigercat 220D Loader

Controls and operation

CLEANING COOLER PACKAGE

PROCEDURE:

The A/C condenser core is located on the right side of the machine and is one of the cooler cores in the stack of four cores of the cooler package. The cooling fan is mounted on the front of the engine. The fan draws air from the right side of the machine through the door screen and the cooler package blowing it out of the oposite side of the machine.

Remove the capscrews and washers and remove the screen cover on the right side of the engine compartment.

This cooler package must be checked daily and may require thorough cleaning on a regular basis depending on operating conditions.

CAUTION • If using compressed air for cleaning, use at 30 psi. or less.

• Always use personal protective equipment to guard against flying debris.

AIR CHARGE COOLER

•• RADIATOR

Compressed air or water may be used for cleaning. Use personal protective equipment to guard against flying debris.

•• A/C CONDENSER

OIL COOLER

•

If an oil leak occurs in this area it should be thoroughly power-washed with a mild soap to ensure that all of the oil is removed.

••

Care must be taken when cleaning this assembly, as the components can be damaged by careless handling and cleaning.

230C-002 COOLER PACKAGE The cooler package should be manually checked every 8 hours (every shift) or more often where conditions cause accumulation of twigs, leaves, pine needles and dust. All of the engine enclosure doors should also be checked.

2.30

Tigercat 220D Loader

Controls and operation

STARTING THE ENGINE CAUTION

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

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

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

2. Turn Battery Disconnect Switch ON. 3. Turn ignition key to RUN position and observe warning lights.

PowerView warning lights will turn on momentarily then turn off (as a bulb test).

CAUTION

WAIT for Warning Lights to turn OFF before starting engine.

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

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

4. As a bulb test, depress Warning Light Bulb Test Switch and observe that all Warning lights turn on and turn off when switch is deactivated.

5. Sound horn to warn personnel of machine start-up.

6. Turn ignition key switch to the START position to crank the engine. When engine is started place key switch in RUN position and observe gauges and display module and proceed to MACHINE PREPARATION procedure.

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

2. Ensure key is turned to OFF. 3. Refill fuel tank completely.

CAUTION

4. Remove engine fuel filter and fill with clean fuel.

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

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

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

WARNING Do not attempt to operate any function or accessory while starting the engine.

Serious injury or property damage may result.

WARNING DO NOT USE ETHER! Engine is equipped with an electric heater starting aid. Use of ether may cause an explosion and severe injury.

2.31

Tigercat 220D Loader

Controls and operation

SETTING THE MACHINE

WARNING

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

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

Refer to the following steps to ensure safe operation. (a) Locate the loader on firm level ground only. (b) Lower the stabilizers to set them firmly on stable ground. If the loader is mounted to a trailer, the stabilizers should be used to raise the rear of the trailer off the ground. Ensure loader is sufficiently stable to perform all log loading operations.

VERTICAL CENTERLINE

LOWER FRAME

•

COUNTERBALANCE VALVE

•

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

STABILIZER UP IN VERTICAL POSITION

• • •

CYLINDER

STABILIZER COUNTERBALANCE/CHECK CARTRIDGE REMOVAL

230-06A

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

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

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

2.32

Tigercat 220D Loader

Controls and operation

MACHINE PREPARATION

NOTE: The right hand joystick button performs two separate functions depending on the status of the delimber arms. With delimber arms closed the button operates the top saw. With the delimber arms open the button operates the slasher saw.

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

Warm up the hydraulic system.

•

Test all systems for proper operation.

•

Inspect for hydraulic oil leaks.

(m) Continue testing and operating various functions until engine and hydraulic oil has warmed up to near normal operating temperatures. Never load the machine until it has sufficiently warmed up. Doing so may cause damage to the engine and hydraulic components.

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

(n) Lower the grapple onto the trailer or stable ground ensuring grapple and booms are fully supported. (o) Set engine speed to LOW IDLE.

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

WARNING

(b) Sound horn to warn personnel of machine operation. (c) Ensure gauges and warning lights are indicating normal operating conditions. (d) Check that all personnel are safe and clear of the machine.

Never use your bare hand to check for fluid leaks.

Fluid leaks under pressure may not be visible.

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

(e) Ensure both armrests are in the lowered position and press the PILOT RESET button. (f) Set engine speed to warm-up position (1400 rpm). (g) Ensure all stabilizers are firmly set on level, stable ground.

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

(h) Ensure grapple and booms are not attached, chained or clamped around trailer or any other stationary object. (i) Slowly raise and lower the hoist boom and stick boom and check for proper operation. (j) With the grapple raised slightly off the ground, test the grapple rotate in both directions and test the open and close functions. (k) Operate the swing in both direction to ensure proper operation. (l) Test all accessory equipment including delimber, top saw, slasher saw etc.

2.33

Tigercat 220D Loader

Controls and operation

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

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

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

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

4. Do not race engine before shut-off 5. Stop engine by turning Key switch to the OFF position.

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

2.34

Tigercat 220D Loader

Controls and operation

LOADER MOUNTING/INSTALLATION The mounting procedure will vary with the type of trailer being used. The following procedure is intended as a guide for mounting the loader on a typical I-beam or Channel beam trailer. The procedure may not be complete or may differ from the actual method or procedure used.

TRAILER STUDS

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

•• WASHERS

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

••

•

•• • ••

NUTS YOKE

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

220C-060

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

3. Ensure that trailer is stable and will not move.

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

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

7. Check torque of mounting bolts as specified in maintenance schedule.

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

8. Ensure installation conforms to all applicable regulations.

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

2.35

Tigercat 220D Loader

Controls and operation

CARE OF THE MACHINE

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

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

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

2. Follow proper procedure for cleaning windows described in this section.

3. Lubricate all necessary points as per the maintenance schedule in section 3.

WARNING

4. Never apply a load to a cold engine.

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

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

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

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

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

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

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

CARE OF POLYCARBONATE WINDOWS IN CAB Most windows used in the cab are made from a polycarbonate resin thermoplastic. This material is a replacement for glass when improved strength, durability and safety is required.

Polycarbonate material is expected to resist heavy impact from large branches and falling tree tops and to absorb high levels of energy when contacted by high velocity thrown objects such as wood chips, disc saw blade teeth or broken harvester head saw chain.

The extreme operating environment seen in logging applications heightens the need to regularly inspect and properly maintain polycarbonate cab windows.

Polycarbonate windows are an essential piece of operator protective equipment and should be maintained as such. It is important to note that cracks, chips, notches or scarring anywhere on the viewing surface or edges of the window will decrease ability to resist heavy impacts and therefore compromise effectiveness as operator safety protective equipment. Windows with these defects must be replaced immediately.

Refer to the next section for detailed information regarding inspection and maintenance of polycarbonate windows.

3. Raise all four stabilizers to their fully upright positions. Turn off the machine and turn the battery disconnect switch to OFF. 4. Ensure that the setup conforms to all applicable local, state, provincial and federal regulations for mounting and transporting equipment. Check height, width and weight restrictions.

2.36

Tigercat 220D Loader

Controls and operation

INSPECTION AND MAINTENANCE Daily inspection and maintenance is essential to confirm that the window’s ability to protect the operator has not been compromised.

• Inspect all windows daily and immediately after any impacts.

• Check for any damage to the window material or steel structure in the area of the window mounting.

• The edges of the polycarbonate window must be evenly and fully supported on a flat surface around the entire window opening at all times.

Bent or dented skylight structures must be replaced immediately. Bent or dented cab structures must be evaluated immediately for possible repair or replacement.

• The edges of the polycarbonate window must be free from cracks, chips, notches or scarring and must not be pinched or stressed.

These defects will decrease ability to resist heavy impacts. Windows with these defects must be replaced immediately.

• Cracks, chips, notches or scarring anywhere on the viewing surface of the window will decrease ability to resist heavy impacts.

Windows with these defects must be replaced immediately.

• Bent, dented or missing window retaining parts must be replaced immediately.

• Rubber materials used in mounting the window must be maintained in good condition.

• Identification of the polycarbonate originally used by Tigercat is hot stamped in a corner of the window to identify its composition. Do not use any replacement window without proof of its material composition. Do not substitute with any other materials.

• Skylights, cab structures, windows and window retaining parts must not be modified or replaced with components that are not approved by Tigercat.

2.37

RESISTANCE TO CHEMICALS The resistance of polycarbonate material to chemical exposure varies widely. Fortunately, polycarbonate materials have good resistance to diesel fuel, grease, hydraulic oil, kerosene and engine oil.

Other chemicals however can seriously weaken the polycarbonate.

DO NOT permit any of the following chemicals to come into contact with polycarbonate windows: • acetone • air conditioning refrigerant • ammonia • anti-freeze • benzene • brake fluid • carbon tetrachloride • cutting oils • gasoline • lacquer thinner • toluene • turpentine • xylene RESISTANCE TO WATER Polycarbonate material has good resistance to water up to approximately 65°C (150°F). Above this temperature the effect of water is timetemperature related. This means that the higher the water temperature, the shorter the time before the polycarbonate is adversely affected.

Exposing polycarbonate to repeated steam cleanings or high temperature pressure washing may result in crazing, a phenomenon that causes clouding of the surface. Crazing can ultimately result in a loss of physical strength and may precede a fracture.

Tigercat 220D Loader

Controls and operation

CLEANING INSTRUCTIONS

CAUTIONS

The viewing surfaces of polycarbonate cab windows are specially treated with a hard coating to provide enhanced resistance to abrasion and ultra-violet (UV) radiation.

•

DO NOT use abusive cleaning procedures either by hand or pressure washing on polycarbonate windows.

•

DO NOT use brushes, razor blades, scrapers, squeegees or other sharp tools on polycarbonate windows.

•

DO NOT clean polycarbonate windows when the daytime temperature is high or in direct sunlight.

•

DO NOT use abrasive or highly alkaline cleaners on polycarbonate windows.

•

DO NOT use glass cleaners in either aerosol or non-aerosol containers to clean polycarbonate windows.

•

Failure to follow these cleaning instructions will shorten the service life of polycarbonate and may cause visual hazing, loss of light transmission and delamination of the polycarbonate hard surface coating.

The following instructions are provided to prolong the life of this protective hard coating.

1. Rinse the window thoroughly with lukewarm water 2. Using a soft cloth, cellulose sponge or chamois, gently wash the window with a mild solution of soap or detergent in lukewarm water. Do not scrub or use brushes or squeegees.

Brand name soaps and detergents recommended for cleaning polycarbonate are: • Fantastik • Formula 409 • Hexcel F.O. 554 • Joy • Lysol • Mr. Clean • Neleco-Placer • Pine-Sol • Top Job 3. Rinse the window thoroughly with lukewarm water.

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: • • •

4. Dry the window with a moist soft cloth, cellulose sponge or chamois to prevent water spotting.

Johnson’s Paste Wax Novus Plastic Polish #1 and #2 Mirror Glaze Plastic Polish

Be certain to clean the polycarbonate window as outlined prior to application of an automotive polish. Refer to CLEANING INSTRUCTIONS.

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 also to RESISTANCE TO CHEMICALS for a list of chemicals which should not be permitted to come into contact with polycarbonate windows.

2.38

Tigercat 220D Loader

Controls and operation

GRAFFITI REMOVAL •

•

For removal of paints, marking pen inks, etc., the use of Butyl Cellosolve is generally effective. The use of masking tape, adhesive tape or lint removal tools works well for lifting off old weathered paints.

WINDOW SCREEN HANDKNOB

•

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.

173-25

SIDE WINDOW SCREEN

SIDE WINDOW SCREENS The side window screens (if equipped) can be removed to clean the windows. Screens are provided for the personal protection of the operator and must be reinstalled immediately after cleaning the windows.

Refer also to RESISTANCE TO CHEMICALS for a list of chemicals which should not be permitted to come into contact with polycarbonate windows.

A handknob is provided on both the inside and the outside. By unscrewing either (not both) of these knobs, the screen will be free to swing out on the hinges. Be aware that the screen will swing outwards with considerable force, if the door is open.

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.

All handles should be hand tight only at all times.

20231A R1

2.39

Tigercat 220D Loader

Controls and operation

2.40

Tigercat 220D Loader

SECTION 3 - LUBRICATION & MAINTENANCE CONTENTS - SECTION 3 AIR CLEANER FILTER RESTRICTION INDICATOR ....................................................... 3.15 IMPORTANT STEPS TO FOLLOW .......................................................... 3.14 IMPROPER SERVICING .......................................................................... 3.14 MAINTENANCE ........................................................................................ 3.14 UNLOADER VALVE ................................................................................. 3.15 AIR CONDITIONING .................................................................................... 3.16 APPROVED HYDRAULIC OILS ..................................................................... 3.9 ELECTRICAL SCHEMATIC ............................................ 3.25, 3.26, 3.27, 3.28 EMERGENCY EXITS, CHECK MONTHLY .................................................... 3.5 FILTER RESTRICTION INDICATOR ........................................................... 3.15 FIRE PREVENTION ....................................................................................... 3.5 FIRST 50-100 HOUR INSPECTION AND SERVICE ...................................... 3.2 GENERAL ...................................................................................................... 3.5 HYDRAULIC OIL RETURN FILTERS .......................................................... 3.12 LUBRICATION AND SERVICE POINTS ...................................................... 3.10 NEW MACHINE MAINTENANCE .................................................................. 3.2 OIL LOST FROM LEAKAGE .......................................................................... 3.2 OIL SAMPLE COLLECTION PROCEDURES ................................................ 3.4 OIL SAMPLING PROGRAM ........................................................................... 3.3 PAG OIL ....................................................................................................... 3.16 PILOT PRESSURE FILTER ......................................................................... 3.13 PRE-DELIVERY INSPECTION ...................................................................... 3.2 PRESSURE SETTINGS ..................................................................... 3.20, 3.21 PREVENTIVE MAINTENANCE SCHEDULE ................................................. 3.2 REFRIGERANT ............................................................................................ 3.16 SCHEDULED MAINTENANCE EVERY 8 HOURS ....................................................................................... 3.6 EVERY 24 HOURS ..................................................................................... 3.7 EVERY 125 HOURS ................................................................................... 3.7 EVERY 250 HOURS ................................................................................... 3.7 EVERY 500 HOURS ................................................................................... 3.7 EVERY 1000 HOURS ................................................................................. 3.8 EVERY 2000 HOURS ................................................................................. 3.8 TORQUE CHART ......................................................................................... 3.17 TORQUE, FLUID CONNECTIONS .......................................... 3.22, 3.23, 3.24 TORQUE SPECIFICATIONS - GENERAL ................................................... 3.18 UNLOADER VALVE ..................................................................................... 3.15 WEIGHTS OF COMMERCIAL WOOD ......................................................... 3.19

MARCH, 2009

Tigercat 220D Loader

Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE NEW MACHINE MAINTENANCE

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

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

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

Tightening points:~

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

All hydraulic connections Hose clamps Pin retainers Check torque on swing bearing retaining bolts

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

Engine mounting bolts Pump mounting bolts Pilot pump mounting bolts Swing gearbox mounting bolts

CAUTION

Swing motor 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.

Cab securing bolts Boom pin nuts Heel pin nuts Trailer mounting studs Any other loose nut, bolt or fitting

*OIL LOST FROM LEAKAGE

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

PER DAY 0.424 0.852 4.26 14.2 90.83

LOST 0IL (LITERS) PER PER MONTH YEAR 12.72 152.0 25.6 306.6 127.76 1533.1 425.86 5110.31 2725.5 32706.0

3.2

PER DAY 0.112 0.225 1.125 3.75 24.00

LOST 0IL (GALLONS) PER PER MONTH YEAR 3.36 40.0 6.75 81.0 33.75 405.0 112.5 1350.0 720.0 8640.0

Tigercat 220D Loader

Lubrication and Maintenance

TIGERCAT OIL SAMPLING PROGRAM Effective for all 2008 model year 200 series log loaders sold in U.S.A. and Canada, oil sampling must be performed during the warranty period as per the schedule below. Warranty coverage of Powertrain components, specifically main pump, pilot pump (if applicable), swing pump (if applicable), rotary manifold, swing motor, swing gearbox and swing bearing, main control valves, track motors and final drive gearboxes (if applicable) is contingent on performance of regular oil sampling at the owner’s expense during the warranty period.

200 Series Location

First Sample

Follow-up Samples

Hydraulic Oil

100 hrs

Every 1000 hrs or 6 Months

Swing Drive Gearbox

100 hrs

Every Oil Change (500 hours or 3 Months)

Track Drive Gearboxes (if applicable)

100 hrs

Every 1000 hrs or 6 Months

FIRST SAMPLE There will be no charge for the first oil samples required to be taken during the 100-Hour Inspection Service that will be scheduled and performed by your Tigercat dealer. Refer to NEW MACHINE MAINTENANCE in THIS SECTION. FOLLOW-UP SAMPLES All follow-up samples must be taken as indicated in the chart above and will be the responsibility of the machine owner.

Copies of all oil analysis results must be forwarded to the Tigercat Warranty Department for continued warranty coverage. If samples are taken using the Tigercat Oil Analysis Program, a copy of all results will automatically be sent to Tigercat.

Tigercat Oil Analysis Kits are available from your Tigercat dealer parts department. If required, arrangements can also be made with your Tigercat dealer to supply and perform all of the required followup oil samples.

Refer also to OIL SAMPLE COLLECTION PROCEDURES in THIS SECTION for sample valve and drain plug locations.

TIGERCAT OIL ANALYSIS KITS Each kit includes a Pre-paid Sample Bottle and Sample Information Form. Pre-printed mailing labels are also included to ensure all samples are quickly returned directly to the lab for immediate analysis and results within 24 hours of receipt.

The same type of sample bottle can be used for all types of oil testing including: Hydraulic Circuits, Final Drives, Axles, Gearboxes, Engines, etc.

To ensure accurate and meaningful results are obtained, each kit also includes detailed instructions on how properly collect, prepare and ship the oil samples.

Contact your Tigercat Dealer Parts Department to order Kits.

3.3

Tigercat 220D Loader

Lubrication and Maintenance

TIGERCAT OIL SAMPLING PROGRAM OIL SAMPLE COLLECTION PROCEDURES Fill out the Sample Information Form (SIF) completely and accurately. When taking multiple oil samples, fill out all of the required SIF forms in their entirety, prior to taking any oil samples. Then, immediately package each completed SIF form together with the matching oil sample in the black outer shipping container as each individual sample is taken. This will reduce the possibility of mixing up or incorrectly identifying the SIF forms and oil samples. Incorrectly identified samples could result in a false warning alarm.

OIL SAMPLING CONNECTOR

•

230C-012

The accuracy of the lab analysis results is very dependent on the quality of the oil sample taken.

Collection of clean oil samples that are representative of the main body of oil are essential if meaningful lab results are to be obtained.

Hydraulic Oil Samples: • Hydraulic oil samples should be taken from the circulating oil flow at operating temperature, with no functions actuated, using sample valves that are permanently located on the machine whenever possible.

Erroneous readings may result if proper collection, handling, packaging and shipping practices are not followed prior to the sample being tested by the lab. To be able to accurately compare and trend the lab results over time, all follow-up samples should be consistently taken from the same location using the same techniques as all previous samples.

•

Ensure that all sample valves and drain plugs are clean and free of debris.

•

Remove the sample bottle cap only when ready to take the sample. Keep the cap clean – do not put it in your pocket or let it get contaminated in any way.

•

Do not allow any airborne dirt, etc. to enter the sample bottle.

•

Avoid contamination of the sample – replace the sample bottle cap immediately after filling the bottle to approximately ¾ full. All samples taken should be immediately forwarded to the lab for processing.

HYDRAULIC OIL RETURN MANIFOLD

•

To obtain a representative oil sample, sample valves must be purged before the actual oil sample is taken. Drain a minimum of 3 or 4 ounces of oil into a separate container and discard this oil using approved recycling methods.

•

Replace the dust cover on the sample valve immediately after taking the oil sample and sealing the sample bottle.

Gearbox Samples: • These samples can be taken during the oil change process.

Contact your Tigercat dealer to purchase additional or replacement hydraulic sample valves or drain plugs.

In cases where oil samples must be pumped or otherwise drawn out of a reservoir or housing, a hand operated oil suction pump is also available from your Tigercat dealer.

3.4

•

To obtain a representative oil sample, ensure the oil is warm and has not settled very long (within 30 minutes of shutdown).

•

Place the required drain container under the machine to capture the used oil to be discarded using approved recycling methods.

•

Remove the drain plug and allow approximately 50% of the oil to drain, then place the sample bottle in the stream of draining oil to obtain a representative sample.

Tigercat 220D Loader

Lubrication and Maintenance

GENERAL Clean around filler caps before checking or adding fluids.

Clean around hydraulic fittings before breaking connection. Plug or cap immediately.

Clean up spills as soon as possible.

Always use clean oil and containers.

FIRE PREVENTION Maintaining your machine properly will greatly extend its life and reduce your operating costs.

Fire can result in a machine loss which can be financially devastating.

CAUTION

Drain dirty oil while still warm.

Do not exceed recommended fluid levels.

Service all hydraulic filters after the failure of a pump, motor, cylinder or valve. Failures of this nature could contaminate the entire hydraulic system.

Top up diesel fuel at each shift to reduce contamination by condensation.

AFTER transporting (trucking) a machine from one job sight to the next, open all doors and access panels and blow off any debris that could have re-positioned itself onto the engine and exhaust parts due to wind turbulence caused by the journey.

1. Pine needles and bark when allowed to accumulate, form a fuel source that when ignited is extremely difficult to extinguish. A thorough program of regular cleaning and washing will reduce the possibility of a fire starting. In the event a fire does start, the regular cleaning program will improve the chances of successfully extinguishing a fire.

Clean up oil spills in engine enclosure immediately.

Before welding on machine be sure the negative battery terminal is disconnected and the anti-stall controller and all multi pin connectors from the engine are unplugged.

When welding, secure ground connection as close to working position as possible to prevent arcing across machined surfaces or through bearings.

2. Pay close attention to wiring and plumbing routings during maintenance, ensure that ALL wiring harnesses or hydraulic hoses are properly restrained and clamped to prevent damage from chaffing.

Clean away all branches, bark and chips.

Clean up all traces of oil to avoid fires.

Inspect the EXHAUST SYSTEM DAILY for any signs of LEAKAGE. Check for worn, cracked, broken, or damaged pipes or muffler.

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

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

Always have a fire extinguisher at hand.

For safety, always lower boom assembly to the ground when leaving cab, leaving machine unattended or during service.

3.5

3. If equipped, read the fire suppression system manual and have the system serviced regularly by qualified personnel.

4. In case of fire lower the boom system to the ground and shut off the engine before discharging the fire suppression system.

Also refer to FIRE PREVENTION in SECTION 1 of THIS MANUAL for additional information.

Tigercat 220D Loader

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 8 HOURS:~

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

• Check engine coolant level • Check engine oil level

• Remove potentially damaging limbs or sticks and all debris

• Drain fuel/water separator • Check swing gearbox oil level. Fill reservoir to half way mark.

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

• Check air cleaner unloader valve.

• Check air intake filter restriction indicator.

Replace primary filter if indicator is in red zone.

Replace secondary (safety) filter every third primary filter change to guarantee maximum performance and reliability.

• For loose nuts, bolts and fittings • Condition and tension of fan belts.

• 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.

• Exhaust system for leaks.

• Check hydraulic oil level Lubricate:~ • Swing bearing; 1-fitting - 4 shots while swinging

• Conduct an overall visual inspection.

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

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

• *Boom joint; 2-fittings - purge • *Stick joint; 2-fittings - purge • *Cylinder pins; boom, stick & tilt; 4-fittings - purge

WARNING

*Lubricating cylinder pins and boom joints:1. Ensure machine is on level ground 2. Fully extend stick boom cylinder

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

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

•

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

•

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

•

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

4. While in this position lubricate all cylinder retaining pins and boom joints • Yoke pins; 2-fittings - purge • Grapple rotate pinion; 1-fitting - 4 shots, rotate 90° after each shot • Grapple arm pins; 6-fittings - purge • Grapple cylinder pins; 4-fittings - purge 3.6

Tigercat 220D Loader

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 250 HOURS:~

EVERY 24 HOURS:~ • Perform 8 hour maintenance

• Perform 8 hour maintenance • Perform 24 hour maintenance

And in addition:~ • Lubricate stabilizer arm pins; 8-fittings - purge

• Perform 125 hour maintenance And in addition:~ • Check fire extinguisher and turn it to mix contents

• Lubricate stabilizer cylinders; 8-fittings - purge • Lubricate grapple rotate bearing; 1-fitting - 4 shots, rotate 90° after each shot

EVERY 500 HOURS:~ • Perform 8 hour maintenance

EVERY 125 HOURS:~

• Perform 24 hour maintenance

• Perform 8 hour maintenance

• Perform 125 hour maintenance

• Perform 24 hour maintenance

• Perform 250 hour maintenance

And in addition:~ • Check return filter restriction indicator with engine running at high idle and oil flow

And in addition:~ • Replace air cleaner safety element • Replace engine fuel filter

Check:~ • Fluid level in batteries unless maintenance free

• Replace fuel/water separator filter • Replace oil in swing gearbox. Fill reservoir to half way mark

• Engine RPM

• Replace hydraulic oil return filters †

• All hydraulic pressures

• Replace hydraulic oil pilot pressure filter †

• Hydraulic pumps and motor securing bolts

• Lubricate door and cover hinges; 8 fittings - 1 shot

• Torque tightening points as per new machine maintenance

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

Visually check for damage to:~ • Main and stick booms and cylinders • Lower frame, stabilizer arms and cylinders

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

• Swing bearing area • Attachment Make repairs immediately Visually inspect for:~ • Frayed electrical wiring and hydraulic hoses • Wear in any other components Clean/replace:~ • Air conditioner re-circulation filter • Cab fresh air filter • Refer to diesel engine service manual and attachment manual for additional required maintenance at this scheduled time period.

3.7

Tigercat 220D Loader

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 1000 HOURS:~

EVERY 2000 HOURS:~

• Perform 8 hour maintenance

• Perform 8 hour maintenance

• Perform 24 hour maintenance

• Perform 24 hour maintenance

• Perform 125 hour maintenance

• Perform 125 hour maintenance

• Perform 250 hour maintenance

• Perform 250 hour maintenance

• Perform 500 hour maintenance

• Perform 500 hour maintenance

And in addition:~ • Check intank fuel strainer. Drain tank, clean or replace as necessary.

• Replace air cleaner unloader valve.

• Perform 1000 hour maintenance And in addition:~ • Drain and refill hydraulic oil tank with recommended hydraulic oil. Refer to APPROVED HYDRAULIC OILS in THIS SECTION. • Replace all air intake rubber components such as elbows and connectors - High temperatures in this area can cause the rubber to harden.

See AIR INTAKE MAINTENANCE in THIS SECTION. ______________________________________________

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

3.8

Tigercat 220D Loader

Lubrication and Maintenance

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

3.9

Tigercat 220D Loader

Lubrication and Maintenance

42360BENG

3.10

Tigercat 220D Loader

Lubrication and Maintenance

3.11

Tigercat 220D Loader

Lubrication and Maintenance •

FILTER HEAD

• GASKET

•

FILTER ELEMENT

SQUARE SECTION GASKET INSTALLATION FILTR_SEALS 2

Square Section Gasket 1-WATER ABSORBING RETURN FILTER (COLOUR BLUE)

•• •

•

Remove used gasket and clean groove in head.

Apply clean oil to new gasket surfaces.

Install new gasket into groove in filter head.

Screw on new filter until gasket makes contact.

Tighten filter an additional 3/4 turn.

•

HYDRAULIC RETURN FILTERS

HYDRAULIC RETURN FILTERS 250B-014 HYDRAULIC OIL RETURN FILTERS The majority of return oil entering the hydraulic tank passes through 3 spin-on hydraulic oil filters. One of the filters is a water absorbing filter (color blue) which is in place to assist with the removal of unwanted moisture from the hydraulic oil (the filters are rated 10 micron abs).

DO NOT use bottom nut for filter installation or damage/leakage may result. Bottom nut is to assist in filter removal only.

FILTER HEAD

• • GASKET

Each filter head has a bypass valve with a 1.7 Bar (25 psi) cracking pressure so that oil can bypass the filters if they become restricted. The "in" side of the filter heads are connected to a return manifold. A filter restriction indicator and an oil sampling connector are mounted onto the manifold. To check the condition of the filter elements; With the hydraulic oil at normal operating temperature, place engine throttle control to FULL and with no machine functions operating, the filter restriction indicator should be in the GREEN zone. If the pointer is in the RED zone replace allfilter elements.

Changing the filters: 1. Ensure Loader is on level ground with stabilizers down. Lower grapple to ground and stop engine.

2. Wipe clean the area around the filter and head.

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

• FILTR_SEALS 2

FILTER ELEMENT

'O' RING GASKET INSTALLATION

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

Apply clean oil to new gasket surfaces.

Install new gasket on inside lip of filter.

Screw on new filter until gasket makes contact.

Tighten filter until top edge makes metal to metal contact with filter head. (approximately 1 1/2 additional turns after gasket contact) DO NOT use bottom nut for filter installation or damage/leakage may result. Bottom nut is to assist in filter removal only.

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

6. Start the engine and check for leaks.

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

3.12

Tigercat 220D Loader

Lubrication and Maintenance Changing the filter or strainer: 1. Ensure Loader is on level ground with stabilizers down. Lower grapple to ground and stop engine.

2. Wipe clean the area around the filter and head.

LOCATED LOWER LEFT SIDE OF ENGINE COMPARTMENT

•

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

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

PILOT FILTER ELEMENT

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

230C-007

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

HYDRAULIC PILOT FILTER

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

For service and replacement intervals see SERVICE AND LUBRICATION CHART in THIS SECTION.

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

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

DO NOT use bottom nut for filter installation or damage/leakage may result. Bottom nut is to assist in filter removal only.

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

9. Start the engine and check for leaks.

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

3.13

Tigercat 220D Loader

Lubrication and Maintenance

In addition to the LUBRICATION AND MAINTENANCE SCHEDULE, the following instructions should also be noted.

AIR CLEANER MAINTENANCE The most common and most damaging air intake servicing problems are: 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.

220D-010

AIR CLEANER

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

IMPROPER SERVICING

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

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

SAFETY ELEMENT

1. Release the seal gently to reduce the amount of dust dislodged.

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

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

4. Always clean the inside of the outlet tube.

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

••

6. Inspect the new filter for damage.

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

8. Check connection and ducts for air tight fit.

Ensure that all clamps, bolts and connections are tight. Leaks here send dust directly to the engine.

3.14

AIR CLEANER .PLT

PRIMARY ELEMENT

AIR FILTER ELEMENTS

Tigercat 220D Loader

Lubrication and Maintenance

•

INDICATOR

SAFETY ELEMENT

••

250B-023

FILTER RESTRICTION INDICATOR

FILTER RESTRICTION INDICATOR A filter restriction indicator is located in the engine enclosure to the left of the frame access panel.

The indicator is remote mounted and is connected to the outlet side of the air filter with a 1/4" diameter hose. Replace the primary air filter when the indicator shows RED. This indicator provides a continuous reading whether the engine is running or is shut down. After replacing the filter, reset the indicator by pressing the reset button.

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

•

PRIMARY ELEMENT

••

UNLOADER VALVE AIR CLEANER .PLT

AIR FILTER ELEMENTS

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

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

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

The valve should suck closed at engine warm-up speed.

220D-010

AIR CLEANER

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

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

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

3.15

Tigercat 220D Loader

Lubrication and Maintenance

CHECKING AIR CONDITIONING SYSTEM

CAUTION

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

R134a REFRIGERANT

If using compressed air for cleaning, use at 30 psi. or less.

• Always use personal protective equipment to guard against flying debris.

PAG OIL (polyalkylene glycol)

1.5 KG (3.25 LBS)

AIR CHARGE COOLER

0.06 KG (2 OZ)

••

Any service work must be performed by authorized A/C technicians. The system should be charged with 1.5 kg (3.25 lbs) of R134a refrigerant. At least 0.06 kg (2 oz) of PAG (polyalkylene glycol) oil should be present in the system and must be used on 'O' rings and fittings during assembly.

RADIATOR

•• A/C CONDENSER

•

A/C COMPRESSOR OIL COOLER

•

250B-023

A/C COMPRESSOR

230C-002

•

RADIATOR COMPARTMENT RIGHT SIDE

Use the following checklist to maintain system between service intervals. The compressor and charge valves are located on the left side of the engine and accessible through the engine compartment door. The receiver dryer is located in the lower engine compartment beside the front left engine mount and accessible from either underneath the engine compartment or through the engine compartment door.

Perform the following checks on system: a. Check and adjust compressor drive belt tension. Do not over tighten. b. Check fresh air filter and re-circulating air filter.

Clean or replace as required. c. Check to see that compressor clutch will engage. d. Check blower operation and air vents. e. Check the condenser core for dirt and debris.

3.16

Tigercat 220D Loader

Lubrication and Maintenance

TORQUE CHART LOCATION

THREAD DIAMETER

TORQUE (LUBRICATED) lbf-ft Nm

Cylinders Hoist, Piston nut Hoist, Keeper plate bolts Stick, Piston nut Stick, Keeper plate bolts Stabilizer, Piston nut Stabilizer, Gland Heel, Piston nut Heel, Keeper plate bolts

2"-12 UNF (GC) 3/4"-16 UNF (G8) 2"-12 UNF (GC) 3/4"-16 UNF (G8) 2"-12 UNF (GC) M14-2.0 2" -12 UNF (GC) 3/4"-10 UNC (G8)

2500 250 2500 250 2100 129 1640 282-310

3390 340 3390 340 2847 175 2224 382-420

Boom joint and cylinder pin retaining bolts

3/4"-10 UNC (G8)

282-310

393-420

2"-12 UNF (G8)

400

540

Heel to Stick boom pin retaining nut

1 3/4"-12 UNF (G8)

400

540

Cab securing bolts Trailer mounting studs

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

400-450 500

542-610 680

Swing bearing bolts Swing gearbox mounting bolts

7/8"-9 UNC (G8) M20 (12.9)

400-450 400

542-610 540

Engine mounting Bolts, bracket/mount to chassis Bolts, bracket to engine Flex drive coupling hub setscrew Engine cooling fan mounting bolts

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

400-450 75 63 40

542-610 100 83 54

Pump drive Drive plate to flywheel Bell housing to engine

3/8"-16 UNC (G8) M10 (10.9)

33-36 47

45-49 63

Pump mounting Main Pump to Engine

1/2" 13 UNC (G8)

80

108

Main and Stick boom pin retaining nut

*

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

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

3.17

Tigercat 220D Loader

Lubrication and Maintenance

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

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

IMPERIAL GRADE 8 BOLTS

GRADE 5 BOLTS

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

DRY lbf-ft Nm 11 - 12 15 - 16 26 - 30 35 - 40 44 -48 60 - 65 70 - 77 95 - 104 106 - 117 144 - 158 153 - 168 208 - 228 212 - 233 288 - 316 376 - 414 510 - 561 606 - 667 822 - 904 909 - 1000 1233 - 1355 1288 - 1417 1746 - 1921 1817 - 1999 2464 - 2710 DRY lbf-ft Nm 13 - 14 18 - 19 23 - 28 31 - 38 49 - 54 67 - 73 78 - 86 106 - 116 120 - 132 163 - 179 171 - 188 232 - 255 240 - 264 326 - 358 420 - 462 570 - 626 668 - 735 906 - 996 995 - 1096 1359 - 1486 1445 - 1590 1960 - 2155 2012 - 2213 2728 - 2997

LUBRICATED lbf-ft Nm 8 - 10 11 - 13 20 - 28 27 - 38 33 - 36 45 - 49 52 - 57 71 - 77 80 - 88 109 - 119 115 - 127 156 - 172 159 - 175 216 - 237 282 - 310 393 - 420 455 - 501 617 - 679 682 - 750 925 - 1016 966 - 1062 1310 - 1441 1360 - 1496 1844 - 2027 LUBRICATED lbf-ft Nm 10 - 13 14 - 17 18 - 25 25 - 33 37 - 41 50 - 55 58 - 64 79 - 86 90 - 99 122 - 134 128 - 141 174 - 191 180 - 198 244 - 268 315 - 347 427 - 470 501 - 550 679 - 745 746 - 821 1012 - 1113 1083 - 1191 1469 - 1613 1509 - 1660 2046 - 2250

DRY LUBRICATED COARSE lbf-ft Nm lbf-ft Nm THREAD 1/4" - 20 7- 8 10 - 11 8 - 10 11 - 13 5/16" - 18 14 - 18 19 - 24 10 - 15 13 - 20 3/8" - 16 31 - 34 42 - 46 23 - 25 31 - 34 7/16" - 14 49 - 54 66 - 73 37 - 41 50 - 55 1/2" - 13 75 - 83 102 - 112 57 - 63 77 - 85 9/16" - 12 109 - 120 148 - 162 82 - 90 111 - 122 5/8" - 11 150 - 165 204 - 223 113 - 124 152 - 168 3/4" - 10 266 - 293 360 - 397 200 - 220 271 - 298 7/8" - 9 394 - 433 535 - 586 296 - 326 402 - 441 1" - 8 591 - 649 802 - 879 443 - 489 601 - 663 1 1/8" - 7 794 - 873 1077 - 1183 596 - 656 808 - 889 1 1/4" - 7 1120 - 1232 1519 - 1670 840 - 924 1139 - 1252 FINE DRY LUBRICATED lbf-ft Nm lbf-ft Nm THREAD 1/4" - 28 9 - 10 12 - 13 9 - 10 12 - 13 5/16" - 24 17 - 22 23 - 29 16 - 20 21 - 27 3/8" - 24 35 - 39 48 - 53 26 - 29 35 - 39 7/16" - 20 55 - 61 75 - 83 41 - 45 56 - 61 1/2" - 20 85 - 94 116 - 127 64 - 70 87 - 95 9/16" - 18 121 - 133 164 - 180 91 - 100 124 - 135 5/8" - 18 170 - 187 231 - 253 128 - 141 174 - 191 3/4" - 16 297 - 327 403 - 443 223 - 245 303 - 332 7/8" - 14 434 - 477 589 - 646 326 - 359 442 - 486 1" - 14 646 - 711 876 - 965 484 - 534 657 - 724 1 1/8" - 12 891 - 980 1208 - 1328 668 - 735 906 - 996 1 1/4" - 12 1240 - 1364 1682 - 1849 931 - 1024 1262 - 1387

METRIC

METRIC BOLT TORQUE SPECIFICATIONS SIZE

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

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

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

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

M6 M8 M10

4.8 12.0 23.0

3.5 8.5 17.0

6.0 15.0 29.0

4.5 11.0 21.0

9.0 22.0 43.0

6.5 16.0 32.0

11.0 28.0 55.0

8.5 20.0 40.0

13.0 32.0 63.0

9.5 24.0 47.0

17.0 40.0 80.0

12.0 30.0 60.0

15.0 37.0 75.0

11.5 28.0 55.0

19.0 47.0 95.0

14.5 35.0 70.0

M12 M14 M16

40.0 63.0 100.0

29.0 47.0 73.0

50.0 80.0 125.0

37.0 60.0 92.0

75.0 120.0 190.0

55.0 88.0 140.0

95.0 150.0 240.0

70.0 110.0 175.0

110.0 175.0 275.0

80.0 130.0 200.0

140.0 225.0 350.0

105.0 165.0 225.0

130.0 205.0 320.0

95.0 150.0 240.0

165.0 260.0 400.0

120.0 190.0 300.0

M18 M20 M22

135.0 190.0 260.0

100.0 140.0 190.0

175.0 240.0 330.0

125.0 180.0 250.0

260.0 375.0 510.0

195.0 275.0 375.0

330.0 475.0 650.0

250.0 350.0 475.0

375.0 530.0 725.0

275.0 400.0 540.0

475.0 675.0 925.0

350.0 500.0 675.0

440.0 625.0 850.0

325.0 560.0 460.0 800.0 625.0 1,075.0

410.0 580.0 800.0

M24 M27 M30

330.0 490.0 675.0

250.0 360.0 490.0

425.0 625.0 850.0

310.0 650.0 450.0 950.0 625.0 1,300.0

M33 900.0 M36 1,150.0

475.0 825.0 600.0 925.0 675.0 1,150.0 850.0 1,075.0 800.0 1,350.0 1,000.0 700.0 1,200.0 875.0 1,350.0 1,000.0 1,700.0 1,250.0 1,600.0 1,150.0 2,000.0 1,500.0 950.0 1,650.0 1,200.0 1,850.0 1,350.0 2,300.0 1,700.0 2,150.0 1,600.0 2,700.0 2,000.0

675.0 1,150.0 850.0 1,750.0 1,300.0 2,200.0 1,650.0 2,500.0 1,850.0 3,150.0 2,350.0 2,900.0 2,150.0 3,700.0 2,750.0 850.0 1,450.0 1,075.0 2,250.0 1,650.0 2,850.0 2,100.0 3,200.0 2,350.0 4,050.0 3,000.0 3,750.0 2,750.0 4,750.0 3,500.0

TORQUECHARTGENERAL.XLS

3.18

Tigercat 220D Loader

Lubrication and Maintenance

Weights of Commercial Wood

Species

kg/m3

lb/ft3

Species

kg/m3

lb/ft3

Alder, Red Ash, White Aspen, Quaking Bald Cypress Basswood, American Beech, American Birch, Paper Birch, Yellow Cedar, Alaska Cedar, Incense Cedar, Northern White Cedar, Port-Orford Cedar, Western Red Cherry, Black Cottonwood, Eastern Douglas Fir, Coast Douglas Fir, Inland North Elm, American Fir, Alpine Fir, Balsam Fir, Nobel Fir, Red Fir, Silver Fir, White Gum, Black Gum, Blue Gum, Red Gum, Tupelo Hemlock, Eastern Hemlock, Western Hickory, Pecan Hickory, True Larch, Western Locust, Black Magnolia, Cucumber

737 769 689 817 673 865 801 929 577 721 449 897 433 721 785 881 577 865 449 721 481 769 577 753 721 1121 801 897 801 657 993 1009 769 929 785

46 48 43 51 42 54 50 58 36 45 28 36 57 45 49 55 36 54 28 45 30 48 36 47 45 70 50 56 50 41 62 63 48 58 49

Maple, Big Leaf Maple, Black Maple, Red Maple, Silver Maple, Sugar Oak, Black Oak, Chestnut Oak, Red Oak, Red, Swamp Oak, Swamp Chestnut Oak, White Oak, White, Swamp Pine, Jack Pine, Loblolly Pine, Lodgepole Pine, Long Leaf Pine, Norway, Red Pine, Short Leaf Pine, Slash Pine, Sugar Pine, Western Yellow Pine, White-Western Pine, White-Eastern Poplar, Yellow Redwood Spruce, Black Spruce, Engleman Spruce, Red Spruce, Sitka Spruce, White Sweetgum Sycamore, American Tamarack Walnut, Black Willow, Black

753 865 801 721 897 1009 977 1009 1073 1041 993 1105 801 993 625 993 673 993 993 817 721 561 577 609 801 513 625 545 529 545 801 833 753 929 801

47 54 50 45 56 63 61 63 67 65 62 69 50 62 39 62 42 62 62 51 45 35 36 38 50 32 39 34 33 34 50 52 47 58 50

Note: The values shown here are green weights.

3.19

Tigercat 220D Loader

Lubrication and Maintenance

PRESSURE SETTINGS Engine RPM ............................................................2280 - 2320 rpm ........................................................................................... 2200 rpm ................................................................................... 800 - 900 rpm Pilot Valve Main relief ................................................................ 31 Bar/450 psi STICK valve Main and Port reliefs: Main relief .............................................................. 190 Bar/2750 psi Port relief Grapple Rotate CCW ......................... ¶ 207 Bar/3000 psi Port relief Grapple Rotate CW ........................... ¶ 207 Bar/3000 psi Port relief Stick OUT .......................................... 234.4 Bar/3400 psi Port relief Stick IN ............................................... 103.4 Bar/1500 psi Port relief Saw RETRACT (option) ..................... 1103.4 Bar/500 psi Port relief Slasher CUT (option) ......................... § 207 Bar/3000 psi Port relief Drive FWD. (SP option) ........................ 172 Bar/2500 psi Port relief Drive REV. (SP option) .......................... 172 Bar/2500 psi Port relief Live Heel IN (option) ............................. 207 Bar/3000 psi Port relief Live Heel OUT (option) ......................... 207 Bar/3000 psi

@ Full throttle (no load) @ Rated working @ Idle (no load) @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle

HOIST valve Main and Port reliefs: Main relief .............................................................. 190 Bar/2750 psi Port relief Grapple OPEN ...................................... 207 Bar/3000 psi Port relief Grapple CLOSE .................................... 207 Bar/3000 psi Port relief Hoist UP ............................................. 234.4 Bar/3400 psi Port relief Hoist DOWN ...................................... 103.4 Bar/1500 psi Port relief Slasher CUT (option) ......................... § 207 Bar/3000 psi Port relief Top Saw CUT (option) ........................... 207 Bar/3000 psi Port relief Drive FWD. (SP option) ........................ 172 Bar/2500 psi Port relief Drive REV. (SP option) .......................... 172 Bar/2500 psi Port relief Butt Board UP(CS option) ..................... 138 Bar/2000 psi Port relief Butt Board DOWN (CS option) ............. 138 Bar/2000 psi

@ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle

SWING valve Main and Port reliefs: Main relief .............................................................. 179 Bar/2600 psi Port relief Swing CCW .......................................... 207 Bar/3000 psi Port relief Swing CW ............................................. 207 Bar/3000 psi Port relief Stabilizer DOWN ................................... 207 Bar/3000 psi Port relief Stabilizer UP ......................................... 138 Bar/2000 psi Port relief Delimber OPEN (option) ....................... 207 Bar/3000 psi Port relief Spare (option) ....................................... 207 Bar/3000 psi Port relief Steer LEFT (SP option) ......................... 138 Bar/2000 psi Port relief Steer RIGHT (SP option) ...................... 138 Bar/2000 psi Port relief Saw CUT (CS option) ........................... 138 Bar/2000 psi Port relief Saw RETRACT (CS option) .................. 138 Bar/2000 psi

@ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle @ Full throttle

Swing motor Crossline Reliefs ................................................. **121 Bar/1750 psi

@ Idle

BRAKE valve (SP option) ......................................... 4.8 Bar/70 psi

@ Full throttle

CIRCLE valve Main and Port reliefs: Main relief .............................................................. 172 Bar/2500 psi Port relief ............................................................... 207 Bar/3000 psi

@ Full throttle @ Full throttle

NOTE: The above values are for reference purposes only, SEE SERVICE MANUAL FOR SETTING PROCEDURE. 20089B-R1.06/09/04

3.20

Tigercat 220D Loader

Lubrication and Maintenance

PRESSURE SETTINGS IMPORTANT System to be at operating temperature when setting pressures. ** Using the following procedure to set crossline reliefs: a. Install swing locking device or secure boom to keep the machine from swinging. b. Disconnect and cap the pilot hose running to the swing motor crossline relief valves. c. At idle adjust both swing motor crossline relief valves to the value given on the chart. d. Reconnect the pilot hose and purge the air out of the lines. ¶ Applicable to Hultdins and Rotobec HD grapples only.

Refer to grapple manufacturers specifications for all other models. § SLASHER CUT port relief valve on "HOIST" valve must be turned up above 214 Bar (3100 psi) before setting port relief on "STICK" valve. * Do not adjust pressure over 207 Bar (3000 psi) or pump may be damaged. *** Factory set at 10 gpm.

20089B-R1.06/09/04

3.21

Tigercat 220D Loader

Lubrication and Maintenance

Par ker ark

Assemb que Assemblly Tor orque The four-bolt port is simply a circular opening (flow passage) surrounded by four tapped holes in a certain pattern for acceptance of the flange clamping bolts.

The flat surface of the port compresses the O-ring contained in the groove in the flange head when the clamp bolts are torqued. In some instances, the groove is in the port and not in the flange head. The bolts, through the clamp halves, clamp down the flange head on to the flat surface of the port compressing and trapping the O-ring in the groove and leaving no gap for it to extrude under pressure. The hydraulic pressure is thus sealed by the compressed O-ring as long as the bolts are tightened enough to maintain solid metal to metal contact between the flange head at the outside diameter of the O-ring and the top of the port.

The 4-Bolt Split Flange consists of four main components: • A body (flange head) • An O-ring • One “captive” or two “split” flange clamps

• Four bolts and washer

WASHERS

•• •• •

BOLTS FLANGE CLAMP

Flange Port Assembly FLANGE HEAD

The steps to properly assemble the flange port clamping bolts are: 1. Make sure sealing surfaces are free of burrs, nicks, scratches or any foreign particles.

2. Lubricate the O-ring.

3. Position flange and clamp halves.

4. Place lock washers on bolts and insert through clamp halves.

5. Hand tighten bolts.

6. Torque bolts in diagonal sequence (see Fig. T9) in small increments to the appropriate torque level listed in Table T6 or Table T7 on this page.

O-RING

•• •

TAPPED HOLES

•• FLANGE.TIFF

Fig. T8 - 4 Bolt Split Flange Components

FLANGE2.TIFF

Fig. T9 - Flange Bolt Tightening Sequence

Dash Size

Flange Size

Inch Bolt (J518)

Torque ft. lbs.

Metric Bolt (ISO 6162)

Torque N-m

8 12 16 20 24 32 40 48 56 64 80

1/2 3/4 1 1-1/4 1-1/2 2 2-1/2 3 3-1/2 4 5

5/16-18 3/8-16 3/8-16 7/16-14 1/2-13 1/2-13 1/2-13 5/8-11 5/8-11 5/8-11 5/8-11

17 +/- 2 25 +/- 3.5 31 +/- 4.5 41 +/- 5 52 +/- 6 60 +/- 6 85 +/- 9 144 +/- 15 125 +/- 8 125 +/- 8 125 +/- 8

M8 M10 M10 M12* M12 M12* M12 M16 M16 M16 M16

25 49 49 85 85 135 95 220 220 220 220

DASH SIZE 8 12 16 20 24 32

FLANGE SIZE 1/2 3/4 1 1 1/4 1 1/2 2 SO

INCH BOLT (J518) 5/16-18 3/8-16 7/16-14 1/2-13 5/8-11 3/4-10

TORQUE METRIC BOLT TORQUE FT LBS (ISO 6162) N-M 17 +/- 2 M8 25 30 +/- 4.5 M10 49 46 +/- 4.5 M12 85 69 +/- 6 M14* 135 125 +/- 8 M16 210 208 +/- 20 M20 425

* Does not meet ISO 6162 specification.

Table T7 - Code 62 Flange Recommended Bolt Torque

* Does not meet ISO 6162 specification.

Table T6 - Code 61 Flange Recommended Bolt Torque

3.22

Tigercat 220D Loader

Lubrication and Maintenance

Par ker ark

Assemb que Assemblly Tor orque

JIC 37 Degree Flare SAE Dash Size

Tube Connection Swivel or Hose Connection FFWR FFWR

Thread Size

-2 -3 -4 -5 -6 -8 -10 -12 -14 -16 -20 -24 -32 -40

NPTF

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

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

O'ring Face Seal / Seal-Lok

-2 -3 -4 -5 -6 -8 -10 -12 -14 -16 -20 -24 -32 -40

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

NA NA 1/4 TO 1/2 NA 1/4 TO 1/2 1/4 TO 1/2 1/4 TO 1/2 1/4 TO 1/2 NA 1/4 TO 1/2 1/4 TO 1/2 1/4 TO 1/2 NA NA

2-3 NA 2-3 NA 2-3 2-3 NA 2-3 NA 1.5-2.5 1.5-2.5 1.5-2.5 1.5-2.5 NA

BSPT

Tube Connection Swivel or Hose Connection FFWR FFWR

Thread Size

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

F.F.W.R : Flats From Wrench Resistance All values are for Steel, Stainless Steel and Brass

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

Non-Adjustable Thread Size

Seal-Lok

ft. lbs (in. lbs) 5/16-24 (310) 3/8-24 (310) 7/16-20 (310) 1/2-20 (360) 9/16-18 (420) 3/4-16 60 7/8-14 100 1 1/16-12 135 1 3/16-12 175 1 5/16-12 200 1 5/8-12 250 1 7/8-12 305 2 1/2-12 375

N-m 20 20 20 40 46 80 135 185 235 270 340 415 510

Adjustable

Triple-Lok Ferulok Pipe Fittings ft. lbs (in. lbs) (85) (155) (260) (280) (350) (620) 85 135 175 200 250 305 375

N-m 10 18 29 32 40 70 115 183 237 271 339 414 509

Plugs Hollow Hex

Seal-Lok ft. lbs (in. lbs) (310) (310) (310) (360) (420) 60 100 135 175 200 250 305 375

3.23

N-m 20 20 20 40 46 80 135 185 235 270 340 415 510

Triple-Lok Ferulok ft. lbs (in. lbs) (60) (100) (180) (250) (350) (620) 85 135 175 200 250 305 375

N-m 7 11 20 28 40 70 115 183 237 271 339 414 509

HP5ON-S ft. lbs (in. lbs) (30) (55) (120) (170) (410) 60 100 135 175 200 250 305 375

N-m 3.5 6 13.5 19 46 80 135 185 235 270 340 415 510

Hex Head P5ON-S ft. lbs (in. lbs) (85) (155) (260) (280) (350) (620) 85 135 175 200 250 305 375

N-m 10 18 29 32 40 70 115 183 237 271 339 414 509

Tigercat 220D Loader

Lubrication and Maintenance

Assemb que Assemblly Tor orque

EATON Aeroquip Recommended Parallel Connection Assembly torque

Eaton recommends that a

The values listed are for

Torque wrench be used to

steel connections. Contact

assure proper fitting

Eaton Aeroquip for torques values for

assembly of these

other materials

connections.

Straight Thread O-Ring Boss Low Pressure with 37º (SAEJ514) 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

Straight Thread O-Ring Boss High Pressure with ORS (J1453)

Jam Nut or Jam Nut or Straight Straight Fitting Torque Fitting Torque lb.-ft.

Newton Meters 8-9 12-13 13-15 18-20 14-15 19-21 23-24 32-33 40-43 55-57 43-48 59-64 68-75 93-101 83-90 113-122 112-123 152-166 146-161 198-218 154-170 209-230 218-240 296-325

Dash Size -03 -04 -05 -06 -08 -10 -12 -14 -16 -20 -24

ORS

Dash Size -04 -06 -08 -10 -12 -16 -20 -24

Thread Size (inches) 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 3/16-12 1 5/16-12 1 5/8-12 1 7/8-12

Jam Nut or Jam Nut or Straight Straight Fitting Torque Fitting Torque lb.-ft.

Newton Meters 8-10 11-16 14-16 20-22 18-20 24-27 24-26 33-35 50-60 68-78 72-80 98-110 125-135 170-183 160-180 215-245 200-220 270-300 210-280 285-380 270-360 370-490

SAE 37º (JIC)

Thread Size (inches) 9/16-18 11/16-20 13/16-16 1-14 1 3/16-12 1 7/16-12 1 11/16-12 2-12

Swivel Nut Torque lb.-ft.

10-12 18-20 32-35 46-50 65-70 92-100 125-140 150-165

Swivel Nut Torque Newton Meters 14-16 24-27 43-47 62-68 88-95 125-136 170-190 204-224

Dash Size -04 -05 -06 -08 -10 -12 -16 -20 -24 -32

Metric Thread Size mm M10x1 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M20x1.5 M22x1.5 M26x1.5 M27x2 M33x2 M42x2 M48x2

Thread Size (inches) 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 5/16-12 1 5/8-12 1 7/8-12 2 1/2-12

Swivel Nut Torque lb.-ft.

11-12 15-16 18-20 38-42 57-62 79-87 108-113 127-133 158-167 245-258

Swivel Nut Torque Newton Meters 15-16 20-22 24-28 52-58 77-85 108-119 148-154 173-182 216-227 334-352

BSPP Straight Adapter or Locknut Torque lb.-ft.

Newton Meters 13-15 18-20 15-19 20-25 19-23 25-30 33-40 45-55 37-44 50-60 52-66 70-90 55-70 75-95 81-96 110-130 96-111 130-150 162-184 220-250 170-192 230-260 258-347 350-470

Nominal Thread Size Straight Adapter or Locknut Torque inches** lb.-ft.

Newton Meters G1/8-28 13-15 18-20 G1/4-19 19-23 25-30 G3/8-19 33-40 45-55 G1/2-14 55-70 75-95 G3/4-14 103-118 140-160 G1-11 162-184 220-250 G1 1/4-11 170-192 230-260 G1 1/2-11 258-347 350-470 ** "G" denotes parallel threads, other than ISO 6149 (Port connection only)

Eaton Aeroquip Fluid Conveyance Products A-HOOV-MC001-E January 2005

3.24

Tigercat 220D Loader

220D-003

Lubrication and Maintenance

ELECTRICAL SCHEMATIC - STANDARD MACHINES 33562B R0 - SHEET 1 OF 4 3.25

Tigercat 220D Loader

220D-004

Lubrication and Maintenance

ELECTRICAL SCHEMATIC - STANDARD MACHINES 33562B R0 - SHEET 2 OF 4 3.26

Tigercat 220D Loader

220D-005

Lubrication and Maintenance

ELECTRICAL SCHEMATIC - STANDARD MACHINES 33562B R0 - SHEET 3 OF 4 3.27

Tigercat 220D Loader

220D-006

Lubrication and Maintenance

ELECTRICAL SCHEMATIC - STANDARD MACHINES 33562B R0 - SHEET 4 OF 4 3.28